Uen R 79590001

Engine Service Manual
Models
TH414C GC
TH417C GC
TH314D
TH417D
SN KRF00150 to Present
SN LYN00150 to Present
SN NAB00150 to Present
SN NMM00150 to Present
SN MYT00150 to Present
SN MYF00150 to Present
SN MLZ00150 to Present
SN MKY00150 to Present
Engine
458-0043 & 458-0044
31211014
UENR7959-01
Revised
May 16, 2017
EFFECTIVITY PAGE
July 31, 2014 - A - Original Issue Of Manual
May 16, 2017 - B - Revised front cover.
31211014 TH414C GC, TH417C GC, TH314D, TH417D i

EFFECTIVITY PAGE
ii TH414C GC, TH417C GC, TH314D, TH417D 31211014

FOREWORD
TH414C GC, TH417C GC, TH314D, TH417D 31211014Read and observe the information in this documentation. You
will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.
This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment
manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The
manufacturer will not be liable for damages resulting from this. The user bears the sole risk.
Use for the intended purpose also includes observance of the operating, maintenance and repair instructions
specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar
with this and are aware of the risks involved.
Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and
that they have understood the contents.
Failure to observe this documentation may lead to malfunctions and engine damage as well as injury to persons for
which the manufacturer will not accept any liability.
Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and
special tools and their perfect condition.
Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury when handled
incorrectly.
The pertinent rules for the prevention of accidents and other generally recognised health and safety regulations
must be observed.
Maximum economy, reliability and long life is only guaranteed when using original parts.
Repair of the engine must correspond to its use for the intended purpose. Only parts released by the manufacturer
for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude
manufacturer liability for resulting damages. Failure to observe this will void the warranty.
The engines are developed for a wide range of applications. A wide range of variants ensures that the respective
special requirements are met.
The engine is equipped according to the installation case, i.e. not all the parts and components described in this
documentation are installed in your engine necessarily.
DISCLAIMER: Information provided within (excluding Section 1) is supplied directly from the component
manufacturer. Due to continuous improvements, the component manufacturer reserves the right to make changes
without prior notification.
31211014 TH414C GC, TH417C GC, TH314D, TH417D iii

FOREWORD
iv TH414C GC, TH417C GC, TH314D, TH417D 31211014

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
Safety information / User information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Operation Manual and Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Explanation of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section 3
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Crankshaft Sealing Ring (Flywheel Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2 Gasket Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3 Closing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4 Lubricating Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5 Closing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6 V-Rib Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.7 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.8 Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.9 Lubricant Oil Filter Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.10 Transfer Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.11 Lubricating Oil Line (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.12 Lubricating Oil Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.13 High-Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.14 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3.15 Fuel Pre-Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.16 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.17 Fuel Supply Pump (Engine 458-0043). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.18 V-Belt Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.19 Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.20 Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3.21 Charge Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.22 Charge Air Pressure/Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.23 Charge Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.24 Coolant Pump V-Rib Belt Pulley (Engine 458-0044). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3.25 Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
3.26 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
3.27 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
TH414C GC, TH417C GC, TH314D, TH417D i

Section Subject Page
3.28 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

3.29 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3.30 Screw Plug (Engine 458-0044) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3.31 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3.32 Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
3.33 Compensator Structure (Exhaust Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
3.34 Line (Crankcase Housing, Exhaust Gas Circulation, Coolant Line). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
3.35 Line (Thermostat Housing, Exhaust Gas Circulation, Coolant Line) . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3.36 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3.37 Exhaust Manifold (Exhaust Turbocharger). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3.38 Generator (Fastening Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3.39 Console (V-Rib Belt, Level 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.40 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3.41 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3.42 Turning Gear/Locking Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3.43 Fuel Filter Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
3.44 Compensator Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
3.45 Impulse transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
3.46 Impulse Transmitter (Camshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3.47 Pressure Transmitter Installation (Oil Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
3.48 Connection Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3.49 Connection Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
3.50 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
3.51 Differential Pressure Sensor (Diesel Particle Filter) (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . 3-154
3.52 Holder (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158
3.53 Relay Holder (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
3.54 Compensator Structure (Assembly Material) (Engine 458-0043). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
3.55 Inlet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
3.56 Outlet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
Section 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section 5
Engine Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Engine Harness (Engine 458-0043). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Engine Harness (Engine 458-0044). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 Equipment Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Power Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Exhaust After Treatment Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Section 6
Wire Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Engine Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Engine Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Signal Wire Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Section 7
Diagnostics ....................................................................... 7-1
7.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
ii TH414C GC, TH417C GC, TH314D, TH417D

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TH414C GC, TH417C GC, TH314D, TH417D 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
directions for meeting every possible contingency during assistance and how to use a first aid kit and fire extinguisher/
operation, maintenance, or testing. When additional fire suppression system. Keep emergency telephone
information is desired consult the local Caterpillar dealer. numbers (fire department, ambulance, rescue squad/
paramedics, police department, etc.) nearby. If working
Many factors contribute to unsafe conditions: carelessness, alone, check with another person routinely to help assure
fatigue, overload, inattentiveness, unfamiliarity, even drugs personal safety.
and alcohol, among others. For optimal safety, encourage
everyone to think, and to act, safely.
1.6 SAFETY ALERT SYSTEM AND SIGNAL
Appropriate service methods and proper repair procedures WORDS
are essential for the safety of the individual doing the work,
for the safety of the operator, and for the safe, reliable
operation of the machine. All references to the right side, left
side, front and rear are given from the operator seat looking in DANGER
a forward direction.
Supplementary information is available from the
manufacturer in the form of Service Bulletins, Service DANGER indicates an imminently hazardous situation
Campaigns, Service Training Schools, the service website, which, if not avoided, will result in death or serious injury.
other literature, and through updates to the manual itself.
1.2 DISCLAIMER WARNING

All information in this manual is based on the latest product
information available at the time of publication. The WARNING indicates a potentially hazardous situation which,
manufacturer reserves the right to make changes and if not avoided, could result in death or serious injury.
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation. CAUTION
1.3 OPERATION & MAINTENANCE MANUAL
CAUTION indicates a potentially hazardous situation which,
The mechanic must not operate the machine until the if not avoided, may result in minor or moderate injury.
Operation & Maintenance Manual has been read and
understood, training has been accomplished and operation
of the machine has been completed under the supervision of
an experienced and qualified operator.
An Operation & Maintenance Manual is supplied with each
machine and must be kept in the manual holder located in
the cab. In the event that the Operation & Maintenance
Manual is missing, consult the local Caterpillar dealer before
proceeding.
1-2 TH414C GC, TH417C GC, TH314D, TH417D

Safety Practices
1.7 SAFETY INSTRUCTIONS 1.7.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions before proceeding. to use it.
CLEANLINESS: Wear eye protection, and clean all
1.7.1 Personal Hazards components with a high pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat. Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run off.
least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.7.2 Equipment Hazards machine is needed, ensure the machine is shut down before
pressure-washing. Should pressure-washing be utilized to
LIFTING OF EQUIPMENT: Before using any lifting equipment
wash areas containing electrical/electronic components, it is
(chains, slings, brackets, hooks, etc.), verify that it is of the
recommended a maximum pressure of 52 bar (750 psi) at a
proper capacity, in good working order, and is properly
minimum distance of 30.5 cm (12 in) away from these
attached.
components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation,
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal and recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep
tools clean and in good working order, and use special
service tools only as recommended.

Safety Practices
1.7.4 Operational Hazards PRESSURE TESTING: When conducting any test, only use test
equipment that is correctly calibrated and in good condition.
ENGINE: Stop the engine before performing any service
Use the correct equipment in the proper manner, and make
unless specifically instructed otherwise.
changes or repairs as indicated by the test procedure to
VENTILATION: Avoid prolonged engine operation in achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to the
SOFT SURFACES AND SLOPES: NEVER work on a machine ground before leaving the machine.
that is parked on a soft surface or slope. The machine must be
TIRES: Always keep tires inflated to the proper pressure to
on a hard level surface, with the wheels blocked before
help prevent tipover. DO NOT over inflate tires.
performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID TEMPERATURE: NEVER work on a machine when the
Always use matched sets according to machine
engine, cooling or hydraulic systems are hot. Hot
specifications.
components and fluids can cause severe burns. Allow
systems to cool before proceeding. MAJOR COMPONENTS: Never alter, remove, or substitute any
items such as counterweights, tires, batteries or other items
FLUID PRESSURE: Before loosening any hydraulic or diesel
that may reduce or affect the overall weight or stability of the
fuel component, hose or tube, turn the engine OFF. Wear
machine.
heavy, protective gloves and eye protection. NEVER check
for leaks using any part of your body; use a piece of BATTERY: DO NOT charge a frozen battery.Charging a frozen
cardboard or wood instead. If injured, seek medical attention battery may cause it to explode. Allow the battery to thaw
immediately. Diesel fluid leaking under pressure can before jump starting or connecting a battery charger.
explode. Hydraulic fluid and diesel fuel leaking under
pressure can penetrate the skin, cause infection, gangrene 1.8 SAFETY DECALS
and other serious personal injury.
Check that all safety decals are present and readable on the
Refer to the engine manufacturers manual for specific details
machine. Refer to the Operation & Maintenance Manual
concerning the fuel system.
supplied with machine for information.
Relieve all pressure before disconnecting any component,
part, line or hose. Slowly loosen parts and allow release of
residual pressure before removing any part or component.
Before starting the engine or applying pressure, use
components, parts, hoses and pipes that are in good
condition, connected properly and are tightened to the
proper torque. Capture fluid in an appropriate container and
dispose of in accordance with prevailing environmental
regulations.
COOLANT SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns and
eye injury. To prevent personal injury, NEVER remove the
coolant system cap while the cooling system is hot. Wear
safety glasses. Turn the coolant system cap to the first stop
and allow pressure to escape before removing the cap
completely. Failure to follow the safety practices could result
in death or serious injury.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.
FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic
systems near an open flame, sparks or smoking materials.
NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture
can cause an explosion.
Section 2
Safety information / User information
Contents

2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Operation Manual and Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Explanation of Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.1 GENERAL engine. Unauthorised persons are prohibited access to

the machine room.
The documentation of the service manual has been created • Wear close-fitting clothing and ear protectors in the
based on the engine available at the time of going to press. machine room when the engine is in operation.
There may be deviations in the descriptions, illustrations and • Only deploy trained personnel to do repairs and
parts due to further developments. maintenance work.
The valid documentations published by Engine • Do not work on the fuel system when the engine is
Manufacturer (for example Technical Circulars, Service running. The fuel system is under high pressure - danger
Bulletins, etc.) must be observed. of death.
The maintenance work described in the operation manual & • Go to the workshop immediately in case of leaks in the
in the service manual must be carried out on schedule and fuel system.
completely. The maintenance personnel must have the
2. for the engine room:
necessary technical knowledge to perform the work. Safety
and protection devices which are removed during • Ensure adequate ventilation (do not cover air shafts).
maintenance work must be replaced again afterwards.
• Provide first aid kit and suitable fire extinguishers.
Caution Check the filling and readiness for operation regularly.
The rules for the prevention of accidents and the safety • Only store inflammable materials in the machine room
regulations must be observed during maintenance work. if they are essential for operation of the system.
Reference is made in the service manual job cards to the • Smoking and naked flames are prohibited in the
regulations in Section 2.2, “Specifications,”. These must be machine room.
read before working on the engine and must be strictly
3. for operation, maintenance and repairs on the engine:
followed.
The maintenance intervals and the work to be performed are • The common rail systems used work with operating
pressures up to approximately 2000 bar. In the case of
specified in the maintenance schedule of the operation
potential faults, the pressure can even rise to
manual. The job cards contain technical documentation on significantly higher values before the pressure reducing
the execution of maintenance work. valve opens.
• After shutting down the engine, wait at least 30 seconds
2.2 SPECIFICATIONS before performing work on the fuel system.
Depending on the version of common rail system, the
2.2.1 Accident prevention and safety fuel pressure in the common rail system will still not
regulations have dissipated after 30 seconds. The fuel pressure can
permanently be several 100 bar.
The legally prescribed rules for the prevention of accidents The fuel pressure here does not drop until the fuel
must be observed. These are available from professional system is opened and the fuel can escape.
associations or from dealers. These are dependent on the
• Only start the engine when all the protective devices
application site, operating mode & operating and auxiliary have been fitted. Make sure no-one is standing in the
materials being used. danger area.
Special protection measures are specified depending on the • Cleaning, maintenance and repair work may only be
work being carried out, and are identified in the job performed with the engine at a standstill and secured
description. against starting.
Among other things it generally applies that: • Fuel lines, injection lines or fuel high-pressure lines
All information in this manual is based on the latest product must never be disconnected when the engine is
information available at the time of publication. The running.
manufacturer reserves the right to make changes and • Danger of injury. The fuel jet can deeply penetrate the
improvements to its products, and to discontinue the skin.
manufacture of any product, at its discretion at any time
• Do not come close to the leakage area in the fuel high-
without public notice or obligation.
pressure system with any body parts (for example
1. For the Personnel: hand).
• Only briefed personnel may operate or maintain the

• Always carry out an exact visual inspection of all high- 6. Electrical plug connections must be plugged when
pressure carrying components before tests on the spraying.
running engine. Wear suitable protective clothing (for
7. Remove loose parts (for example paint chips from
example goggles, gloves) for this. Leakages entail
potential hazard sources for the workshop personnel. assembly work) with an industrial vacuum cleaner or
other suction device. Only suction may be used in
• Even if no leakages can be discerned in the fuel high- assembly work on the open fuel system.
pressure system, the workshop personnel should avoid
the direct hazard zone or wear protective clothing (for 8. Only work on the fuel system in a clean environment
example goggles, gloves) during tests when the engine (no dust, no grinding or welding). Avoid draughts (dust).
is running and during the first test run. Clean the workshop floor regularly. No brake or
performance test benches may be kept or operated in
• Always stay out of range of a fuel jet, as it could cause
the same room.
severe injury.
9. Air currents which kick up dust, such as those caused by
• Fuel lines, injection lines and high-pressure lines must
brake repairs or the starting of engines, should be
not be deformed.
avoided.
• Damaged fuel lines, injection lines and
10. For work such as removal and installation on defective
high-pressure lines must be replaced.
hydraulic components on the Common Rail System. it is
• Smoking is strictly prohibited when working on the fuel recommended to partition off a separate workshop area
system. in the factory. This must be separate from other areas in
• Do not work near to sparks and flames. which general vehicle repairs such as brake repairs are
carried out.
• Never disconnect an injector when the engine is
running. 11. No general machine tools may be operated in this room.
• Loosen screw connections slowly and not abruptly. 12. Regular cleaning of the workshop area is mandatory.
Draughts, ventilation systems and heating fans should
• Open screw connections on the fuel system with be minimised.
extreme caution.
13. Areas of the engine room from which particles of dirt
• After all work on the fuel system, it must be bleeded - could be loosened (for example the bottom part of the
see the operation manual, “chapter 6 Fuel system”.
tipped driver cab) must be covered with fresh clean film.
2.2.2 Cleanliness instructions and measures 14. Working materials and tools must be cleaned before
for working with common rail systems work. Only use tools without damage to the chrome
plating or tools which are not chrome-plated.
The common rail systems used in engines comprise
high-precision components subjected to extreme loads. In b. Notes and measures to be observed during work on
view of the high-precision technology, ensure utmost the fuel system or with the fuel system open.
cleanliness when working on the fuel system.
1. Only work in clean overall.
a. Notes and measures to be observed before starting 2. Only lint-free cleaning cloths may be used for work on
work on the fuel system. the fuel system.
1. The fuel system must be closed. Make a visual 3. Remove loose parts (for example paint chips from
inspection for leaks/damage to the fuel system. assembly work) with an industrial vacuum cleaner or
2. Clean the whole engine and engine room with the other suction device. Only suction may be used in
system closed before starting work on the fuel system. assembly work on the open fuel system.
3. The engine must be dry when you start working on the 4. Working materials and tools must be cleaned before
fuel system. work. Only use tools without damage to the chrome
4. Blowing (dry) with compressed air is only permissible
with the fuel system closed. 5. Do not use used cleaning fluid or test fluid for cleaning.
5. When using a steam jet, first cover up the control unit, 6. Compressed air must not be used for cleaning on the
the cable plugs, all other electrical plug connections open fuel system.
and the generator. Also, the steam jet may not be 7. Work on removed components may only be performed
pointed directly at them. at a suitably equipped workbench.

8. When removing and installing components, no 2.2.3 Additional information and measures for
materials which can leave behind particles or fibres the handling of exhaust aftertreatment
(cardboard, wood, cloths) may be used. systems
9. Removed parts may only be rubbed down with clean, 1. Basically all the same regulations and instructions up to
lint-free cloths. No dirt particles may be rubbed into the and including Section 2.2.2, “Cleanliness instructions
components. and measures for working with common rail systems,”
10. Openings on the components and on the engine must must also be observed for work on exhaust after
be closed immediately with suitable treatment systems.
stoppers/caps. 2. Utmost cleanliness must be observed for all work.
11. The stoppers/caps may only be removed immediately
before installing. a. DPF (Diesel Particle Filter)
12. Store stoppers/caps free from dust and dirt in the 1. The filter regeneration must be deactivated or, in
original packaging and dispose of after using once. systems with a filter regeneration prompt, not activated
13. Only remove new parts from the original packaging just before performing service work.
before installation. 2. The duration of a full filter regeneration is 25 minutes on
14. Removed components must be kept in new, sealable average. High exhaust temperatures occur in the
bags or if available in the packaging of the new parts. exhaust system/on the end exhaust pipe independently
of the actual load state of the engine (i.e. also during
15. Always use the original packaging of the new part to engine idling).
send back the removed components.
3. No foreign bodies may get into the exhaust line or the
c. Notes and measures for the vehicle workshop area combustion chamber. If this happens, the engine must
be “run free” without diesel particle filter.
1. For work such as removal and installation on defective
4. Tensions and deformations of the shape of the V-belt
hydraulic components on the Common Rail System it is
clip must be avoided. The DPF module may only be
recommended to partition off a separate workshop area
transported using the transport sleeves.
in the factory. This must be separate from other areas in
which general vehicle repairs such as brake repairs are 5. V-belt clips and seals may not be reused (this also
carried out. applies as soon as the screw connection has been
loosened once).
2. The workshop floor is sealed or tiled.
3. No welding gear, grinders, general machine tools, b. Ignition system
brakes or performance test benches may be operated in
this room. 1. Caution! Dangerous high voltage.
The ignition system operates with ignition voltages up
4. Regular cleaning of the workshop area is mandatory. to 10000 Volts.
Draughts, ventilation systems and heating fans should
be minimised. 2. The ignition system must not be operated without a
secondary load.
d. Notes and measures for workbench and tools in the 3. Store the components in a dry and clean area.
vehicle hall 4. It is not permitted to store the components temporarily
1. A special workbench must be set up for work on or stack them without their transport packaging.
removed components. 5. Components may only be stored and transported in the
2. Clean the removal and installation tools regularly and specified packaging.
keep them in a closed tool cabinet. 6. Only remove new parts from the original packaging just
3. Remove loose parts (for example paint chips from before installation.
assembly work) with an industrial vacuum cleaner or 7. Incorrectly operated or damaged components or parts
other suction device. that have been dropped must not be installed.
4. Working materials and tools must be cleaned before 8. Do not subject the components to any hard impacts or
work. Only use tools without damage to the chrome any other use of force.
9. Faulty earthing, cable and plug connections can lead to
malfunctions. Electronic components can be destroyed.

10. Dirt and moisture on the primary and high voltage 2.3 OPERATION MANUAL AND SERVICE
connections can cause malfunctions (leakage current, MANUAL
misfiring, high voltage sparks).
11. Check the protective caps of the ignition lines for The use of job cards (service manual) presupposes
dis-colouration, deformation and cracks before each knowledge of the operating instructions content this
usage. applying in particular for the service specifications. Repairs to
the engine and components are described in the job cards
c. SCR (Selective Catalytic Reduction) (service manual), for the implementation of which more
effort and correspondingly qualified experts are required.
1. AdBlue® is a caustic medium which causes heavy
corrosion damage when it comes into contact with
electronic components or similar.
2.4 EXPLANATION OF SYMBOLS
2. Leaks on the AdBlue® pipes, the tank, the supply
module and the feeding unit must be fixed immediately Danger
to avoid leakage of AdBlue®. Of death or to health. Must be observed.
3. Make sure the room is well ventilated. For example: The incorrect use or conversion
4. Contact with the skin should be avoided. Wear latex of the turbocharger can lead to serious injury.
gloves if possible. Caution!
5. Wash hands thoroughly before taking breaks and at the Danger to the component/engine.
end of shifts. Non-compliance can lead to destruction of
the component/engine.
6. If the substance comes into contact with eyes, rinse Must be observed.
thoroughly with water.
Note
7. If swallowed, rinse out mouth with a lot of water, drink General notes on assembly, environmental
plenty of water and seek medical advice. protection etc. No potential danger for man
8. If discomfort or illness continues, seek medical advice. or machine.
9. Product can pose danger of slipping if spilled. It is Tool
essential to remove spilled liquid. In so doing, ensure Conventional and special tools required for
that the liquid does not enter the sewage system or the work.
ground/surface water. This means that the Auxiliary materials
contamination should be physically removed and Working materials required in addition to the
disposed of in suitable containers. Minimal amounts of tools for performing the work
remaining liquid may be rinsed away with a lot of water. (e.g. greases, oils, adhesives, sealants.
10. The so-called lag time is application-dependent and References
may be up to 2 minutes in engines with an SCR system To important documents
because the SCR pipes have to be pumped empty in this
time.
Reference
Within the workflow or to assemblies in which
2.2.4 Disposal regulations
further documents or job cards are provided.
The work described in the operation manual & service
Test and setting data
manual necessitates renewal of parts and operating
The necessary values are indicated here with
materials among other things. The renewed
link to a table within the job card.
parts/operating materials must be stored, transported and
disposed of according to regulations. The owner himself is Tightening specifications
responsible for this. The necessary values are indicated here with
Disposal includes recycling and the scrapping of link to a table within the job card.
parts/operating materials, although recycling has priority.
Details of disposal and their monitoring are governed by
regional, national and international laws and directives
which the system operator must observe on his own
responsibility.

This Page Intentionally Left Blank

Section 3
Disassembly and Assembly
Contents

3.1 Crankshaft Sealing Ring (Flywheel Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.1 Crankshaft Sealing Ring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.1.2 Crankshaft Sealing Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2 Gasket Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.1 Gasket Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.2 Gasket Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.2.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.3 Closing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4 Lubricating Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4.1 Lubricating Oil Pan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4.2 Lubricating Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.4.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.5 Closing parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6 V-Rib Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.1 V-Rib Belt Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.2 V-Rib Belt Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.6.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.7.1 Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.7.2 Cylinder Head Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.7.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.8 Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.8.1 Lubricating Oil Cooler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.8.2 Lubricating Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.8.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.9 Lubricant Oil Filter Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.10 Transfer Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.10.1 Transfer Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.10.2 Transfer Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.10.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.11 Lubricating Oil Line (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.11.1 Lubricating Oil Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.11.2 Lubricating Oil Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.11.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.12 Lubricating Oil Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.12.1 Oil Return Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.12.2 Oil Return Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.12.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3.13 High-Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3.13.1 High-Pressure Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.13.2 High-Pressure Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.13.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.14 Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3.14.1 Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3.14.2 Fixed Sealing Disc Removal at Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.14.3 Injector Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.14.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3.15 Fuel Pre-Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3.16 Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.17 Fuel Supply Pump (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.18 V-Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.19 Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.19.1 Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.19.2 High-Pressure Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.19.3 Injection Pipes Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.19.4 Pressure Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.19.5 Pressure Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.19.6 Pressure Limiting Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3.19.7 Pressure Limiting Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
3.19.8 Rail Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3.19.9 Injection Pipes Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3.19.10 High-Pressure Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3.19.11 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3.20 Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3.20.1 Fuel Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3.20.2 Fuel Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
3.20.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
3.21 Charge Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.21.1 Charge Air Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.21.2 Charge Air Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.22.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.22 Charge Air Pressure/Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.22.1 Pressure/Temperature Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.22.2 Pressure/Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.22.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.23 Charge Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.24 Coolant Pump V-Rib Belt Pulley (Engine 458-0044) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3.25 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
3.25.1 Thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
3.25.2 Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3.25.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3.26 Thermostat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
3.26.1 Checking Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
3.26.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.27 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3.28 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

3.29 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

3.29.1 Exhaust Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3.29.2 Exhaust Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
3.29.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3.30 Screw Plug (Engine 458-0044). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3.31 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3.32 Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
3.33 Compensator Structure (Exhaust Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
3.34 Line (Crankcase Housing, Exhaust Gas Circulation, Coolant Line) . . . . . . . . . . . . . . . . . 3-119
3.35 Line (Thermostat Housing, Exhaust Gas Circulation, Coolant Line) . . . . . . . . . . . . . . . . 3-120
3.36 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3.36.1 Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3.36.2 Turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
3.36.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
3.37 Exhaust Manifold (Exhaust Turbocharger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3.38 Generator (Fastening Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3.38.1 Generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3.38.2 Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3.38.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3.39 Console (V-Rib Belt, Level 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.39.1 Console Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.39.2 Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
3.39.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3.40 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3.40.1 Starter Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3.40.2 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3.40.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3.41 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3.42 Turning Gear/Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3.42.1 Turning Gear/Locking Device Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3.42.2 Rotating The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
3.42.3 Locking The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
3.43 Fuel Filter Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
3.44 Compensator Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
3.45 Impulse transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
3.46 Impulse Transmitter (Camshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3.47 Pressure Transmitter Installation (Oil Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
3.48 Connection Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3.48.1 Connection Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3.48.2 Connection Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
3.48.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
3.49 Connection Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
3.50 Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
3.50.1 Glow Plugs Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
3.50.2 Glow Plugs Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3.50.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
3.51 Differential Pressure Sensor (Diesel Particle Filter) (Engine 458-0043) . . . . . . . . . . . . 3-154
3.51.1 Differential Pressure Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154
3.51.2 Differential Pressure Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
3.51.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
3.52 Holder (Engine 458-0043). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158

3.53 Relay Holder (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
3.54 Compensator Structure (Assembly Material) (Engine 458-0043) . . . . . . . . . . . . . . . . . . 3-160
3.55 Inlet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
3.56 Outlet Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163

3.1 CRANKSHAFT SEALING RING 3.1.1 Crankshaft Sealing Ring Removal

(FLYWHEEL SIDE)
Standard tools
Special tools:
– Pricker 449-2485
– Assembly lever 449-2488
– Assembly tool 449-2500
– Self-tapping screw
– Washer
1 Gasket housing
2 Shaft sealing ring
3 Hexagon head screw
188 Loctite® 5900TM

1. Remove flywheel. 4. Pull out the crankshaft sealing ring with assembly lever.
2. Make a hole of approximately 3 mm in the crankshaft Ensure that the crankshaft does not get damaged.
sealing ring with a pricker.
Attention!
5. Visually inspect the crankshaft sealing ring running
Do not damage the gasket housing and surface.
crankshaft.
3. Screw in a self-tapping screw (1) with washer.

3.1.2 Crankshaft Sealing Ring Installation
4. Mount assembly sleeve (1).

1. Mount guide sleeve (1). 5. Press on the crankshaft sealing ring to the stop.
2. Tighten screws (2). 6. Plug in the bearing (2).
The bores in the guide sleeve must match the 7. Screw on nut (3).
threaded holes in the crankshaft flange.
8. Tighten nut to the stop of the assembly sleeve (1)

3. Place the crankshaft sealing ring carefully on the The installation depth is determined by the
assembly tool.
peripheral surface.
Do not oil waxed crankshaft sealing rings. 9. Remove assembly tool.
The sealing lip faces the crankcase. 10. Install flywheel.

3.2 GASKET HOUSING 3.2.1 Gasket Housing Removal
Standard tools
– Splint driver
– Packing compound
Loctite® 574TM
– Safety information / User

information
1 Gasket housing
2 Shaft sealing ring
234 Loctite® 574TM

11. Remove flywheel. See Section 3.1, “Crankshaft Sealing 16. Knock out crankshaft sealing ring (1).
Ring (Flywheel Side).” Attention!
12. Remove connection housing. See Section 3.48, Do not damage the sealing surfaces.
“Connection Housing.”
17. Visually inspect the components.
13. Remove lubricating oil pan. See Section 3.4,
“Lubricating Oil Pan.”
14. Unscrew all screws (1).
15. Remove gasket housing (2).

3.2.2 Gasket Housing Installation
1. Clean sealing surfaces. The sealing face (arrows) must be flush with the
oil pan sealing face.
2. Apply Loctite® 574TM (1) evenly on the sealing surface.
Sealing cord strength approx. 0.5 - 0.6 mm.
3. Mount gasket housing.

4. Tighten screws (1).

5. Tighten the screws according to the tightening

sequence.
20 Nm (15 ft-lb)
6. Renew crankshaft sealing ring (flywheel side).
See Section 3.1, “Crankshaft Sealing Ring (Flywheel
Side).”
7. Install lubricating oil pan. See Section 3.4, “Lubricating
Oil Pan.”
8. Install connection housing. See Section 3.48,
“Connection Housing.”
9. Install flywheel. See Section 3.1, “Crankshaft Sealing
Ring (Flywheel Side).”

3.2.3 Technical Data

Tightening specifications
ID no. Name Screw type Notes / Remark Value
A01 095 Gasket housing on crankcase Observe tightening sequence 20 Nm (15 ft-lb)
For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening
torque of +/- 10% is permissible.

3.3 CLOSING PARTS
Standard tools

information
1 Screw plug, Torque to 13 Nm (10 ft-lb)

2 Sealing ring
Use a new sealing ring.

3.4 LUBRICATING OIL PAN 3.4.1 Lubricating Oil Pan Removal
Standard tools
Special tools:
– Separating tool
Loctite® 5900TM
Attention!
Make sure that no gasket residue falls into the
crankcase.
Seal all openings.
Collect leaking operating substances in suitable

vessels and dispose of according to regulations.
Emptying and filling the engine with operating
media must be carried out according to the
operating manual and the appropriate 1 Lubricating oil pan
documentation of the vehicle/equipment 2 Nut
manufacturer.
3 Torx screw

1. Drain lubricating oil, collect and dispose of according to 5. Drive in second separating tool (1) to the stop (2).
regulations.
Attention!
2. Unscrew all screws (arrow).
The tool can only be driven in the area of the
3. Remove lube oil tray (1). crankcase.
Separation in the area of aluminium parts is not
allowed.
Do not damage the sealing surfaces.
4. Drive in separating tool (1) to the stop (2).

Attention!
The tool can only be driven in the area of the
crankcase. 6. Lever out lubricating oil pan.
Separation in the area of aluminium parts is not 7. Remove lubricating oil pan.
allowed.
Do not damage the sealing surfaces.

3.4.2 Lubricating Oil Pan Installation
1. Scrape off Loctite® 5900TM with separating tool. Attention!

Attention! Wear protective glasses.
Wear protective glasses. 3. Clean the sealing surface on the lubricating oil pan with
2. Clean the sealing surface on the crankcase with a wire a wire brush.
brush. The sealing surfaces must be dry and free from
grease and dirt.
The sealing surfaces must be dry and free from
grease and dirt.
4. To align the lubricating oil pan, screw four pin bolts (1)
diagonally opposed into the crankcase.

5. Clean sealing surfaces. 8. Align the lubricating oil pan in the appropriate
The sealing surfaces must be dry and free from installation position with the pin bolts.
grease and dirt. 9. Mount lubricating oil pan.
6. Apply Loctite® 5900TM to the joints (arrows).

Attention!
Do not move the lubricating oil pan any more.
Observe the drying time for the Loctite® 5900TM.
10. Unscrew the pin bolts.
11. Fasten all screws (1).
7. Apply Loctite® 5900TM evenly to the sealing surface.


sequence.
20 Nm (15 ft-lb)
13. Fill in lubricating oil according to operating manual.


A02 030 Lubricating oil pan on crankcase Observe tightening sequence. 20 Nm (15 ft-lb)

3.5 CLOSING PARTS
Standard tools
Collect draining lubricating oil and dispose of

properly.

2 Sealing ring

3.6 V-RIB BELT PULLEY 3.6.1 V-Rib Belt Pulley Removal
Standard tools
– Torque wrench >200 Nm
(148 ft-lb)
– Adapter
1/2 inch inner square
to 1 inch external square
Special tools:
– Force multiplier
– Pin type socket wrench
insert, wrench size 36
– Turning gear / locking
device
– Counter support
– Marker pen, waterproof,

permanent

1 Sensor wheel
information
3 Clamping pin
4 V-rib belt pulley
5 Central screw
6 Clamping pin
7 Washer

1. Remove V-belt. 5. Pull out and turn detent pin (1).

2. Remove starter. See Section 3.40, “Starter.” Observe position of the latches (2).
3. Insert turning gear / locking device (1).
Toothed wheel of the turning gear / locking 6. Turn drive (3) carefully until the detent pin latches into
device in the toothed starter ring. place.
Observe engine direction of rotation.
30 Nm (22 ft-lb)

Version Without Air-conditioning System Version With Air-conditioning System

7. Push spacer sleeve (2) onto screw-in bolt (1). 10. Unscrew screw (1).
8. Screw on the screw-in bolt (1) and spacer sleeve (2). 11. Screw on screw-in bolt (2).
9. Tighten the screw-in bolt (1). 12. Tighten the screw-in bolt (2).
50 Nm (22 ft-lb) If a console is available for the coolant
compressor, mount the screw-in bolt without the
spacer sleeve.
50 Nm (22 ft-lb)

13. Attach pressure plate (1). 15. Align spline end (1) in such a way that the screw-in bolt
Bores (2) and threaded bores (3) must be in lies almost in the centre of the recess.
alignment. 16. Tighten screws (2).
14. Tighten all screws (4).
30 Nm (22 ft-lb)
30 Nm (22 ft-lb)

18. Insert counter support (1). 21. Insert socket wrench insert and force multiplier (1).
19. Fasten all screws (2). 22. Snap in non-return device (2) in position CCW.
30 Nm (22 ft-lb)
Depending on the installation situation, the

counter holder can be positioned variably.
23. Hold force multiplier.

24. Loosen central screw in direction of arrow.
25. Remove force multiplier and socket wrench insert.
26. Remove central screw.

3.6.2 V-Rib Belt Pulley Installation
27. Loosen screws (1).

1. Install sensor wheel.
2. Press in the clamping pin (1) to the end stop.
Attention!
Ensure that the installation location is free from
faults.
28. Unscrew screws (1).

29. Remove counter holder (2).
31. Remove compressor plate (4)
32. Pull off V-belt pulley.
33. Remove sensor wheel. 3. Apply help marking (1).

4. Pull out and turn detent pin (1). 8. Attach V-belt pulley to bore (2) with clamping pin (1).
Observe position of the latches (2). Observe help markings.
5. Turn drive (3) carefully up to the desired crankshaft 9. Press on V-belt pulley.
position.
10. Turn in new central screw with socket wrench insert.

6. Turn drive carefully until the bore (1) is at the top and
11. Attach pressure plate (1).
the detent pin latches into place.
Bores (2) and threaded bores (3) must be in
7. Apply help marking (2). alignment.

30 Nm (22 ft-lb)

13. Align spline end (1) in such a way that the screw-in bolt 17. Insert counter support (1).
lies almost in the centre of the recess.
30 Nm (22 ft-lb)
30 Nm (22 ft-lb)
Depending on the installation situation, the
counter holder can be positioned variably.
16. Tighten new central screw with torque wrench.

Stage 1:
19. Insert socket wrench insert and force multiplier (1).
100 Nm (74 ft-lb)
20. Snap in non-return device (2) in position CW.

21. Set graduated collar (1) to “0”. 24. Keep torque wrench pressed in direction of arrow.
25. Move non-return device (1) into position CCW.
Danger!
There is danger of injury if a force multiplier is
removed without being discharged.
26. Remove force multiplier and socket wrench insert.
22. Hold force multiplier (1).

23. Tighten central screw in direction of arrow.
Stage 2:
130°
27. Loosen screws (1).

28. Unscrew screws (1). Version With Air-conditioning System

29. Remove counter holder (2). 34. Unscrew screw-in bolt (1).
30. Unscrew screws (3). 35. Fasten screw (2).
31. Remove compressor plate (4) 36. Tighten screw (2).
Version Without Air-conditioning System 37. Unscrew screw (1).

32. Unscrew screw-in bolt (1). 38. Remove turning gear / locking device (2).
33. Remove screw-in bolt (1) and spacer sleeve (2). 39. Install starter. See Section 3.40, “Starter.”
40. Mount and tighten V-belt.


Use new screw.
A05 030 V-rib belt pulley on crankshaft 100 Nm (74 ft-lb)
Stage 1:
A05 030 V-belt pulley on crankshaft Stage 2: 130°
A49 050 Turning gear / locking device, fastening 30 Nm (22 ft-lb)

3.7 CYLINDER HEAD COVER 3.7.1 Cylinder Head Removal
Standard tools
– Fitting compound
Ultra 5 Moly

information
1 Cylinder head cowling

2 Seal
3 Screw
4 Filler lock
5 Plug piece

1. Removing the crankcase breather. 5. Remove gasket (1).

2. Unscrew screws (1). 6. Visually inspect the components.
3. Remove cylinder head cowling (2).
4. Pull out plug element (1).

3.7.2 Cylinder Head Cover Installation
3. Insert new plug piece (1).

1. Mount new gasket (1).
4. Mount cylinder head cover (1).

2. Coat new plug piece (1) with Ultra 5 Moly.


sequence.
8.5 Nm (6 ft-lb)
6. Install crankcase breather.


A08 004 Cylinder head cover on cylinder head 8.5 Nm (6 ft-lb)

3.8 LUBRICATING OIL COOLER 3.8.1 Lubricating Oil Cooler Removal
Standard tools

The appropriate operating manual should be
observed for emptying and filling the engine.
1 Lubricating oil cooler

2 Seal

3.8.2 Lubricating Oil Cooler Installation

2. Remove lubricating oil cooler (2). 1. Visually inspect the components.
3. Remove gasket (3). 2. Clean sealing surfaces.
Collect draining lubricating oil and dispose of 3. Turn in screws, M8x20-10.9 (arrows).
properly.
4. Fasten new seal (1) on lubricant oil cooler housing with
4. Visually inspect the components. screws.
5. Mount lubricating oil cooler (1).

7. Tighten all screws (2) alternately.
30 Nm (22 ft-lb)


A15 051 Oil cooler housing on crankcase 30 Nm (22 ft-lb)

3.9 LUBRICANT OIL FILTER CONSOLE
Standard tools
8190

information

Observe the appropriate operating instructions
for emptying and filling the engine.
1 Interchangeable filter, Torque to 12 Nm (9 ft-lb)

2 Threaded bush, Torque to 40 Nm (29 ft-lb)
3 Cover
4 O-ring
5 Hexagon head screw, Torque to 30 Nm (22 ft-lb)
Use new round sealing ring.

3.10 TRANSFER LINE 3.10.1 Transfer Line Removal
Standard tools
8190
Loctite® 5900TM
1 Transfer line
2 Torx screw

3.10.2 Transfer Line Installation
1. Remove lubricating oil pan. See Section 3.4,

“Lubricating Oil Pan.”
1. Clean sealing surfaces.
Attention!
3. Remove transfer line (2).
No Loctite® 5900TM must get into the oil
4. Visually inspect the component. channel (1).


4. Mount transfer line (1).
20 Nm (15 ft-lb)
6. Install lubricating oil pan. See Section 3.4, “Lubricating
Oil Pan.”


A01 016 Transfer line on crankcase 20 Nm (15 ft-lb)

3.11 LUBRICATING OIL LINE (ENGINE 3.11.1 Lubricating Oil Line Removal
458-0043)
Standard tools

1 Lubricating oil line

2 Hollow screw
3 Sealing ring
1. Unscrew hollow screw (1).

2. Remove sealing rings (2).

3.11.2 Lubricating Oil Line Installation
3. Unscrew hollow screw (1).

4. Remove sealing rings (2). 1. Clean sealing surfaces.
5. Remove lubricating oil pipe (3). 2. Mount lubrication oil line (1).
3. Mount sealing rings (2).
4. Screw on hollow screw (3).

6. Mount lubrication oil line (1).
7. Mount sealing rings (2).
8. Tighten hollow screw (3).
18 Nm (13 ft-lb)

Attention!
Install tension-free.
9. Tighten hollow screw (1).

18 Nm (13 ft-lb)
Attention!


Lubricating oil pipe on exhaust turbo-
A43 047 Hollow screw Use new sealing rings 18 Nm (13 ft-lb)
charger
A43 048 Lubricating oil line on crankcase Hollow screw Use new sealing rings 18 Nm (13 ft-lb)

3.12 LUBRICATING OIL RETURN LINE 3.12.1 Oil Return Line Removal
Standard tools
– Disassembly tool
Ultra 5 Moly

1 Fastening flange
2 O-ring
3 Oil return line
4 O-ring
7 Seal

1. Unscrew screws (1). 5. Remove flange (1) in direction of arrow.

2. Remove gasket (2). 6. Remove round sealing ring (2) with disassembly tool.
7. Visually inspect the component.
3. Unscrew screw (1).

4. Pull out oil return line (2) in direction of arrow. 8. Remove the O-ring (1) with the disassembly tool.

3.12.2 Oil Return Line Installation

1. Clean sealing surfaces. 9. Mount oil return pipe (1).
2. Lightly coat new round sealing ring with Ultra 5 Moly 10. Insert oil return line (1) in direction of arrow.
mounting compound. 11. Fasten screw (2).
3. Insert new O-ring (1).

4. Clean sealing surfaces. 13. Mount gasket (1).
5. Lightly coat new round sealing ring with Ultra 5 Moly 14. Mount oil return pipe (2).
mounting compound.
6. Insert new O-ring (1).
8.5 Nm (6 ft-lb)
7. Insert flange (2) in direction of arrow.

16. Tighten screw (1).

8.5 Nm (6 ft-lb)
Attention!


A43 044 Oil return line on exhaust turbocharger 8.5 Nm (6 ft-lb)
A43 046 Oil return line on crankcase 8.5 Nm (6 ft-lb)

3.13 HIGH-PRESSURE PUMP 3.13.1 High-Pressure Pump Removal
Standard tools:
– Separating tool
– Key 449-2496
– Plugs/caps 449-2493
– Mirror
permanent
– Multipurpose Grease

information
Danger!
Do not carry out work on the fuel system when 1 High-pressure pump
the engine is running.
The fuel system is under high pressure - Danger of 2 Spacer
death. 3 Hexagonal nut
The fuel pressure can continuously remain up to
several 100 bar even after stopping the engine. 4 Washer
Here the fuel pressure is only reduced if the fuel 5 O-ring
system is opened and the fuel can escape outside.
6 Hexagonal nut
Attention! 7 O-ring
Ensure utmost cleanliness for all work. 293 Multipurpose Grease

Remove any paint residue and dirt particles
before disassembly.
Clean the area around the components
concerned carefully. Blow wet parts dry with
compressed air.
Observe the safety regulations and national
specifications for handling fuels.
Close all connections immediately after opening
with new, clean plugs/caps.
Do not remove plugs/caps until immediately
before assembling.

1. Unlock cable plug and remove. 7. Turn crankshaft in engine direction of rotation until
2. Remove high-pressure line. marking is visible.
3. Remove fuel pipes. Note: (1) Marking high-pressure pump gear wheel
4. Unscrew locking screw (1).
5. Remove sealing ring. See Section 3.1, “Crankshaft
Sealing Ring (Flywheel Side).”
6. Install turning gear / locking device. See Section 3.42,
“Turning Gear/Locking Device.”
8. Apply help marking (1).

High-pressure pump gear wheel and intermediate
gear
Attention!
Do not turn the crankshaft any more.

9. Unscrew nuts (1).

Attention! Attention!
Do not twist the high-pressure pump. Do not damage the high-pressure pump gear
Do not twist the spacer. wheel.
Do not damage the components.
10. Remove high-pressure pump (2). Use a suitable tool.
Attention!
Do not turn the crankshaft any more. 11. Hold high-pressure pump gear wheel (1).
12. Unscrew nut (2).
13. Remove washer (3).
14. Pull off high-pressure pump gear wheel (1) with
separating tool.
15. Remove spacer (4).

3.13.2 High-Pressure Pump Installation
17. Remove the O-rings (1) with the disassembly tool.

Attention! 1. Clean sealing surfaces.
All the help markings must be transferred when 2. Mount new O-rings (1).
renewing/changing a part.
3. Push on spacer (2).
Do not turn the crankshaft any more.
Attention!
faults.
Recess (3) is on the fuel supply side.

4. Mount high-pressure pump gear wheel (1).

Attention! Attention!
Pay attention to installation position. Ensure that the installation location is free from
faults.
Note: (2) Surrounding groove
Do not damage the high-pressure pump gear
Note: (3) Marking wheel.
The clamping pin (1) must engage in the
groove (2).
5. Fit washer (3).
6. Screw on nut (4).
Use a suitable tool.
7. Hold high-pressure pump gear wheel (5).

8. Tighten nuts (4).
80 Nm (59 ft-lb)

9. Coat the O-ring (1) with multipurpose grease.

10. Coat bordering surfaces of the spacer (2) with Attention!
multipurpose grease.
Observe direction of rotation of the high-pressure
pump drive.
Observe position of the drive shaft and high
pressure pump.
Note: (1) Marking high-pressure pump gear wheel.
View Direction of rotation
On high-pressure pump drive right (clockwise)
Attention!
Dry running is not permissible.
Sufficient fuel pressure must be available at the
high-pressure pump.
Note: Fuel pressure at the supply: at least 4.3 bar

11. Install high-pressure pump.

Attention!
Markings must be visible. Do not twist the high-pressure pump.
Help marking must match. 12. Screw on nuts (1).
Note: (1) Marking high-pressure pump gear wheel 13. Tighten nuts (1).
Note: (2) Help marking high-pressure pump gear wheel and 20 Nm (15 ft-lb)
intermediate gear
14. Install locking screw.
15. Install fuel pipes.
16. Fit new high-pressure line.
17. Plug in and lock cable plug.
18. Remove turning gear / locking device. See Section 3.42,
“Turning Gear/Locking Device.”


High-pressure pump gear wheel and Hold high-pressure pump gear
A17 004 80 Nm (59 ft-lb)
high-pressure pump drive shaft wheel.
A17 031 High-pressure pump on crankcase 20 Nm (15 ft-lb)

3.14 INJECTOR 3.14.1 Injector Removal
Standard tools
– Diagnostic tool SerDia 2010

– Assembly pliers
– Torx tool set
– Lever tool 449-2497
– Extraction tool
– Slide hammer

information
Danger!
Do not carry out work on the fuel system when
The fuel system is under high pressure - 1 Injector
Danger of death. 2 Sealing disc
3 Clamping claw
several 100 bar even after stopping the engine.
Here the fuel pressure is only reduced if the fuel 4 Torx screw
5 Clip
6 O-ring
Attention!
Ensure utmost cleanliness for all work.
before disassembly.
compressed air.
Close all connections immediately after
opening with new, clean plugs/caps.
before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according to
regulations.

1600 Bar Injection system
1. Unlock cable plug and remove.

2. Disconnect the fuel line from the injector. See Section
3.14, “Injector.”
Attention!
Note assignment of the injector to the
Attention!
cylinder. Position (1):
The injector is assigned by the relevant The injector must be renewed if the pipe
IMA code (1) to the corresponding cylinder. connection is disconnected.
The assignment is saved in the control unit. 3. Hold pipe connection (1).
Each time an injector is replaced/renewed, the 4. Remove injection line.
correct assignment to the relevant 5. Unscrew screw (2).
cylinder must be made by transferring the new
IMA code in the control unit.
Observe installed injection system.
The IMA codes of the different injection systems
are basically different.
The injector calibration depends on the installed
injection system.
The exact procedure can be taken from the listed
documentation and must be observed.
The following work procedure describes the

removal and installation of an injector.
Proceed in the same way to remove further
injectors.

6. Insert lever tool (1) in the clamping claw.

7. Loosen the injector by moving the lever tool (1) in the Attention!
direction of the arrow.
Do not damage the injector.
8. Remove injector and clamping claw.
10. Remove the round sealing ring (1) carefully from the
injector with the disassembly tool.
Attention!
Do not brush off the nozzle tip of the injector.
Do not damage nozzle head on the injector dur-
ing disassembly of the sealing disc (1).
9. Grip fixed sealing disc (1) using the assembly pliers (2)
and pull off with slight turning movements.

3.14.2 Fixed Sealing Disc Removal at Cylinder

Head
4. Install slide hammer (1) on disassembly device.

5. Pull out fixed sealing disc.
1. Insert extraction device (1).
The supports (arrow) must rest in the bore of
the sealing disc.
2. Screw in spindle (1) until the sealing disc is fastened on

the pull-out device.
Hold puller on hexagon.
3. Install adapter (2) on disassembly device.

3.14.3 Injector Installation
Attention!
Attention! Note assignment of the injector to the cylinder.
Do not damage the O-ring. Ensure that the installation location is free from
faults.
1. Mount new O-ring (1).
3. Insert injector carefully in the cylinder head.
4. Mount clamping shoe.
5. Insert screw (1).
Do not tighten the screw until after assembling
the injection line.
6. Mount new injection pipe.

Do not tighten union nuts.
2. Mount new sealing disc (1) on injector.

Attention!
Before installing the injector, combustion residue
must be cleaned carefully from the bore on the
cylinder head.
Suck off dirt particles.

Attention!
Position (1):
The injector must be renewed if the pipe
connection is disconnected.
30 Nm (22 ft-lb)
8. Tighten union nuts of the injection line.
9. Connect fuel line.
Attention!
Removed, missing and bent clips must be
renewed.
The clip must spring back to the hold position
automatically. Otherwise renew the clip.


Observe order of
A19 001 Injector on cylinder head, clamping claw installation. 30 Nm (22 ft-lb)
Install injector without tension.

3.15 FUEL PRE-FILTER
Standard tools

information
– Operation manual
Danger!
The fuel system is under high pressure -
Danger of death.
Here the fuel pressure is only reduced if the fuel
1 Fuel pre-filter
3 Sensor, Torque to 1.6 Nm (1 ft-lb)
Attention!
Ensure utmost cleanliness for all work. 4 Sealing ring
Remove any paint residue and dirt particles 10 Fuel filter
before disassembly.
concerned carefully. Blow wet parts dry with Use a new sealing ring.
compressed air. Vent fuel system according to operating
Observe the safety regulations and national instructions.
Close all connections immediately after opening Fuel pre-filter
before assembling.

3.16 FUEL FILTER
Standard tools
8190

information
Danger!
Danger of death.
1 Fuel spare filter
3 Pressure sensor, Torque to 25 Nm (18 ft-lb)
Attention!
Ensure utmost cleanliness for all work. 4 Hexagon head screw, Torque to 42 Nm (31 ft-lb)
Remove any paint residue and dirt particles 6 O-ring
before disassembly.
10 Filter head
compressed air. Use new round sealing ring.
before assembling.

3.17 FUEL SUPPLY PUMP (ENGINE 458-0043)
Standard tools

information
Danger!
Do not carry out work on the fuel system when the
engine is running.
Danger of death.
system is opened and the fuel can escape outside. 1 Supply pump
2 Clip
Attention! Fastening Screws, 4 x M5-8.8
7.5Nm (5 ft-lb)
Remove any paint residue and dirt particles before
disassembly.
Clean the area around the components concerned Attention!
carefully. Blow wet parts dry with compressed air. Ensure that the installation location is free from
Observe the safety regulations and national faults.
before assembling.

1 Nut Terminal +, Torque to 7.5 Nm (5 ft-lb)

2 Nut Terminal -, Torque to 7.5 Nm (5 ft-lb)
3 Connection Nozzle Fuel outlet
Attention!
Ensure that the cables are connected properly.

3.18 V-BELT PULLEY
Standard tools

information
1 V-belt pulley

3.19 RAIL 3.19.1 Rail Removal
Standard tools:
– Wrench insert size 14
– Long socket wrench insert

– Key 449-2496

permanent
– Multipurpose Grease

information
Danger!
Do not carry out work on the fuel system when the 1 Rail
engine is running.
The fuel system is under high pressure - 2 High-pressure line
Danger of death. 3 Injection line
several 100 bar even after stopping the engine. 4 Injection line
Here the fuel pressure is only reduced if the fuel 5 Torx screw
6 Spacer
Attention! 7 Repair kit
Ensure utmost cleanliness for all work. Pressure sensor

Remove any paint residue and dirt particles before Pressure limiting valve
disassembly.
8 Nut
Clean the area around the components concerned
carefully. Blow wet parts dry with compressed air. 9 Screw
10 Pipe clip
Close all connections immediately after opening 11 O-ring
with new, clean plugs/caps. 259 Mounting grease
before assembling.

3.19.2 High-Pressure Line Removal 3.19.3 Injection Pipes Removal
1. Remove fuel return line. 1. Unscrew lock nuts (1) with special wrench.
2. Unscrew union nut (1) with special wrench. Attention!
3. Remove cable harness holder and swing aside. Position (3):
4. Unscrew union nuts (2) with special wrench. The injector must be renewed if the pipe
connection is disconnected.
5. Remove high-pressure line (3).
Collect draining fuel and dispose of according to 2. Hold pipe connection of injector.
regulations. 3. Unscrew lock nuts (2).
4. Remove injection lines.
Collect draining fuel and dispose of according to
regulations.

3.19.4 Pressure Sensor Removal
5. Unlock cable plug.

6. Pull out cable plug. 1. Unscrew the rail pressure sensor (1) with the socket
7. Unscrew screws (1). wrench.
8. Remove the rail (2). Collect draining fuel and dispose of according to
regulations.
9. Remove spacer (3).

3.19.5 Pressure Sensor Installation
Attention!
Do not touch the pin contacts of the rail pressure Attention!
sensor with your hands to avoid electrostatic dis-
No foreign bodies may get into the rail.
charging.
Ensure utmost cleanliness. Especially on the
Ensure absolute cleanliness of the connector.
thread and the sealing surface of the rail.
2. Visually check the thread and the sealing edge (arrows)
See the spare parts documentation.
of the rail pressure sensor.
Rail pressure sensor and pressure limiting valve
must be replaced as a pair.
1. Clean thread and sealing area of the rail.
2. Coat the thread and sealing edge of the rail pressure
sensor lightly with assembly grease.

3.19.6 Pressure Limiting Valve Removal
Attention! 1. Unscrew pressure limiting valve (1).

Only tighten the rail pressure sensor with the Collect draining fuel and dispose of according to
hexagon. regulations.
3. Screw in rail pressure sensor (1).
4. Tighten rail pressure sensor (1) with the socket wrench
insert.
70 Nm (52 ft-lb)
2. Visually check the thread and the sealing edge of the

pressure limiting valve.

3.19.7 Pressure Limiting Valve Installation
3. Remove the O-ring with the disassembly tool.
Attention!
No foreign bodies may get into the rail.
Ensure utmost cleanliness. Especially on the
thread and the sealing surface of the rail.
See the spare parts documentation.
Rail pressure sensor and pressure limiting valve
must be replaced as a pair.
1. Mount new O-ring (1).

3.19.8 Rail Installation
2. Lightly coat the thread and sealing edge of the pressure

limiting valve with assembly grease.
1. Mount rail (1) with spacer (2).
2. Loosely preassemble rail (1) with screws (3).
Do not tighten screws.
3. Clean thread and sealing area of the rail.

4. Screw in pressure limiting valve (1).
5. Tighten pressure limiting valve.
100 Nm (74 ft-lb)

3.19.9 Injection Pipes Installation
Attention!
Attention! Pay attention to alignment of the injection pipes.
The injection lines must always be renewed after Lines must not be in the bores (1) of the union
disassembly. nuts.
Install injection lines without tension and without
touching.
Note assignment and installation position of the
They must be a safe distance away from adjacent
injection lines.
parts.
1. Mount new injection lines (1). 2. Align injection lines.
3. Tighten union nuts hand-tight.

3.19.10 High-Pressure Line Installation
Attention!
Attention! Pay attention to alignment of the high-pressure
line.
The high-pressure line must always be renewed
after dismantling. Line may not touch in the bore (1) of the union
nut.
Install high-pressure line without tension and
Ensure that the installation location is free from contact.
faults.
They must be a safe distance away from adjacent
1. Mount new high-pressure line (1). parts.
2. Align high-pressure line.
3. Tighten union nuts hand-tight.

4. Tighten screws (1). 6. Draw help markings (1).

30 Nm (22 ft-lb) 7. Tighten union nut.
Stage 2:
+ 5°
60°
8. Check injection lines for perfect installation position.
9. Check the high-pressure line for perfect installation
position.
10. Mount fuel return line.
11. Mount cable harness holder.
Ensure that the connection is perfect.
5. Tighten the union nuts in order.

Stage 1:
10 Nm (7 ft-lb)


Injection line on rail and injector, Stage 1:
A21 003 high-pressure line on high-pressure Union nut Observe assembly instructions. 10 Nm (7 ft-lb)
pump and on rail Use new line.
Injection line on rail and injector,
+ 5°
A21 003 high-pressure line on high-pressure Stage 2: 60°
pump and on rail
A21 038 Rail on cylinder head Observe assembly specification. 30 Nm (22 ft-lb)
Lightly coat the thread and seal-
A21 039 Pressure limiting valve on rail 100 Nm (74 ft-lb)
ing edge with assembly grease.
Lightly coat the thread and seal-
A21 040 Pressure sensor on rail M18x1.5 70 Nm (52 ft-lb)
ing edge with assembly grease.

3.20 FUEL LINE 3.20.1 Fuel Line Removal
Standard tools
– Spring band pliers 449-2489


information
Danger!
Danger of death.
1 Fuel line
Attention!
2 Return line
3 Hose holder
before disassembly. 5 Spring band clip
6 Hose pipe
compressed air. 7 Pipe clip
Observe the safety regulations and national 8 Hexagon head screw
before assembling.

6. Loosen spring band clip (1) with spring band pliers.

Attention! 7. Pull off hose pipe (2).
Removed, missing and bent clips must be 8. Remove fuel line (3).
renewed. 9. Visually inspect the components.
The clip must spring back to the hold position
10. Replace damaged components.
automatically. Otherwise renew the clip.
Attention!
1. Press in the clip (1) to the stop.
Damaged fuel lines must be replaced completely.
2. Pull out return line (2).
3. Remove return line (1) from hose holder (2).

4. Unlock coupling plug (3) and pull off.

3.20.2 Fuel Line Installation
Attention!
Attention!
faults.
Damaged fuel lines must be replaced completely.
Fuel line with fabric casing:
If a hose piece is pulled off of the hose connec-
faults.
tion, the hose line must be replaced completely.
Lines must be pushed on so that they are flush.
Push hose piece onto the hose connection up to
1. Position fuel pipe. the end stop.
2. Position the spring band clip (1) with the spring band 4. Position fuel pipe.
pliers.
5. Insert return line (1) in hose holder (2).
+2
Dimension X 4 −2 mm
6. Position pipe clips (3).
3. Mount the hose pipe (2).
8. Mount coupling plug (5) and latch into place.


Attention! 30 Nm (22 ft-lb)
Removed, missing and bent clips must be
renewed. 12. Carry out a trial run.
The clip must spring back to the hold position 13. Check fuel system for leaks.
automatically. Otherwise renew the clip. 14. Visual inspection for leaks
9. Position return line (1) vertically to the injector.
10. Insert return line (1) in injector by hand.
Attention!
faults.
Return line must snap in audibly.


A12 095 Pipe clips, fastening 30 Nm (22 ft-lb)

3.21 CHARGE AIR LINE 3.21.1 Charge Air Line Removal
Standard tools

information
1 Charge air line

2 Seal

3.21.2 Charge Air Line Installation
1. Remove fuel return line.

2. Unlock cable plug and disconnect. 1. Clean sealing surfaces.
3. Unscrew screws (1). 2. Mount new gasket (1).
4. Remove charge air line (2). 3. Turn screws into the seal a few turns.
5. Remove gasket (3). The seal is locked by the screw thread.
6. Visually inspect the components. Ensure that the installation location of the gasket
is free from faults.

4. Mount charge air line (1). 6. Tighten the screws according to the tightening
5. Tighten screws (2). sequence.
Do not move gasket. 30 Nm (22 ft-lb)
Attention!
Ensure that the cables are laid perfectly.

8. Mount fuel return line.


A22 030 Charge air line on cylinder head 30 Nm (22 ft-lb)

3.22 CHARGE AIR PRESSURE/TEMPERATURE 3.22.1 Pressure/Temperature Sensor Removal

SENSOR
Standard tools
Special tools:
Ultra 5 Moly

information
1 Pressure/Temperature sensor
3 O-ring
242 Ultra 5 Moly
1. Unlock cable plug.

2. Pull out cable plug.
3. Unscrew screw (1).
4. Remove pressure/temperature sensor (2).
3.22.2 Pressure/Temperature Sensor

Installation
5. Remove the O-ring (1) with the disassembly tool.

6. Visually inspect the component. 1. Insert new O-ring (1).
2. Lightly coat O-ring with Ultra 5 Moly.
3. Insert pressure/temperature sensor.

Ensure that the installation location is free
from faults.

11 Nm (8 ft-lb)
5. Plug on cable plug.



Pressure/temperature sensor on charge
A48 046 Use new round sealing ring 11 Nm (8 ft-lb)
air line

3.23 CHARGE AIR LINE
Standard tools
Special tools:

information
1 Hose pipe
2 Spring band clip
3 Spring band clip
4 Seal
5 Charge air line
Use a new gasket.

Positions
1
2
3
Attention!
faults.
Dimension I - 1 mm
Dimension II - 4 mm
Dimension III - 2 mm
Dimension IV - 24 mm

3.24 COOLANT PUMP V-RIB BELT PULLEY

(ENGINE 458-0044)
Standard tools

information
1 V-rib belt pulley


3.25 THERMOSTAT 3.25.1 Thermostat Removal
Standard tools
8190

1 Thermostat housing
2 Thermostat
4 Sealing ring
6 Seal
8 Temperature sensor

3.25.2 Thermostat Installation
1. Drain, collect and dispose of coolant according to

regulations.
2. If present: Remove coolant hose from outlet nozzle.
2. Insert thermostat (1).
4. Remove thermostat housing (2)
3. Insert screws (1).

4. Fix new gasket (2) to the thermostat housing with
screws.
6. Remove gasket (1).
7. Remove thermostat (2).

5. Mount thermostat housing (1).

7. Fasten screws (3).

30 Nm (22 ft-lb)
9. If present: Push coolant hose onto outlet nozzle and
fasten.
10. Fill cooling system according to the operating manual.


A38 001 Thermostat housing on cylinder head 30 Nm (22 ft-lb)

3.26 THERMOSTAT TEST 3.26.1 Checking Thermostat
Standard tools:
– Thermometer
Danger!
Risk of injury.
Hot water and hot thermostat.
1 Thermostat housing
2 Thermostat
4 Sealing ring
6 Seal
8 Temperature sensor

1. Measure beginning of stroke, dimension (a). 3. Heat up the thermostat in the water bath.
2. Note measured value, dimension (a). 4. Determine beginning of opening.
In order to determine the exact beginning of
opening, the temperature should be measured as
close as possible to the thermostat.
Do not touch the thermostat.
The water should be continuously stirred for an
even temperature distribution. The temperature
rise should not take place faster than 1°C/min.
Otherwise the beginning of opening will be
delayed accordingly.
Nominal value:
86°C

5. Measure water temperature. 8. Determine stroke.

Nominal value:
99°C Calculation Example
6. Measure end of stroke, dimension (b). Desired: Stroke

7. Note measured value, dimension (b). Given: -
Beginning of stroke, dimension (a)
Measured:
End of stroke, dimension (b)
Calculation: Dimension (b) - dimension (a)
Result: = stroke
9. Compare result with setpoint value.
Nominal value:
9 mm


Testing and setting data
ID no. Name Additional information Value
P38 11 Thermostat, beginning of opening 86°C
P38 13 Thermostat, stroke at 99 , minimum 9 mm
P38 14 Thermostat, stroke, test temperature 99°C

3.27 LINE
Standard tools
8190
1 Coolant line
12 Washer

3.28 LINE
Standard tools
8190
Special tools:

information

1 Elbow
2 Spring band clip
3 Coolant line
4 Pipe clip
5 Hose pipe
7 Support plate

Position
5
Attention!
Lay the hose pipe free from chafing and tension.
Marking (1) faces the crankcase.

3.29 EXHAUST LINE 3.29.1 Exhaust Line Removal
Standard tools
1 Exhaust line
2 Seal

3.29.2 Exhaust Line Installation
1. Remove turbocharger. See Section 3.36,

“Turbocharger.”
2. Remove cooler. See Section 3.8, “Lubricating Oil Cooler.”
3. Turn in screws (arrows).
4. Remove exhaust line (2).
4. Fasten new seal (1) with screws on exhaust line.

6. Mount exhaust line (1).
Note installation position.


sequence.
30 Nm (22 ft-lb)
9. Install the turbocharger. See Section 3.36,
“Turbocharger.”
10. Install cooler. See Section 3.8, “Lubricating Oil Cooler.”


A41 001 Exhaust line on cylinder head Observe tightening sequence 30 Nm (22 ft-lb)

3.30 SCREW PLUG (ENGINE 458-0044)

Standard tools
8190

information


2 O-ring

3.31 CONNECTION
Standard tools
8190
Ultra 5 Moly

1 Hose nozzles
2 O-ring
1. Lightly coat new round sealing ring with Ultra 5 Moly

mounting compound.

3.32 HOLDER
Standard tools

information
1 Holder, Torque to 20 Nm (15 ft-lb)


3.33 COMPENSATOR STRUCTURE (EXHAUST

LINE)
Standard tools
1 Compensator
2 Seal
Use a new gasket.
Attention!
Check seal.
faults.
Install without tension (without torsional stresses)
and do not pre-compress.

3.34 LINE (CRANKCASE HOUSING, EXHAUST

GAS CIRCULATION, COOLANT LINE)
Standard tools
8190
Special tools:

1 Hose pipe
2 Spring band clip
Attention!

3.35 LINE (THERMOSTAT HOUSING,

EXHAUST GAS CIRCULATION, COOLANT
LINE)
Standard tools
8190
Special tools:
– Torx tool set

1 Coolant line
2 Torx screw, Torque to 10 Nm (7 ft-lb)
4 Pipe clip
5 Seal
6 Rubber sleeve
7 Spring band clip
8 Sealing ring
Attention!
Use a new gasket.


3.36 TURBOCHARGER 3.36.1 Turbocharger Removal
Standard tools
1 Exhaust turbocharger
2 Seal

3.36.2 Turbocharger Installation
1. Remove intake nozzle.

2. Remove the lubricating oil line. 1. Clean sealing surfaces.
3. Remove lubricating oil return line. See Section 3.12, 2. Mount gasket (1).
“Lubricating Oil Return Line.” 3. Mount turbocharger (2).
5. Remove turbocharger (2).
30 Nm (22 ft-lb)
5. Fit intake nozzle.
6. Install lubricating oil line.
7. Install lubricating oil return line. See Section 3.12,
“Lubricating Oil Return Line.”


A43 020 Turbocharger on exhaust line 30 Nm (22 ft-lb)

3.37 EXHAUST MANIFOLD (EXHAUST

TURBOCHARGER)
Standard tools
1 Exhaust manifold
2 Clip
3 Nut, Torque to 10 Nm (7 ft-lb)

3.38 GENERATOR (FASTENING PARTS) 3.38.1 Generator Removal
Standard tools

1. Remove V-rib belt.

2. Disconnect the battery's negative terminal.
3. Remove plus cable.
4. Unlock cable plug (1) and disconnect.

3.38.2 Generator Installation

6. Remove generator (2). 1. Mount generator (1).
7. Visually inspect the components. 2. Tighten screws (2).
42 Nm (31 ft-lb)
3. Mount cable plug (1) and lock.

4. Fit plus cable.
5. Connect the battery's negative terminal.
6. Position V-rib belt.


A44 012 Generator on console 42 Nm (31 ft-lb)

3.39 CONSOLE (V-RIB BELT, LEVEL 1) 3.39.1 Console Removal
Standard tools
Loctite® 574TM

information
1 Console
2 Clamping sleeve
4 Clamping pin
234 Loctite® 574TM

3.39.2 Console Installation
1. Remove V-rib belt.

2. Remove generator (level 1). See Section 3.41, 1. Clean sealing surfaces.
“Generator.”
Make sure the clamping pin (arrow) is in place.
4. Remove console (2).

Sealing cord strength approx. 3 mm

4. Mount console (1) over the clamping pins. 7. Tighten all screws according to the tightening
5. Fasten screw (2). sequence.
M8x85-10.9 30 Nm (22 ft-lb)
6. Fasten screws (3). 8. Mount generator (level 1). See Section 3.41, “Generator.”
M8x60-10.9 9. Fit the V-rib belt according to the running direction.


A44 013 Console on crankcase/gear case 30 Nm (22 ft-lb)

3.40 STARTER 3.40.1 Starter Removal
Standard tools
1 Starter
1. Disconnect the battery's negative terminal.

2. Remove plus cable.
3. Unlock cable plug and remove.
5. Remove starter (2).
3.40.2 Starter Installation
1. Insert starter (1).

2. Insert screws (2).
60 Nm (44 ft-lb)
Attention!
Lay the cables free from chafing and tension.

5. Fit plus cable.
6. Connect the battery's negative terminal.


A44 001 Starter on connection housing 60 Nm (44 ft-lb)

3.41 GENERATOR
Standard tools

information
1 Generator
2 Voltage regulator
3 Fan
7 V-rib belt pulley
8 Fastening parts, Torque to 90 Nm (66 ft-lb)

3.42 TURNING GEAR/LOCKING DEVICE 3.42.1 Turning Gear/Locking Device Installation
Standard tools
Special tools:
– Turning gear / locking
device

information
1. Remove starter. See Section 3.40, “Starter.”

2. Insert turning gear / locking device (1).
Toothed wheel of the turning gear / locking
device in the toothed starter ring.

30 Nm (22 ft-lb)

3.42.2 Rotating The Engine 3.42.3 Locking The Engine
1. Pull out and turn detent pin (1). 1. Pull out and turn detent pin (1).
Observe position of the latches (2). Observe position of the latches (2).
2. Turn drive (3) carefully up to the desired crankshaft 2. Turn drive (3) carefully until the detent pin latches into
position. place.
Observe engine direction of rotation. Observe engine direction of rotation.
Attention!
Detent pin must latch easily into place.
The crankshaft is locked and can no longer be
turned.

3.42.4 Turning Gear / Locking Device

Installation

2. Remove turning gear / locking device (2).
3. Install starter. See Section 3.40, “Starter.”


A49 050 Turning gear / locking device, fastening 30 Nm (22 ft-lb)

3.43 FUEL FILTER FASTENING PARTS
Standard tools
8190

information
Danger!
Danger of death.
Attention!
before disassembly.
compressed air.
before assembling.

3.44 COMPENSATOR STRUCTURE
Standard tools

information
Danger!
Hot components.
Danger of burns/explosion.
Let the engine/components cool down
sufficiently (to at least ambient temperature).
Attention!
The installation situation is application and
equipment-dependent. 1 Compensator
The documentation of the vehicle manufacturer/
equipment manufacturer must be observed for
disassembly and installation. Use new gaskets.
Externally damaged parts must be renewed. Use new V-belt clips.
V-belt clips must be replaced each time they are
loosened.
The gaskets must be disposed of properly and Attention!
always renewed. Check seal.

Use new gaskets.

Use new V-belt clips.
Attention!
Install without tension (without torsional
stresses) and do not pre-compress.
faults.
Note flow direction.
The arrow indicates the flow direction.
Check seal.
Dimension X 198 mm

3.45 IMPULSE TRANSMITTER
Standard tools
Special tools:

information
Attention!
before disassembly.
compressed air.
1 Holder
before assembling. 2 Impulse transmitter
3 Hexagon head screw, Torque to 8.5 Nm (6 ft-lb)
5 O-ring
1. Remove the O-ring with the disassembly tool.

2. Insert new O-ring.

3.46 IMPULSE TRANSMITTER (CAMSHAFT)
Standard tools

information
1 Impulse transmitter
3 O-ring


3.47 PRESSURE TRANSMITTER

INSTALLATION (OIL PRESSURE)
Standard tools:
– Long socket wrench insert

information
1 Pressure sensor, Torque to 25 Nm (18 ft-lb)

2 O-ring

3.48 CONNECTION HOUSING 3.48.1 Connection Housing Removal
Standard tools

2 Bushing
1. Remove flywheel. See Section 3.1, “Crankshaft Sealing

3. Remove connection housing (2).

3.48.2 Connection Housing Installation

1. Clean contact surfaces. 5. Tighten all screws (1) alternately.
Make sure the clamping bushings (1) are in 170 Nm (125 ft-lb)
place.
6. Install flywheel. See Section 3.1, “Crankshaft Sealing
2. Position connection housing (1).

3. Centre connection housing over the clamping
bushings.


A52 080 Connection housing on crankcase Tighten diagonally opposed 170 Nm (125 ft-lb)

3.49 CONNECTION HOUSING
Standard tools

information
1 Connection housing
3 Cover plate
5 Sealing ring

3.50 GLOW PLUGS 3.50.1 Glow Plugs Removal
Standard tools:
– Crowfoot wrench size 10
Special tools:
– Torque handle
– Insert holder long

information
1 Glow plug
2 Connecting rail
1. Disconnect the battery.

2. Unscrew nuts (1).
3. Remove connecting rail (2).

3.50.2 Glow Plugs Installation
4. Unscrew glow plugs (1).

5. Visually inspect the components. 1. Screw in glow plugs (1).
Attention!
faults.
2. Tighten glow plugs (1).
13.5 Nm (10 ft-lb)

3. Mount connecting rail (1).

4. Turn on nuts (2).
Attention!
5. Tighten nuts (2).

2.5 Nm (2 ft-lb)


A63 032 Glow plug on cylinder head 13.5 Nm (10 ft-lb)
A63 033 Connecting rail on glow plug 2.5 Nm (2 ft-lb)

3.51 DIFFERENTIAL PRESSURE SENSOR 3.51.1 Differential Pressure Sensor Removal

(DIESEL PARTICLE FILTER) (ENGINE
458-0043)
Standard tools
Special tools:
– Hose clip pliers
– Special wrench
– Key 449-2496

information
– Installation guideline
Danger!
Hot components. 1. Unlock cable plug and remove.
Danger of burns/explosion. 2. Remove hose pipe (1).
sufficiently (to at least ambient temperature). 3. Remove hose pipe (2).
The filter regeneration must be deactivated or, in Attention!
systems with a filter regeneration prompt, not Note assignment and installation position.
activated before performing service work.
4. Remove screws.
5. Remove differential pressure sensor (3).
Attention!
before disassembly.
compressed air.
before assembling.

3.51.2 Differential Pressure Sensor Installation
Attention!
Note assignment and installation position.
Attention!
7. Unscrew lock nut (1). The following must be observed during
installation:
8. Unscrew lock nut (2).
Component manufacturer installation guidelines.
9. Remove hose pipes. Installation guideline/documentation of the vehi-
10. Visually inspect the components. cle manufacturer/equipment manufacturer.
faults.
1. Mount hose pipes.
2. Tighten lock nut (1).
Pipe diameter 6 mm
20 Nm (15 ft-lb)
3. Tighten lock nut (2).
Pipe diameter 8 mm
28 Nm (21 ft-lb)

4. Install differential pressure sensor (1).

5. Tighten screws.
6 Nm (4 ft-lb)
6. Mount hose pipe (2).
7. Mount hose pipe (3).
Attention!
faults.


A71 069 Pipe, differential pressure sensor Pipe diameter 8 mm 28 Nm (21 ft-lb)
A71 069 Pipe, differential pressure sensor Pipe diameter 6 mm 20 Nm (15 ft-lb)
A71 070 Differential pressure sensor, fastening 6 Nm (4 ft-lb)

3.52 HOLDER (ENGINE 458-0043)
Standard tools
8190

information
Danger!
Hot components.
Attention!
equipment-dependent. 1 Holder
disassembly and installation.
Make sure that the inlet module, outlet module,
particle filter, V-belt clips and fastening points are
reassembled in the same installation position.
Do not scratch or damage surfaces.
Externally damaged parts must be renewed.
All the help markings must be transferred when
loosened.
The gaskets must be disposed of properly and
always renewed.
1 Screw, Torque to 12 Nm (9 ft-lb)

2 Clamping band

3.53 RELAY HOLDER (ENGINE 458-0043)
Standard tools
8190
1 Holding plate
3 Relay

3.54 COMPENSATOR STRUCTURE (ASSEMBLY

MATERIAL) (ENGINE 458-0043)
Standard tools

information
Danger!
Hot components.
Attention!
1 Clip, Torque to 12 Nm (9 ft-lb)
equipment-dependent. 2 Seal
disassembly and installation. Use new gaskets.
Externally damaged parts must be renewed. Use new V-belt clips.
loosened.
The gaskets must be disposed of properly and Attention!
always renewed.
Ensure that the installation location is free
from faults.
Check seal.

3.55 INLET MODULE

Attention!
Standard tools: equipment dependent.
– Industrial vacuum cleaner Externally damaged parts must be renewed.
– Lifting gear The documentation of the vehicle manufacturer/
– Carrying straps equipment manufacturer must be observed for
– Fitting compound Dismantling and assembly should only be done in
Henkel C5-A Anti-Seize the vertical position.
– Cleaning fleece All the help markings must be transferred when
– Marker pen, waterproof, renewing/changing a part.
permanent V-belt clips must be replaced each time they are
loosened.
The gaskets must be disposed of properly and
– Safety information / User always renewed.
information
Use a new gasket.
Danger!
Hot components.
Danger of burns.
Do not carry out work when the engine is
running.
When using hoists (workshop crane) the safety
regulations for handling hoists must be observed.
It is not permitted to stay under moving loads.
Place the components on a level and secure
surface.
Secure the components against tipping over.
Wear a respirator with at least protection class
FFP2, goggles and protective gloves as protection
against fine dust and soot particles.
Extract soot from the end faces with an industrial
vacuum cleaner.
Do not blow compressed air onto soot-covered
areas.


Use a new gasket.
1 Inlet module
2 V-belt clip, Torque to 10 Nm (7 ft-lb)
4. Coat surfaces (arrows) with Henkel C5-A Anti-Seize.
3 Seal
Attention!
4 Cap, Torque to 10 Nm (11 ft-lb) Make sure it is applied evenly and without gaps.
V-belt clip must be replaced each time it is
1. Mark installation position.
loosened.
2. Apply help markings.
5. Perform leak test.
Attention!
faults.
Make sure that the inlet module, outlet module,
particle filter, V-belt clips and fastening points are
reassembled in the same installation position.
Do not scratch or damage surfaces.
Note flow direction.
The arrow indicates the flow direction.

3.56 OUTLET MODULE

Attention!
Standard tools: equipment-dependent.
– Industrial vacuum cleaner Externally damaged parts must be renewed.
– Lifting gear The documentation of the vehicle manufacturer/
– Carrying straps equipment manufacturer must be observed for
Dismantling and assembly should only be done in
the vertical position.
Henkel C5-A Anti-Seize
– Cleaning fleece
permanent
loosened.

information
Danger!
Hot components.
Danger of burns.
Do not carry out work when the engine is
running.
When using hoists (workshop crane) the safety
regulations for handling hoists must be observed.
It is not permitted to stay under moving loads.
Place the components on a level and secure
surface.
Secure the components against tipping over.
Wear a respirator with at least protection class
FFP2, goggles and protective gloves as protection
against fine dust and soot particles.
Extract soot from the end faces with an industrial
vacuum cleaner.
Do not blow compressed air onto soot-covered
areas.

1 Outlet module
Attention!
Disassemble and assemble according to the job
card listed below.
See Section 3.55, “Inlet module.”

Section 4
Special Tools
Contents

4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.1 Pressure Pump (P/N 449-2474) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Assembly Pliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Socket Wrench Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.4 Measuring Instrument (P/N 449-2482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.5 Torx Tool Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.6 Rotation Angle Disc (P/N 449-2484). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.7 Pricker (P/N 449-2485) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.8 Disassembly Tool (P/N 449-2487) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.9 Assembly Lever (P/N 449-2488). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.10 Spring Band Pliers (P/N 449-2489) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.11 Long Socket Wrench Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.12 Plug (P/N 449-2493). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.13 Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.1.14 Key (P/N 449-2496) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.1.15 Lever Tool (P/N 449-2497) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.1.16 Disassembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.1.17 Assembly Tool (P/N 449-2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.18 Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.19 Separating Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.1.20 Turning/Locking Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Special Tools
4.1 TOOLS 4.1.3 Socket Wrench Insert
Special tools:
These must be ordered like a normal spare
part by specifying the order number.
4.1.1 Pressure Pump (P/N 449-2474)
• Wrench size 32
4.1.4 Measuring Instrument (P/N 449-2482)
• Checking cooling system for leak-tightness.
4.1.2 Assembly Pliers
• 150 to 600 N.
• Check V-belt tension.
• Removing valve shaft seals.

Special Tools
4.1.5 Torx Tool Set 4.1.7 Pricker (P/N 449-2485)
• Contents of case: • Removing rotary shaft lip seal.

- Double-ended ring spanner E6/E8.
4.1.8 Disassembly Tool (P/N 449-2487)
- Double-ended ring spanner E10/E12.
• Socket wrench insert E8 and E10 (1/4 inch).
- Socket wrench insert E10 and E12 (3/8 inch).
- Socket wrench insert E18 (1/2 inch).
4.1.6 Rotation Angle Disc (P/N 449-2484)
• Disassemble pin screw (M8).
• With magnet.
• Setting valve clearance.

Special Tools
4.1.9 Assembly Lever (P/N 449-2488) 4.1.11 Long Socket Wrench Insert
• Removing and installing valves. • Installing and removing pressure sensors (rail pressure,
oil pressure, fuel pressure).
4.1.10 Spring Band Pliers (P/N 449-2489)
4.1.12 Plug (P/N 449-2493)
• 320 mm
• 1 set of differently-sized stoppers and caps.
• Tighten spring clamp.
• Sealing openings on the fuel system.

Special Tools
4.1.13 Assembly Tool 4.1.15 Lever Tool (P/N 449-2497)
• Mount pin screw (M8). • Removing the injector.
4.1.14 Key (P/N 449-2496) 4.1.16 Disassembly Tool
• Wrench size 17. • Removing O-ring.

• Removing and installing high-pressure lines.

Special Tools
4.1.17 Assembly Tool (P/N 449-2500) 4.1.19 Separating Tool
• Installing crankshaft sealing ring (flywheel side). • Removing metal sheet lubricating oil pan from
crankcase.
4.1.18 Assembly Tool
4.1.20 Turning/Locking Device
• Installing crankshaft sealing ring (opposite side to

flywheel). • Turn or block crankshaft at the flywheel.

Section 5
Engine Electrical Schematic
Contents

5.1 Engine Harness (Engine 458-0043) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Engine Harness (Engine 458-0044) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 Equipment Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Power Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Exhaust After Treatment Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-2
5.1
U
0.75 BK
C OOLING
t
1
B43
0.75 BK
D2
TE MPE R ATUR E
N6
N6
X17:62
1
1.5 BK 1.5 BK
X17:24 X17:35
CYL. 1
A28
A33 A16
Y15.1
2
0.75 BK 1.5 BK 1.5 BK
INJ E C TOR
X17:28
1
0.75 BK 0.75 BK
U
A47 A17
X17:29
2
0.75 BK 0.75 BK
N6
N6
X17:22 X17:42
B48
1
0.75 BK 0.75 BK 0.75 BK 1.5 BK 1.5 BK
3
KC
TE MPE R ATUR E
p&t
X17:23 X17:37
A48 A18
A40 A27 A24 A43

CYL. 4
Y15.3
2
0.75 BK 0.75 BK 1.5 BK 1.5 BK
4
INJ E C TOR
BOOS T PR E S S UR E /
P
1
0.75 BK
A31 A01
X17:26
A44
0.75 BK 0.75 BK
2
N6
N6
B6
X17:38
1
1.5 BK
3
1.5 BK
KD
X17:27 X17:61
CYL. 3
A29
A32 A02
OIL PR E S S UR E
Y15.2
U
2
0.75 BK 0.75 BK 1.5 BK 1.5 BK
4
0.75 BK
VA
INJ E C TOR
N6
sheet4:X23.2:14
N6
0.75 BK X17:40
1
1.5 BK 1.5 BK
P
0.75 BK
1
X17:41
CYL. 2
A46 A03
Y15.4
1.5 BK
2
X17:17 1.5 BK
K61
INJ E C TOR
0.75 BK 0.75 BK
B 51
3
FUE L LOW
PR E S S UR E
ENGINE HARNESS (ENGINE 458-0043)
U
0.75 BK
4
N6
N6
X17:20
1
1.5 BK 1.5 BK
MPR OP
X17:19
A05 A04
Y19
1.5 BK
2
1.5 BK
AC TUATOR
X17:31
P
0.75 BK 0.75 BK
1
FUE L
X17:25
0.75 BK 0.75 BK
2
B 49
X17:32
A25 A26 A07
A57 K56
U
0.75 BK 0.75 BK
3
R AIL PR E S S UR E
EDC17CV54 Connector Teil 1
A59
2
X17:14
U
0.75 WH 0.75 WH
N7
N7
1
X17:13
A37 A52
B40.1
0.75 BK 0.75 BK
C AMS HAFT
X17:2
sheet5:K15.1
0.75 BK 0.75 BK X17:9
START-RELAY
E NG INE S PE E D
X17:3 0.75 BK 0.75 BK

CS B40.1:C
CS B40.1:B
K28 K73
CS B40.1:A
sheet5:K15.2
0.75 BK 0.75 BK
A53
0.75 BK
K47
2
X17:15
U
0.75 WH 0.75 WH
N7
1
N7
X17:21
B40.2
0.75 BK 0.75 BK
C R ANKS HAFT
X17:1
A39 A54 A38
E NG INE S PE E D
X23.1:56 0.75 BK 0.75 BK 0.75 BK

CS B40.2:C
CS B40.2:B
CS B40.2:A
sheet5:K2.1
0.75 BK 0.75 BK
PRE-HEAT-RELAY X23.1:55
A35 A45
sheet5:K2.2
0.75 BK 0.75 BK
K17 K72
X23.1:53
A23
sheet5:K2.3
0.75 BK 0.75 BK
PRE-HEAT-RELAY SENS
MAP31770
TH414C GC, TH417C GC, TH314D, TH417D

D2
X23.2:4 X23.2:6
2.5 BK 2.5 BK 2.5 BK 2.5 BK 2.5 BK 2.5 BK
A1
B1
D2
VI
VH
4.0 BK 2.5 BK 2.5 BK 4.0 BK 4.0 BK
X23.2:5 X23.2:7
K02 K04 K06

K01 K03 K05
2.5 BK 2.5 BK 2.5 BK 2.5 BK 2.5 BK
KI.31 / TERMINAL 31
2.5 BK
KI.30 / TERMINAL 30
N6
N6
N6
VJ
X23.1:9
K38
A1
B1
X23.1:50
CAN 0 H (OUTPUT) 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK 2.5 BK 2.5 BK
15
30
VK
X23.1:51 X23.1:24
K54 K76
K88 K35
CAN 0 L (OUTPUT) 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
(120 Ohm)
50
X23.1:61
K78 K52 K45

CAN 0 H (INPUT) 0.75 BK 0.75 BK sheet4:X23.2:1
S1
0.75 BK
X23.1:62
S WITC H
IG NITION
CAN 0 L (INPUT) 0.75 BK 0.75 BK
N6
N6
Generell Customer CAN

X23.1:57
K17
1
1
0.75 BK 0.75 BK 0.75 BK
N6
X23.1:7
N6
K68 K41
BRAKE
X17:48
2
2
0.75 BK 0.75 BK
SWITCH

1
1.5 BK 1.5 BK
VL
X23.1:16
M
3
0.75 BK 0.75 BK 0.75 BK
0.75 BK
X17:47
X23.1:17
2
1.5 BK 1.5 BK
1
0.75 BK 0.75 BK 0.75 BK
4
VM
X23.1:18 X23.2:10 X17:51
K14
BRAKE
sheet4:VO
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
5
SWITCH
0.75 BK 0.75 BK
3
Y20
GND
X23.1:19
K62 K63 K46 K16

X17:46
A20 A19 K77 K85

0.75 BK 0.75 BK
6
REDUNDANT
0.75 BK
E XHAUS T G AS
0.75 BK 0.75 BK
4
X23.2:36
SIG
B77
R E C IR C ULATION
POS
1
0.75 BK 0.75 BK
7
X17:50
X23.2:32 X23.2:37 NEG
AC C E LE R ATOR
0.75 BK 0.75 BK
PE DAL S WITC H
5
5V
0.75 BK 0.75 BK
2
0.75 BK 0.75 BK
8
X23.2:33 X23.2:39
A10
RES
0.75 BK 0.75 BK 0.75 BK 0.75 BK
9
CRUISE
OFF
X23.2:34 X23.2:38
K18 K37 K32 K12

CONTROL
K60
0.75 BK 0.75 BK 0.75 BK 0.75 BK
10
X23.2:35
K66
0.75 BK 0.75 BK 0.75 BK
0.75 BK
11
0.75 BK
12
0.75 BK
X23.1:2
0.75 BK
1
0.75 BK 0.75 BK 0.75 BK
X23.1:36
SWITCH
K87 K67
2
0.75 BK 0.75 BK
CONTROLLER
1
0.75 BK
0.75 BK
X23.1:5
K15
1
2
0.75 BK 0.75 BK 0.75 BK
SWITCH
CLUTCH
Level
X23.1:40
K13
2
K82 K58
0.75 BK 0.75 BK
0.75 BK
Coolant
or V-Belt
1
0.75 BK
0.75 BK
X23.1:39
K40
1
2
0.75 BK 0.75 BK 0.75 BK
AKTIVATION
switch
X23.1:37
K86
pressure
Air-Filter
2
0.75 BK 0.75 BK
differential
1
0.75 BK
0.75 BK
X23.1:8
K19
SWITCH
1
2
0.75 BK 0.75 BK 0.75 BK
DROOP
CHOICE
X23.1:41
SWITCH
K22
REGENERATION DIAGNOSTIC
2
0.75 BK 0.75 BK
2
X23.1:52
0.75 BK
0.75 BK 0.75 BK 0.75 BK
1
X23.1:27
LAMP
K29 K92
3
X39:6
1
0.75 BK 0.75 BK 0.75 BK
OBD OR
RESERVE
STOP
X23.1:42 0.75 BK 0.75 BK
U
DPF
K31
ENGINE
SWITCH
0.75 BK
2
0.75 BK 0.75 BK
2
0.75 BK
X39:7
2
0.75 BK
0.75 BK 0.75 BK
VD
B 58
1
PR E S S UR E
X23.1:28
LAMP
X39:8
K48
K84 K44 K83
P
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
PREHEAT
SWITCH
DIFFE R E NTIAL
X23.1:38
K42
OVERRIDE
2
0.75 BK 0.75 BK
2
0.75 BK
1
X23.1:11 X23.2:28
K10 K69
n
TEMPE-
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK
RATURE
SPEED
COOLANT
WARNING
X23.1:10
SENSOR
K34 K11
VEHICLE
K21 K20
2
0.75 BK 0.75 BK
U
2
X23.1:32
0.75 BK 0.75 BK
LAMP
1
X23.1:22 X23.1:33
K70 K65
K80
1
2
3
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK
DIAGNOSTIC
MSS 1
2
X23.1:23 X23.1:58
K74
K33
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
VN
1
X23.1:31 LAMP
K90 K71

0.75 BK 0.75 BK
X23.1:20
A12
1
2
1
0.75 BK
3
0.75 BK 0.75 BK
DPF SYSTEM
X23.1:26
sheet5:K3.2
0.75 BK 0.75 BK
FUEL PUMP
MSS 2
X23.1:21 X23.1:25
K26
A51
sheet5:K3.1
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK
2
X23.1:44
K79
t
OIL
1
0.75 BK 0.75 BK 0.75 BK
TURE
1
X23.1:29
K89 K27
AMBIENT
U
2
0.75 BK 0.75 BK 0.75 BK
TEMPERA-
WARNING
X23.1:43
2
t
1
0.75 BK 0.75 BK 0.75 BK
VO
1
X23.1:4 X23.1:30
TURE 1
K39 K82
K93
U
ENGINE
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK

N6
N6
TEMPERA-
X23.1:47
RUNNING
COSTOMER
0.75 BK
sheet3:X17:51 0.75 BK 0.75 BK CAN 1 L ( OUTPUT )
VF
N8
X23.2:13 X23.1:1 120 Ohm

2
A11
t
X23.1:46
K53 K75
N4
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK CAN 1 H ( OUTPUT )
0.75 BK 0.75 BK
VG
X23.1:35
1
X23.2:14
TEMP.
A50 A34
N8
sheet2:VA
RATION
U
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK
REGENA-
AIR INLET
INDICATOR
X23.2:8
N6
1
0.75 BK 0.75 BK X23.1:49
FAN
X23.2:9 0.75 BK
CAN 1 L ( INPUT )
MAP31780
A60 A15
2
0.75 BK 0.75 BK 120 Ohm
X23.1:48 N4
CONTROL 1
0.75 BK CAN 1 H ( INPUT )
X23.2:1
sheet3:D2:K45
1
0.75 BK 0.75 BK
n
X23.2:15
K91
2
0.75 BK 0.75 BK
SENSOR
FAN SPEED
U
3
0.75 BK
MAP31790
X23.1:3 X23.1:15
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK ENGINE SPEED
LE VE L
X23.1:13 X23.2:12
WATE R
F78
K64 K57
K49 K25
IN FUE L
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK TORQUE OUTPUT
5-3
KI.30 / TERMINAL 30
U-BAT.+ SWITCHED /
TERMINAL 15
A1 A1
10A / 24V
150A
B1
20A / 12V B1
S TAR TE R PR E -HE AT
R E LAY R E LAY R E LAY
K3 K15 K2
1 2 3 4 1 2 3 4 1 2 3 4
0.75 BK
0.75 BK
10.0 BK
0.75 BK
0.75 BK
0.75 BK
0.75 BK
0.75 BK
X18
1 1
2.5 BK
2.5 BK
P M4 FUE LPUMP M M1 S TAR TE R 2.5 BK

2.5 BK
2 2 sheet2:X23.1:56
sheet2:X23.1:55
sheet2:X23.1:53
sheet4:X23.1:25
sheet2:X17:2
sheet2:X17:3
sheet4:X23.1:26
R1.1 R1.2 R1.3 R1.4
HE ATE R PLUG HE ATE R PLUG HE ATE R PLUG HE ATE R PLUG
KI.31 / TERMINAL 31
MAP31800

5.2
U
0.75 BK
COOLING
t
1
B43
0.75 BK
D2
TEMPERATURE
N6
N6
X 17:62
1
1.5 BK 1.5 BK
X 17:24 X 17:35
CYL. 1
A28
A33 A16
Y15.1
2
0.75 BK 1.5 BK 1.5 BK
INJECTOR
X17:28
1
0.75 BK 0.75 BK
U
A47 A17
X17:29
2
0.75 BK 0.75 BK
N6
N6
X17:22 X 17:42

B48
TEMPERATURE
1
3
0.75 BK 0.75 BK 0.75 BK 1.5 BK 1.5 BK
KC
p&t
X17:23 X 17:37
CYL. 4
A48 A18
A40 A27 A24 A43
BOOST PRESSURE /
Y15.3
2
0.75 BK 1.5 BK
4
0.75 BK 1.5 BK
INJECTOR
P
0.75 BK
1
A31 A01
X17:26
A44
0.75 BK 0.75 BK
2
N6
N6
B6
X 17:38
1
1.5 BK
3
1.5 BK
OIL PRESSURE
KD
X17:27 X 17:61
CYL. 3
A32 A02
A29
Y15.2
U
2
0.75 BK 0.75 BK 1.5 BK
INJECTOR
1.5 BK
4
0.75 BK
VA
N6
sheet4:X23.2:14
N6
0.75 BK X 17:40
1
1.5 BK 1.5 BK
0.75 BK
P
1
X 17:41
CYL. 2
A46 A03
Y15.4
2
1.5 BK 1.5 BK
INJECTOR
K61
X17:17
0.75 BK 0.75 BK
B51
3
FUEL LOW
PRESSURE
U
0.75 BK
4
ENGINE HARNESS (ENGINE 458-0044)
N6
N6
X 17:20
1
1.5 BK 1.5 BK
MPROP
X 17:19
Y19
A05 A04
2
1.5 BK 1.5 BK
ACTUATOR
X 17:31
P
0.75 BK 0.75 BK
1
FUEL
X 17:25
0.75 BK 0.75 BK
2
B49
X 17:32
A57 K56
A25 A26 A07
U
0.75 BK 0.75 BK
3
RAIL PRESSURE
A59
:
2
X 17:14
U
0.75 WH 0.75 WH
:
N7
N7
1
X 17:13
A37 A52
CAMSHAFT
B40.1
X 17:2 0.75 BK 0.75 BK

sheet5 K15.1
ENGINE SPEED
0.75 BK 0.75 BK X 17:9

START-RELAY
X 17:3 0.75 BK 0.75 BK
CS B40.1:C
K28 K73
CS B40.1:B
CS B40.1:A
sheet5 K15.2
0.75 BK 0.75 BK
A53
0.75 BK
K47
2
X 17:15
U
0.75 WH 0.75 WH
N7
1
N7
X 17:21
B40.2
0.75 BK 0.75 BK
CRANKSHAFT
ENGINE SPEED
X 17:1
A39 A54 A38
X 23.1:56 0.75 BK 0.75 BK 0.75 BK

CS B40.2:C
CS B40.2:B
CS B40.2:A
sheet5:K2.1
0.75 BK 0.75 BK
PRE-HEAT-RELAY X 23.1:55
A35 A45
sheet5:K2.2
0.75 BK 0.75 BK
K17 K72
X 23.1:53
A23
sheet5:K2.3
0.75 BK 0.75 BK
PRE-HEAT-RELAY SENS
MAP31810
5-5
5-6
D2
X23.2:4 X23.2:6
2.5 BK 2.5 BK 2.5 BK 2.5 BK 2.5 BK 2.5 BK
B1
A1
VI
VH
4.0 BK 2.5 BK 2.5 BK 4.0 BK 4.0 BK
X23.2:5 X23.2:7
K02 K04 K06

K01 K03 K05
2.5 BK 2.5 BK 2.5 BK 2.5 BK 2.5 BK
KI.31 / TERMINAL 31
2.5 BK
KI.30 / TERMINAL 30
N6
N6
N6
VJ
X23.1:9
B1
A1
X23.1:50
CAN 0 H (OUTPUT) 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK 2.5 BK 2.5 BK
15
30
VK
X23.1:51 X23.1:24
K54 K76
K88 K35
CAN 0 L (OUTPUT) 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
(120 Ohm)
50
D2
X23.1:61
CAN 0 H (INPUT) 0.75 BK 0.75 BK
S1
SWITCH
X23.1:62
IGNITION
CAN 0 L (INPUT) 0.75 BK 0.75 BK
K38
N6
N6
Generell Customer CAN

X23.1:57
K17
1
1
0.75 BK 0.75 BK 0.75 BK
X23.1:7
K68 K41
BRAKE
K78 K52 K45
2
2
0.75 BK 0.75 BK
SWITCH
s heet4:X23.2:1
VL
X23.1:16 0.75 BK
3
0.75 BK 0.75 BK 0.75 BK
0.75 BK
X23.1:17
4
0.75 BK 0.75 BK 0.75 BK
VM
X23.1:18 X23.2:10
K14
BRAKE
5
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
SWITCH
X23.1:19
K62 K63 K46 K16
6
0.75 BK 0.75 BK
REDUNDANT
0.75 BK
N6
N6
X23.2:36 X 17:48
B77
POS
7
0.75 BK 0.75 BK
1
1.5 BK 1.5 BK
X23.2:32
PEDAL SWITCH
X23.2:37 NEG
ACCELERA TOR
M
X 17:47
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK
8
2
X23.2:33 X23.2:39 RES

1.5 BK 1.5 BK
A10
0.75 BK 0.75 BK
3
0.75 BK 0.75 BK
9
X 17:51
CRUISE
OFF
X23.2:34 X23.2:38 s heet4:V O
K18 K37 K32 K12

CONTROL
3
0.75 BK 0.75 BK
Y20
0.75 BK 0.75 BK 0.75 BK 0.75 BK
10
GND
EXHAUST GAS
X23.2:35 X 17:46
A20 A19 K77 K85
K66
RECIRCULATION
0.75 BK 0.75 BK 0.75 BK
0.75 BK
4
0.75 BK 0.75 BK
11
SIG
0.75 BK X 17:50
12
0.75 BK 0.75 BK
5
5V
0.75 BK
X23.1:2
0.75 BK
1
0.75 BK 0.75 BK 0.75 BK
X23.1:36
SWITCH
K60
K87 K67
2
0.75 BK 0.75 BK
CONTROLLER
0.75 BK
1
0.75 BK
X23.1:5
K15
2
1
0.75 BK 0.75 BK 0.75 BK
SWITCH
CLUTCH
Level
X23.1:40
K13
2
0.75 BK 0.75 BK
0.75 BK
Coolant
or V-Belt
1
0.75 BK
0.75 BK
X23.1:39
K40
2
1
0.75 BK 0.75 BK 0.75 BK
AKTIVATION
switch
X23.1:37
K86
pressure
Air-Filter
2
0.75 BK 0.75 BK
differential
1
0.75 BK
0.75 BK
X23.1:8
K19
K82 K58
SWITCH
1
2
0.75 BK 0.75 BK 0.75 BK
DROOP
CHOICE
X23.1:41
SWITCH
K22
REGENERATION DIAGNOSTIC
2
0.75 BK 0.75 BK
X23.1:52
0.75 BK
0.75 BK 0.75 BK 0.75 BK
X23.1:27
1
LAMP
K29 K92
1
0.75 BK 0.75 BK 0.75 BK
OBD OR
RESERVE
STOP
X23.1:42
K31
ENGINE
SWITCH
0.75 BK
2
0.75 BK 0.75 BK
2
0.75 BK
X23.1:28
1
LAMP
K48
1
0.75 BK 0.75 BK 0.75 BK
PREHEAT
SWITCH
X23.1:38
K42
OVERRIDE
2
0.75 BK 0.75 BK
2
0.75 BK
X23.2:28
1
X23.1:11
K10 K69
n
1
0.75 BK
TEMPE-
0.75 BK 0.75 BK 0.75 BK 0.75 BK
RATURE
SPEED
COOLANT
WARNING
X23.1:10
SENSOR
K34 K 11
VEHICLE
2
0.75 BK 0.75 BK
U
K84 K44 K83
X23.1:32
2
0.75 BK 0.75 BK
LAMP
X23.1:33
1
X23.1:22
K70 K65
K80
1
2
3
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK
DIAGNOSTIC
MSS 1
X23.1:58
2
X23.1:23
K74
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK
VN
K21 K20
1
X23.1:31
K90 K71

LAMP
0.75 BK 0.75 BK
X23.1:20
A12
1
2
0.75 BK
3
1
0.75 BK 0.75 BK
DPF SYSTEM
X23.1:26
sheet5:K3.2
0.75 BK 0.75 BK
FUEL PUMP
MSS 2
X23.1:21 X23.1:25
K26
A51
sheet5:K3.1
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK
K33
2
X23.1:44
K79
t
1
OIL
0.75 BK 0.75 BK 0.75 BK
TURE
1
X23.1:29
K89 K27
AMBIENT
U
2
0.75 BK 0.75 BK 0.75 BK
TEMPERA-
WARNING
X23.1:43
t
1
0.75 BK 0.75 BK 0.75 BK
VO
1
X23.1:4 X23.1:30
TURE 1
K93
K39 K82
U
0.75 BK 0.75 BK
ENGINE
0.75 BK 0.75 BK 0.75 BK 0.75 BK
TEMPERA-
RUNNING
COSTOMER
sheet3:X17:51
0.75 BK
X23.1:1
2
X23.2:13
t
A11
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK
X23.1:35
1
X23.2:14
A50 A34
TEMP.
sheet2:VA
U
RATION
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK
REGENA-
AIR INLET
INDICATOR
X23.2:8
N6
N6
1
0.75 BK 0.75 BK X 23.1:47
FAN
X23.2:9 CAN 1 L ( OUTPUT )
A60 A15
0.75 BK 0.75 BK
VF
2
0.75 BK 0.75 BK
N8
120 Ohm
K53 K75
X 23.1:46 N4
CONTROL 1
0.75 BK 0.75 BK CAN 1 H ( OUTPUT )
VG
N8
X23.2:1
MAP31830
sheet3:D2:K45
1
0.75 BK 0.75 BK
n
MAP31820
X23.2:15
K91
2
0.75 BK 0.75 BK
SENSOR
N6
FAN SPEED
U
X 23.1:49
3
0.75 BK CAN 1 L ( INPUT )
0.75 BK
120 Ohm
X 23.1:48 N4
X23.1:3 X23.1:15 0.75 BK CAN 1 H ( INPUT )
1
0.75 BK 0.75 BK 0.75 BK 0.75 BK 0.75 BK ENGINE SPEED
LEVEL
WATER
X23.1:13 X23.2:12
F78
IN FUEL
K64 K57
K49 K25
2
0.75 BK 0.75 BK 0.75 BK 0.75 BK TORQUE OUTPUT

KI.30 / TERMINAL 30
U-BAT.+ SWITCHED /
TERMINAL 15
A1 A1
10A / 24V
150A
B1
20A / 12V B1
STARTER PRE-HEAT
RELAY RELAY RELAY
K3 K15 K2
1 2 3 4 1 2 3 4 1 2 3 4
0.75 BK
0.75 BK
0.75 BK
0.75 BK
0.75 BK
0.75 BK
0.75 BK
10.0 BK
X 18
1 1 2.5 BK
2.5 BK
P M4 FUELPUMP M M1 STARTER 2.5 BK

2.5 BK
2 2
sheet2:X23.1:56
sheet2:X23.1:55
sheet2:X23.1:53
sheet2:X17:2
sheet2:X17:3
sheet4:X23.1:25
sheet4:X23.1:26
R1.1 R1.2 R1.3 R1.4
HEATER PLUG HEATER PLUG HEATER PLUG HEATER PLUG
KI.31 / TERMINAL 31
MAP11840

5.3 EQUIPMENT HARNESS
TERMINAL 30
+ -
D+ Generator N6
Diode
CHARGE-INDICATOR LAMP
TERMINAL 15 OTHER EQUIPMENT
ENGINE SPEED
WARNING COOLANT WARNING FUEL PREHEAT DIAGNOSTIC ENGINE WARNING OIL WARNING
TEMERATURE / LEVEL AND AIR FILTER LAMP RUNNING PRESSURE CHARGE AIR CAN 0 CUSTOMER CAN H - IN
LAMP
TEMPERATURE
CAN 0 CUSTOMER CAN L - IN
CAN 0 CUSTOMER CAN H - OUT
N8 CAN 0 CUSTOMER CAN L - OUT

+
+ + + + + +
A1
FUSE
N7
A
-
XX
B1
A1 - - - - - -
FUSE
30A
B1
TO PIN + OF THE COOLANT LEVEL SWITCH
N 11
S1 30 15-Udat (A)
P,0,I,II
CAN 0 Customer CAN H (M)
CAN 0 Customer CAN L (F)
CAN 1 Diagnostic CAN H (H)
N9
50 15 58
CAN 1 Diagnostic CAN L (G)
31-GND (B)
1,5
1,5
4
X22
Diagnose Stecker
2,5
2,5
U-BAT
N9
X 23 .2:07
X 23.2:06
X 23.1:58
X 23.1:31
X 23.1:52
X 23.1:27
X 23.1:28
X 23.1:33
X 23.1:32
X 23.1:29
X 23.1:30
X 23.1:15
X 23.1:24
X 23.2:28
X 23.1:09
X 23.1:47
X 23.1:50
X 23.1:46
X 23.1:48
X 23.1:51
X 23.1:49
X 23.1:61
X 23.1:62
2,5
2,5
2,5
K71
K90
K92
K35
K48
K65
K49
K70
K93
K29
K27
K 01
K 05
K 03
K69
K88
K53
K53
K75
K54
K75
K76
K54
K76
EDC17CV54 EMR 4, EDC 17CV54
K 02
K 06
K 04
K74
K64
K57
K68
K15
K19
K80
K13
K86
K22
K31
K42
K87
K16
K63
K46
K62
K18
K37
2,5
2,5
2,5
X 23.1:13
X 23.1:05
X 23.1:22
X 23.1:40
X 23.1:37
X 23.1:42
X 23.1:38
X 23.1:02
X 23.1:19
X 23.1:41
X 23.1:03
X 23.1:18
X 23.2:37
X 23.1:57
X 23.2:36
X 23.1:16
X 23.1:17
X 23.1:08
X 23.1:23
X 23.2 X 23.1
X 23.2:04
X 23.2:05
GND
U-BAT
2,5
2,5
N7
4
nach pin X 23.1 :52

TO PIN X 23.1 :52
6 5 4 2 3 1
YELLOW
WHITE
BLACK
GREEN
BLUE
RED
1,5
- + - +
OFF
RES
+ -
S S S
+
L L P IVS Poti
ACCELERATOR PEDAL 1
N 10
2,5
TERMINAL 31 TO OTHER EQUIPMENT
NEUTRAL DIAGNOSTIC SPEED COOLANT AIRFILTER DROOP ENGINE OVERRIDE

TERMINAL 31 DIGITAL UP / DOWN WATER SETPOINT LEVEL CHOICE STOP
DIFFERENCE
IN FUEL PRESSURE
LEVEL
MAP31850

5.4 POWER HARNESS
SWITCHED U-BAT. / TERMINAL 15
A1
XX
B1
N2
RELAY FUELPUMP PRE-HEAT-RELAY
100 A
B1
N3
10 A / 24 V
20 A / 12 V
A1
A1
X23.1:24 (K35) K3 K2
B1
RELAY STARTER
1.5
58 15 50 1 2 3 4 1 2 3 4
GND
U-BAT
GND
U-BAT
N1 K15
P,0,I,II
0.75
0.75
X18
30 S1 1 2 3 4
U-BAT
GND
0.75
0.75
0.75
CHARGE-INDICATORLAMP
2.5
2.5
0.75
0.75
X23.1:25
X23.1:26
2.5
2.5
TERMINAL 30
1 N1
FUELPUMP R1.1 R1.2 R1.3 R1.4
X17:2
X17:3
M4
P
X23.1:53
2
X23.1:55
50 KL 30
G2.1 ACCUMULATOR Ringkabelschuh
X23.1:56
-
M HEATER PLUG HEATER PLUG HEATER PLUG HEATER PLUG
N1
KI. 31
N3
STARTER
ALTERNATOR
G1
DIAGNOSIS AND REGULATOR
B+
IG/+15
S / B+
DFM
A/L
W
Battery-
Battery+
1 2 3 4 5
L / D+
W
TERMINAL 31
N1 WIRING DIMENSIONS ACCORDING TO THE MANUFACTURERS INSTALATION MANUAL.
N2 FUSE RATING DEPENDING ON THE WIRE CROSS-SECTION AND THE POWER REQUIREMENT.
N3 PART OF MANUFACTURERS CONNECTION CABLE AND CABLE HARNESS.
MAP31860

5.5 EXHAUST AFTER TREATMENT HARNESS
X39:1
X39:2
X39:3
X39:4
X39:5
X39:6
X39:7
X39:8
X39:9
X39:10
X39:11
X39:12
X39
1 2 3
B58
DPF DIFFERENTIAL
PRESSURE
MAP31870

Section 6
Wire Sensor Troubleshooting

6.1 Engine Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Engine Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Signal Wire Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.1 ENGINE SENSOR TEST
All Engine Sensors used in the EMR4 systems requires 5000

millivolts and ground. By testing the voltage at the sensor
connector with the power on, the following can be
determined.
• A reading above 5000 millivolts indicates a short to
battery voltage.
• A reading below 5000 millivolts indicates a short to
ground or open.
• A reading of 5000 millivolts indicates the power and
ground wires are OK.

6.2 ENGINE SENSOR CIRCUIT TEST
All Engine Sensor Circuits used in the EMR4 system uses a

pull-up resistor. By testing the voltage at the sensor
connector with the power on, the following can be
determined.
• A reading of 5000 millivolts indicates a short to voltage.
• A reading below 4800 millivolts indicates a short to
ground or open.
• A reading of 4970 volts indicates that the signal wire is
OK.

6.3 SIGNAL WIRE TEST
To test for a broken signal wire from the sensor to the ECU, a
jumper wire can be installed from the ground terminal at the
sensor connector to the signal wire at the same connector.
• If the circuit high fault code goes passive and a circuit
low fault is produced, the signal wire is intact.
• If the circuit high fault code stays active, the signal wire
is broken.

Section 7
Diagnostics

7.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.1.1 KWP Code 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.1.2 KWP Code 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.1.3 KWP Code 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.1.4 KWP Code 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.1.5 KWP Code 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.1.6 KWP Code 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.1.7 KWP Code 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.1.8 KWP Code 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.1.9 KWP Code 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.1.10 KWP Code 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.1.11 KWP Code 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.1.12 KWP Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.1.13 KWP Code 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.1.14 KWP Code 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.1.15 KWP Code 291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.1.16 KWP Code 292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.1.17 KWP Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.1.18 KWP Code 360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.1.19 KWP Code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.1.20 KWP Code 376 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.1.21 KWP Code 377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.1.22 KWP Code 378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.1.23 KWP Code 387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.1.24 KWP Code 388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.1.25 KWP Code 389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.1.26 KWP Code 390 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7.1.27 KWP Code 391 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7.1.28 KWP Code 419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.1.29 KWP Code 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.1.30 KWP Code 421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7.1.31 KWP Code 422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.1.32 KWP Code 423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.1.33 KWP Code 464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.1.34 KWP Code 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7.1.35 KWP Code 472 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7.1.36 KWP Code 473 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7.1.37 KWP Code 474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7.1.38 KWP Code 559 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7.1.39 KWP Code 560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

Diagnostics
7.1.40 KWP Code 561 ............................................................. 7-44

7.1.41 KWP Code 562 ............................................................. 7-45
7.1.42 KWP Code 565 ............................................................. 7-46
7.1.43 KWP Code 566 ............................................................. 7-47
7.1.44 KWP Code 567 ............................................................. 7-48
7.1.45 KWP Code 568 ............................................................. 7-49
7.1.46 KWP Code 569 ............................................................. 7-50
7.1.47 KWP Code 570 ............................................................. 7-51
7.1.48 KWP Code 571 ............................................................. 7-52
7.1.49 KWP Code 580 ............................................................. 7-53
7.1.50 KWP Code 581 ............................................................. 7-54
7.1.51 KWP Code 582 ............................................................. 7-55
7.1.52 KWP Code 583 ............................................................. 7-56
7.1.53 KWP Code 592 ............................................................. 7-57
7.1.54 KWP Code 594 ............................................................. 7-58
7.1.55 KWP Code 595 ............................................................. 7-59
7.1.56 KWP Code 596 ............................................................. 7-60
7.1.57 KWP Code 597 ............................................................. 7-61
7.1.58 KWP Code 612 ............................................................. 7-62
7.1.59 KWP Code 613 ............................................................. 7-63
7.1.60 KWP Code 614 ............................................................. 7-64
7.1.61 KWP Code 615 ............................................................. 7-65
7.1.62 KWP Code 616 ............................................................. 7-66
7.1.63 KWP Code 617 ............................................................. 7-67
7.1.64 KWP Code 618 ............................................................. 7-68
7.1.65 KWP Code 619 ............................................................. 7-69
7.1.66 KWP Code 620 ............................................................. 7-70
7.1.67 KWP Code 621 ............................................................. 7-71
7.1.68 KWP Code 623 ............................................................. 7-72
7.1.69 KWP Code 624 ............................................................. 7-73
7.1.70 KWP Code 625 ............................................................. 7-74
7.1.71 KWP Code 627 ............................................................. 7-75
7.1.72 KWP Code 628 ............................................................. 7-76
7.1.73 KWP Code 637 ............................................................. 7-77
7.1.74 KWP Code 732 ............................................................. 7-78
7.1.75 KWP Code 733 ............................................................. 7-79
7.1.76 KWP Code 736 ............................................................. 7-80
7.1.77 KWP Code 737 ............................................................. 7-81
7.1.78 KWP Code 747 ............................................................. 7-82
7.1.79 KWP Code 752 ............................................................. 7-83
7.1.80 KWP Code 776 ............................................................. 7-84
7.1.81 KWP Code 777 ............................................................. 7-85
7.1.82 KWP Code 825 ............................................................. 7-86
7.1.83 KWP Code 826 ............................................................. 7-87
7.1.84 KWP Code 827 ............................................................. 7-88
7.1.85 KWP Code 828 ............................................................. 7-89
7.1.86 KWP Code 829 ............................................................. 7-90
7.1.87 KWP Code 830 ............................................................. 7-91
7.1.88 KWP Code 831 ............................................................. 7-92
7.1.89 KWP Code 832 ............................................................. 7-93

Diagnostics
7.1.90 KWP Code 833 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

7.1.91 KWP Code 834 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
7.1.92 KWP Code 835 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
7.1.93 KWP Code 836 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
7.1.94 KWP Code 837 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
7.1.95 KWP Code 856 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
7.1.96 KWP Code 857 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
7.1.97 KWP Code 858 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
7.1.98 KWP Code 859 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102
7.1.99 KWP Code 861 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103
7.1.100 KWP Code 862 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104
7.1.101 KWP Code 864 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105
7.1.102 KWP Code 876 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
7.1.103 KWP Code 877 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107
7.1.104 KWP Code 878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
7.1.105 KWP Code 935 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109
7.1.106 KWP Code 940 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
7.1.107 KWP Code 946 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111
7.1.108 KWP Code 947 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
7.1.109 KWP Code 948 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
7.1.110 KWP Code 956 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-114
7.1.111 KWP Code 957 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
7.1.112 KWP Code 958 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
7.1.113 KWP Code 959 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117
7.1.114 KWP Code 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-118
7.1.115 KWP Code 961 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119
7.1.116 KWP Code 973 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120
7.1.117 KWP Code 974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
7.1.118 KWP Code 975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
7.1.119 KWP Code 976 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
7.1.120 KWP Code 980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124
7.1.121 KWP Code 994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7.1.122 KWP Code 995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
7.1.123 KWP Code 996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
7.1.124 KWP Code 997 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
7.1.125 KWP Code 1014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129
7.1.126 KWP Code 1015. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130
7.1.127 KWP Code 1016. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
7.1.128 KWP Code 1022. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132
7.1.129 KWP Code 1023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-133
7.1.130 KWP Code 1024. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134
7.1.131 KWP Code 1025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-135
7.1.132 KWP Code 1157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136
7.1.133 KWP Code 1170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
7.1.134 KWP Code 1180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
7.1.135 KWP Code 1181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139
7.1.136 KWP Code 1223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-140
7.1.137 KWP Code 1224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-141
7.1.138 KWP Code 1226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-142
7.1.139 KWP Code 1227. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-143
Diagnostics
7.1.140 KWP Code 1228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-144

7.1.141 KWP Code 1229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145
7.1.142 KWP Code 1230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-146
7.1.143 KWP Code 1231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147
7.1.144 KWP Code 1232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-148
7.1.145 KWP Code 1505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-149
7.1.146 KWP Code 1669 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150
7.1.147 KWP Code 1679 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151

Diagnostics
7.1 FAULT CODES

KWP Codes are displayed on the Sertia 2010 software.
SPN Codes are displayed on the display in the cab.
7.1.1 KWP Code 45

KWP CODE SPN CODE ERROR PATH
45 168 BattUSRCMax
SPN GROUP Vehicle Electrical Power 1 SPN NAME Battery Potential / Power Input 1
FMI-INFO Voltage above normal or shorted high
FMI-NO. 3
COMPONENT Battery voltage
Short Description
• Battery voltage: the voltage measured by ECU is out of
the target range, system reaction is initiated.
• Sensor error battery voltage; signal range check high,
Battery voltage above warning threshold, Short cut to
battery.
System Reaction
• Warning : Error lamp shows permanent light. entry in
the ECU fault memory.
• Measurement in case of error: Not available.
Power Reduction
• No reduction.
Possible Reason for Error
• Alternator defective.
• Connecting cable damaged.
Possible Consequence
• Error lamp on, for permanent overvoltage,
the ECU can be damaged.
Actions for Repair
• Check wiring,
• Check alternator,
• Check cables and repair or replace if necessary.

Diagnostics
7.1.2 KWP Code 46

46 168 BattUSRCMin
FMI-INFO Voltage below normal or shorted low
FMI-NO. 4
Short Description
• Sensor error battery voltage; signal range check low,
Battery voltage below warning threshold, Short cut to
ground.
System Reaction
• Measurement in case of error : Not available.
Power Reduction
• No reduction.
• Alternator defective, connecting cable damaged.
• Error lamp on, Engine can be shut off due to missing
electric power.
Actions for Repair
• Check wiring.
• Check alternator.

Diagnostics
7.1.3 KWP Code 47

47 168 BattUSysReacMax
FMI-INFO Data erratic, intermittent or incorrect
FMI-NO. 2
Short Description
• Battery voltage; system reaction initiated,
Battery voltage above warning threshold.
System Reaction
Power Reduction
• No reduction.
• Alternator regulator defective.
• Diode in regulator defective.
• Damage in power harness.
• Diagnostic lamp on, for permanent overvoltage,
the ECU can be damaged.
Actions for Repair
• Check alternator and if necessary replace it.
• Check connections and if neccessary renew the cable
for power supply.

Diagnostics
7.1.4 KWP Code 84

84 639 BusDiagBusOffNodeA
J1939 Network #1, Primary Vehicle Network
SPN GROUP Stop Start Broadcast SPN NAME
(previously SAE J1939 Data Link)
FMI-INFO Special Instructions
FMI-NO. 14
COMPONENT CAN Bus Controller
Short Description
• CAN bus 0: the ECU is not allowed to send messages,
because the status "BusOff" is detected.
• CAN-Bus 0 "BusOff-Status", CAN BusOff error;
CAN 0 (Customer CAN).
System Reaction
• Warning : Limp home speed if applicated.
• Error lamp shows permanent light. entry in the ECU
fault memory.
Power Reduction
• No reduction.
• Cable break or short circuit.
• Off-state (CAN bus 0), CAN bus deactivated.
• Connection cable damaged, terminal resisitors defect.
• Diagnostic lamp on (if analog lamp), no damage on
parts.
Actions for Repair
• Check wiring of CAN bus and if necessary repair it.
• Check connection cable and if necessary repair or
replace it.
• Check resistance in CAN lines (60 Ohm).

Diagnostics
7.1.5 KWP Code 85

85 1231 BusDiagBusOffNodeB
SPN GROUP Stop Start Broadcast SPN NAME J1939 Network #2
FMI-NO. 14
COMPONENT CAN Bus Controller
Short Description
• CAN bus 1: the ECU is not allowed to send messages,
because the status "BusOff" is detected.
• CAN-Bus 1 "BusOff-Status", CAN BusOff error;
CAN 1 (engine/diagnostic CAN).
System Reaction
• Measurement in case of error: Not available
Power Reduction
• No reduction.
• Off-state (CAN bus 1), CAN bus deactivated.
• Connection cable damaged, terminal resistors defect.
• Diagnostic lamp on, no damage on further parts.
Actions for Repair
• Check wiring of CAN bus and if necessary repair it
replace it.
• Check resistance in CAN lines (60 Ohm).

Diagnostics
7.1.6 KWP Code 88

88 102 CACDsPSysReacMax
SPN GROUP Inlet/Exhaust Conditions 1 SPN NAME Engine Intake Manifold #1 Pressure
FMI-INFO Data erratic, intermittent, or incorrect
FMI-NO. 2
COMPONENT Charge air pressure sensor
Short Description
• Charge air pressure messured by sensor is above the
warning threshold.
• Charged air pressure; system reaction initiated, Charge
air pressure above warning threshold.
System Reaction
• Warning : Permanent light, entry into error memory.
Power Reduction
• No reduction.
• Charge air pressure control not okay.
• Waste gate system on turbo charger not okay.
• Sensor gives out wrong values.
• Charge air cooler clogged.
• Blocked charge air pipes.
• Diagnostic lamp on, engine can be damaged.
Actions for Repair
• Check waste gate system if necessary replace TC.
• Check CAC if all channels are clean.
• Check charge air piping if necessary clean or
repair it.

Diagnostics
7.1.7 KWP Code 89

89 102 CACDsPSysReacMin
FMI-NO. 2
Short Description
• Charge air pressure messured by sensor is above the
shut off threshold.
• Charged air pressure; system reaction initiated, Charge
air pressure above shut off threshold.
System Reaction
• Warning : Shut off demand.
• Blinking light, entry into error memory.
Power Reduction
• No reduction.
• Charge air pressure control not okay.
• Waste gate system on turbo charger not okay.
• Sensor gives out wrong values.
• Charge air cooler clogged.
• Blocked charge air pipes.
Actions for Repair
• Check waste gate system if necessary replace TC.
• Check CAC if all channels are clean.
• Check charge air piping if necessary clean or
repair it.

Diagnostics
7.1.8 KWP Code 96

96 110 CEngDsTSRCMax
SPN GROUP Engine Temperature 1 SPN NAME Engine Coolant Temperature
FMI-NO. 3
COMPONENT Coolant temperature sensor
Short Description
• Coolant temperature sensor: the voltage of the sensor
measured by ECU is out of the target range.
• Sensor error coolant temperature; signal range check
high, Short cut to battery or open load.
System Reaction
• Ramp to default value engine on (100° C) engine off (0°
C).
• Permanent light, entry into error memory.
• Measurement in case of error: engine on (100° C)
engine off (0° C).
Power Reduction
• No reduction.
• Cable break or short circuit,sensor defective.
• Connection cable damaged.
• Diagnostic lamp on, reduced control for example
engine cold start.
Actions for Repair
• Check wiring, sensor defect.
• Check sensor and if necessary replace it.
replace it.

Diagnostics
7.1.9 KWP Code 97

97 110 CEngDsTSRCMin
FMI-NO. 4
Short Description
• Coolant temperature sensor: the voltage of the sensor
• Sensor error coolant temperature; signal range check
low, Short cut to ground.
System Reaction
• Ramp to default value engine on (100° C) engine off (0°
C).
• Measurement in case of error: engine on (100° C)
engine off (0° C).
Power Reduction
• No reduction.
• Sensor defective
• Diagnostic lamp on, reduced control for example
engine cold start.
Actions for Repair
• Check wiring, sensor defect.
replace it.

Diagnostics
7.1.10 KWP Code 98

98 110 CEngDsTSysReacMax
FMI-INFO Data valid but above normal operational range
FMI-NO. 0
Short Description
• Coolant temperature: the coolant temperature
calculated by ECU is above the target range; the ECU
activates a system reaction.
• Coolant temperature; system reaction initiated, Coolant
temperature above warning threshold.
System Reaction
• Warning : Power reduction.
• Measurement in case of error:
111°C-118°C /100%-70%.
Power Reduction
• 111°C-118°C /100%-70%.
• Radiator is clogged.
• Fan system does not work proper.
• Coolant level too low, thermostat does not open.
Actions for Repair
• Clean radiator.
• Check fan drive.
• Check coolant level.
• Check cooling system in general.
• Check thermostat function.

Diagnostics
7.1.11 KWP Code 99

99 110 CEngDsTSysReacMin
FMI-NO. 0
Short Description
• Coolant temperature: the coolant temperature
calculated by ECU is above the target range; the ECU
• Coolant temperature; system reaction initiated, Coolant
temperature above shut off threshold.
System Reaction
• Warning : Power reduction + engine shut off demand.
• Measurement in case of error:
111°C-118°C /100%-70%.
Power Reduction
• 118°C / 70%.
• Radiator is clogged.
• Coolant level too low, thermostat does not open.
Actions for Repair
• Clean radiator.
• Check fan drive.
• Check cooling system in general.
• Check thermostat function.

Diagnostics
7.1.12 KWP Code 101

101 111 ClntLvSysReac
Engine Fluid Level/
SPN GROUP SPN NAME Engine Coolant Level
Pressure 1
FMI-INFO Data valid but below normal operational range
FMI-NO. 1
Short Description
• Coolant level: the coolant level calculated by ECU is
underneath the allowed minimum.
• Coolant level too low, Coolant level too low.
System Reaction
• Measurement in case of error: actual value.
Power Reduction
• Not available.
• Coolant level too low.
• Leakage in cooling system.
• Sensor defective.
• Wiring damaged.
Actions for Repair
• Inspect cooling system for leakage and if necessary
repair it.
• Check sensor and wiring.

Diagnostics
7.1.13 KWP Code 121

121 1109 CoEngShOffDemIgr
SPN GROUP Shutdown SPN NAME Engine Protection System Approaching Shutdown
FMI-NO. 2
COMPONENT Supervisor Monitoring
Short Description
• Request of engine shut off: the operator ignors the
engine shut off request within an allowed period.
• Engine shut off demand ignored, Engine Shut Off
demand has been ignored by the user.
System Reaction
Power Reduction
• No reduction.
• Shut-off request due to an critical system error has been
ignored by operator.
• Diagnostic lamp on.
Actions for Repair
• Warranty relevant Additional error must be set:
• Charge air temperature.
• Coolant temperature.
• Coolant level.
• Fuel pressure.
• Oil pressure.
• PRV open.

Diagnostics
7.1.14 KWP Code 122

122 523698 CoEngSpvsShOff
SPN GROUP Not Available SPN NAME Manufacturer Assignable SPN
FMI-INFO Not Available
FMI-NO. 11
COMPONENT Supervisor Monitoring
Short Description
• Shut off request from supervisory monitoring function.
• Shut off request from supervisory monitoring function,
Engine Shut Off due to supervisory function.
System Reaction
• Engine Shut off.
Power Reduction
• No reduction.
• Critical system error is active.
• Diagnostic lamp blinking.
Actions for Repair
• Warranty relevant, Additional error must be set:
• Charge air temperature.
• Coolant temperature.
• Coolant level.
• Fuel pressure.
• Oil pressure.
• PRV open.

Diagnostics
7.1.15 KWP Code 291

291 523776 ComTOTSC1TEAct
FMI-NO. 9
COMPONENT CAN message
Short Description
• Missing message TSC1-TE.
• Timeout Error of CAN-Receive-Frame TSC1TE - active,
Timeout Error (Missing CAN Bus message).
System Reaction
• Warning: Permanent light, entry into error
memory.
Power Reduction
• No reduction.
• CAN bus wrong cabled.
• Wiring is damaged.
• Receiver (sender of the message) work inaccurately,
parametering inaccurate.
• Diagnostic lamp on, Limp home speed activated.
Actions for Repair
• Check CAN Bus wiring (Bus scheduling, polarity, short
circuit, power interrupt).
• Test protocol of receiver.
• Check CAN functional range.
• Check actuator.

Diagnostics
7.1.16 KWP Code 292

292 523777 ComTOTSC1TEPas
FMI-NO. 9
Short Description
• Message TSC1-TE has been missing (passive).
• Passive Timeout Error of CAN-Receive-Frame TSC1TE;
Setpoint, Passive timeout Error (Missing CAN Bus
message).
System Reaction
Power Reduction
• No reduction.
• CAN bus wrong cabled, wiring is damaged, receiver
(sender of the message) work inaccurately,
parametering inaccurate.
• Diagnostic lamp on, Limp home speed activated.
Actions for Repair
• Check actuator.

Diagnostics
7.1.17 KWP Code 305

305 898 ComTSC1TETO
SPN GROUP Torque/Speed Control 1 SPN NAME Engine Requested Speed/Speed Limit
FMI-INFO Abnormal update rated
FMI-NO. 9
Short Description
• Missing message TSC1-TE.
• Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint,
Timeout Error (Missing CAN Bus message)
System Reaction
Power Reduction
• No reduction
• Receiver (sender of the message) work inaccurately,
parametering inaccurate
• Diagnostic lamp on, Limp home speed activated
Actions for Repair
• Check CAN Bus wiring (Bus sheduling, polarity, short
circuit, power interrupt)
• Test protocol of receiver
• Check CAN functional range
• Check actuator

Diagnostics
7.1.18 KWP Code 360

306 523982 DevLibBattUHi
FMI-NO. 0
COMPONENT Device Library
Short Description
• Powerstage diagnosis disabled; high battery voltage
• Powerstage diagnosis disabled; high battery voltage,
Powerstage diagnostic can be deactivated due to too
high battery voltage.
System Reaction
• Warning : Permanent light, entry into error memory
Power Reduction
• No reduction
Actions for Repair
• Check wiring.

Diagnostics
7.1.19 KWP Code 361

361 523982 DevLibBattULo
FMI-NO. 1
COMPONENT Device Library
Short Description
• Powerstage diagnosis disabled; low battery voltage.
• Powerstage diagnosis disabled; low battery voltage,
Powerstage diagnostic can be deactivated due to too
low battery voltage.
System Reaction
Power Reduction
• No reduction.
• Diagnostic lamp on
Actions for Repair
• Check wiring.

Diagnostics
7.1.20 KWP Code 376

376 630 EEPEraseErr
SPN GROUP Not Available SPN NAME Calibration Memory
FMI-INFO Bad intelligent device or component
FMI-NO. 12
COMPONENT Hardware monitoring EEPROM
Short Description
• Internal hardware monitoring: the ECU finds an error
during the access to its EEPROM memory or works with
an alternative value.
• Access error EEPROM, Section could not be erased.
System Reaction
Power Reduction
• No reduction.
• Error during EEPROM memory access or EEPROM works
with substitute value.
• Programming error.
• ECU defective.
Actions for Repair
• If not programmed, EEPROM is defect.
• ECU is defect, reprogramm ECU and if necessary replace
it.

Diagnostics
7.1.21 KWP Code 377

377 630 EEPRdErr
FMI-NO. 12
Short Description
during the access to its EEPROM memory or works with
• Access error EEPROM, Minimum 3 blocks could not be
readed.
System Reaction
Power Reduction
• No reduction.
• ECU defective.
Actions for Repair
it.

Diagnostics
7.1.22 KWP Code 378

378 630 EEPWrErr
FMI-NO. 12
Short Description
during the access to it's EEPROM memory or works with
• Access error EEPROM, Block could not be written for
minimum 3 times.
System Reaction
Power Reduction
• No reduction.
• ECU defective.
Actions for Repair
it.

Diagnostics
7.1.23 KWP Code 387

387 523612 EngICO
FMI-NO. 12
COMPONENT Engine Injection Cut Off
Short Description
• Internal hardware monitoring: the CPU of the ECU is
reset and the cause is logged internally; no item will be
created in error memory.
• Internal software error ECU, Injector shut off demand for
the ICO coordinator.
System Reaction
• Warning : Blinking light, entry into error memory.
Power Reduction
• No reduction.
• A recovery occurred which is stored as protected.
Actions for Repair
• Sequence error.
• Check error memory for other errors.

Diagnostics
7.1.24 KWP Code 388

388 190 EngPrtOvrSpd
Electronic Engine
SPN GROUP SPN NAME Engine Speed
Controller 1
FMI-NO. 0
COMPONENT Engine protection
Short Description
• Engine speed: The engine speed calculated by ECU is
above the target range; the ECU activates a system
reaction.
• Engine speed above warning threshold
(FOC-Level 1).
• Overspeed monitoring (Engine speed was over
MoFOvR_nSpdGovLim_C = 2750 rpm).
System Reaction
Power Reduction
• No reduction.
• Engine overspeed detected with system reaction,
maximum engine speed exceeded.
Actions for Repair
• Check powertrain settings regarding overspeed

Diagnostics
7.1.25 KWP Code 389

389 190 EngPrtSysReacFOC1
Electronic Engine
Controller 1
FMI-NO. 0
Short Description
• Engine speed: the engine speed calculated by ECU is
reaction.
(FOC-Level 1).
• Overspeed monitoring during 1 level of FOC
(Failure overrun condition), if engine speed was over
EngPrt_nEnaFOCWarn_C = 2774rpm.
System Reaction
• Warning : Blinking light, entry into error memory
Power Reduction
• No reduction.
Actions for Repair
• Check powertrain settings regarding overspeed.

Diagnostics
7.1.26 KWP Code 390

390 190 EngPrtSysReacFOC2
Electronic Engine
Controller 1
FMI-INFO Failure mode not identifiable
FMI-NO. 11
Short Description
reaction.
(FOC-Level 2).
• Overspeed monitoring during 2 level of FOC
(Failure overrun condition). If engine speed was over
EngPrt_nEnaFOCShOff_C = 2860rpm.
System Reaction
Power Reduction
• No reduction.
Actions for Repair

Diagnostics
7.1.27 KWP Code 391

391 190 EngPrtSysReacORC
Electronic Engine
Controller 1
FMI-NO. 14
Short Description
reaction.
• Speed detection; out of range, signal disrupted,
Overspeed monitoring during ORC (Override
conditions) if engine speed was over
EngPrt_nEnaORC_C = 2774rpm.
System Reaction
Power Reduction
• No reduction.
Actions for Repair

Diagnostics
7.1.28 KWP Code 419

419 190 EpmCaSI1ErrSig
Electronic Engine
Controller 1
FMI-INFO Abnormal frequency, pulse width or period
FMI-NO. 8
COMPONENT Camshaft sensor
Short Description
• Camshaft speed sensor: the ECU receives no signal and
uses the signal from crankshaft speed sensor as
alternative to calculate the engine speed.
• Speed detection; out of range, signal disrupted, Erratic
signal.
System Reaction
Power Reduction
• No reduction.
• Engine running only with crankshaft speed signal,
transmitter defective.
• Cable connection damaged.
• Shielding of wiring broken.
• Diagnostic lamp on, emission regulations are not kept.
Actions for Repair
• Check wiring of camshaft sensor.
• Check camshaft sensor and if necessary replace it.
replace it.

Diagnostics
7.1.29 KWP Code 420

420 190 EpmCaSI1NoSig
Electronic Engine
Controller 1
FMI-NO. 12
Short Description
• Camshaft speed sensor: the ECU receives no signal and
uses the signal from camshaft speed sensor as
• Speed detection; out of range, signal disrupted, Missing
signal.
System Reaction
Power Reduction
• No reduction.
• Engine running only with camshaft speed signal,
transmitter defective.
• Cable connection damaged.
• Shielding of wiring broken.
Actions for Repair
• Check wiring of crankshaft sensor.
• Check crankshaft sensor and if necessary replace it.
replace it.

Diagnostics
7.1.30 KWP Code 421

421 190 EpmCaSI1OfsErr
Electronic Engine
Controller 1
FMI-NO. 2
Short Description
• ECU measures a deviation between camshaft and
crankshaft angle to target.
• Offset angle between crank- and camshaft sensor is too
large, Offset error between crankshaft and camshaft.
System Reaction
Power Reduction
• No reduction.
• Increment wheel angle manipulated.
• Dirt between speed sensor and increment wheel.
• Sensor position manipulated.
• Wrong setting in dataset.
Actions for Repair
• Check increment wheel position.
• Clean and adjust if necessary.
• Check sensor postition, reflash datset with SerDia 2010.

Diagnostics
7.1.31 KWP Code 422

422 190 EpmCrSErrSig
Electronic Engine
Controller 1
FMI-INFO Abnormal frequency, pulse width or period
FMI-NO. 8
COMPONENT Crankshaft sensor
Short Description
• Sensor crankshaft speed; disturbed signal.
signal.
System Reaction
Power Reduction
• No reduction.
• Connecting cable damaged, sensor defective.
• Diagnostic lamp on, emission regulations are not kept,
engine can be damaged.
Actions for Repair
• Check wiring.
• Check cables and repair or replace if necesary,

Diagnostics
7.1.32 KWP Code 423

423 190 EpmCrSNoSig
Electronic Engine
Controller 1
FMI-NO. 12
COMPONENT Crankshaft sensor
Short Description
• Crankshaft speed sensor: the ECU receives no signal and
uses the signal from camshaft speed sensor as
signal.
System Reaction.
Power Reduction
• No reduction.
• Engine running only with cam-shaft speed signal,
transmitter defective, connection cable damaged.
Actions for Repair
• Check wiring of crankshaft sensor.
• Check crankshaft sensor and if necessary replace it.
replace it.

Diagnostics
7.1.33 KWP Code 464

464 97 FlFWLvlSRCMax
SPN GROUP Water in Fuel Indicator SPN NAME Water In Fuel Indicator
FMI-NO. 3
COMPONENT Water level sensor / Fuel pre filter
Short Description
• Fuel filter water level sensor: the voltage of sensor
• Sensor error water in fuel; signal range check high,
Short cut to battery or open load.
System Reaction
• Default value (5000mV).
• Measurement in case of error: 5000mV.
Power Reduction
• No reduction
• Cable break or short circuit, sensor defective,
connection cable damaged.
Actions for Repair
• Check wiring, if sensor is not working,
replace it.

Diagnostics
7.1.34 KWP Code 465

465 97 FlFWLvlSRCMin
FMI-NO. 4
COMPONENT Water level sensor / Fuel pre filter
Short Description
• Fuel filter water level sensor: the voltage of sensor
• Sensor error water in fuel; signal range check low, Short
cut to ground.
System Reaction
• Default value (5000mV).
• Measurement in case of error: 5000mV.
Power Reduction
• No reduction.
Actions for Repair
• Check wiring, if sensor is not working.
replace it.

Diagnostics
7.1.35 KWP Code 472

472 94 FuelPSRCMax
Engine Fluid Level/
SPN GROUP SPN NAME Engine Fuel Delivery Pressure
Pressure 1
FMI-NO. 3
COMPONENT Fuel low pressure sensor
Short Description
• Low fuel pressure sensor: the voltage of sensor
• Sensor error low fuel pressure; signal range check high,
System Reaction
• Ramp to default value (5000hPa).
• Measurement in case of error: 5000hPa.
Power Reduction
• No reduction.
Actions for Repair
• Check wiring, if sensor not working.
replace it.

Diagnostics
7.1.36 KWP Code 473

473 94 FuelPSRCMin
Engine Fluid Level/
Pressure 1
FMI-NO. 4
Short Description
• Low fuel pressure sensor: the voltage of sensor
• Sensor error low fuel pressure; signal range check low,
Short cut to ground.
System Reaction
• Ramp to default value (5000hPa).
Power Reduction
• No reduction.
Actions for Repair
replace it.

Diagnostics
7.1.37 KWP Code 474

474 94 FuelPSysReacMax
Engine Fluid Level/
Pressure 1
FMI-NO. 1
Short Description
• Low fuel pressure: the low fuel pressure calculated by
ECU is underneath the target range; the ECU activates a
system reaction.
• Low fuel pressure; system reaction initiated,
Fuel pressure below warning threshold.
System Reaction
Power Reduction
• 100%
• Fuel tank is empty, fuel filter is blocked or dirty,
fuel pump, relay or fuse is defective.
Actions for Repair
• Check low fuel pressure system (fuel feed pump, relay ,
fuse, wiring, sensor) and if necessary
repair or replace it.

Diagnostics
7.1.38 KWP Code 559

559 523895 IVAdjDiaIVAdj_0
FMI-NO. 13
COMPONENT Injector diagnosis
Short Description
• Missing or wrong injector adjustment value
programming (IMA) injector 1.
• Check of missing injector adjustment value
programming (IMA) injector 1 (in firing order), Missing
or wrong parametrisation of injector adjustment cyl. 1.
System Reaction
• Warning : Errorlamp shows permanent light. Entry in
error memory.
Power Reduction
• No reduction.
• Dataset not valid or does not match to installed injector.
Actions for Repair
• Check dataset and flash correct injector adjustement
value (IMA). Use SERDIA UseCase to check it.

Diagnostics
7.1.39 KWP Code 560

FMI-NO. 13
Short Description
System Reaction
error memory.
Power Reduction
• No reduction.
Actions for Repair
value (IMA).
• Use SERDIA UseCase to check it.

Diagnostics
7.1.40 KWP Code 561

FMI-NO. 13
Short Description
or wrong parametrisation of injector adjustment cyl. 4
System Reaction
• Warning : Errorlamp shows permanent light.
Entry in error memory.
Power Reduction
• No reduction.
Actions for Repair
value (IMA).
• Use SERDIA.
• Use Case to check it..

Diagnostics
7.1.41 KWP Code 562

FMI-NO. 13
Short Description
System Reaction
Power Reduction
• No reduction.
• Dataset not valid or does not match to installed injector
engine can be damaged
Actions for Repair
value (IMA).
• Use SERDIA.
• UseCase to check it.

Diagnostics
7.1.42 KWP Code 565

565 523350 IVDiaBnkShCir_0
FMI-NO. 4
Short Description
• Injector cylinder bank 1: the current drop measured by
ECU is above the target range.
• Injector cylinder-bank 1; short circuit, Short circuit
injection bank 1 (all injectors of this bank can be
affected).
System Reaction
• Measurement in case of error: Actual value.
Power Reduction
• No reduction.
• Short circuit (cylinder bank 1), injector defective,
Actions for Repair
• Check wiring.
• Check injectors and if necessary replace them.
replace it.

Diagnostics
7.1.43 KWP Code 566

566 523352 IVDiaBnkShCir_1
FMI-NO. 4
COMPONENT Injector bank diagnosis
Short Description
• Injector cylinder bank 2: the current drop measured by
ECU is above the target range.
• Injector cylinder-bank 2; short circuit, Short circuit
injection bank 2 (all injectors of this bank can be
affected).
System Reaction
Power Reduction
• No reduction
• Short circuit (cylinder bank 2),
• Injector defective.
Actions for Repair
• Check wiring.
replace it.

Diagnostics
7.1.44 KWP Code 567

567 523354 IVDiaChp_0
FMI-NO. 12
COMPONENT Injector chip diagnosis
Short Description
• Internal hardware monitoring: the ECU detects an error
of its injector high current output.
• Injector powerstage output defect, Chip in powerstage
component defect.
System Reaction
• Warning : Errorlamp shows blinking light.
Power Reduction
• No reduction.
• High power stage Injector group A.
• ECU defective.
• Emission regulations are not kept, engine can be
damaged.
Actions for Repair
• If error is not removable, change ECU.

Diagnostics
7.1.45 KWP Code 568

568 651 IVDiaCylNoLd_0
SPN GROUP Not Available SPN NAME Engine Injector #01
FMI-INFO Current below normal or open circuit
FMI-NO. 5
Short Description
• Injector cyl. 1: interruption of electrical connection.
• Injector 1 (in firing order); interruption of electric
connection, Interruption of electronic connection
Injector cyl. 1.
System Reaction
• Entry in error memory.
Power Reduction
• No reduction.
• Cable break (cylinder 1),
Actions for Repair
• Check wiring.
• Check injector and if necessary replace them.
replace it.
• Use SerDia Injector test for diagnosis.

Diagnostics
7.1.46 KWP Code 569

FMI-NO. 5
Short Description
Injector cyl. 3.
System Reaction
error memory.
Power Reduction
• No reduction.
• Cable break (cylinder 3), injector defective, connection
cable damaged.
Actions for Repair
• Check wiring.
replace it.

Diagnostics
7.1.47 KWP Code 570

FMI-NO. 5
Short Description
Injector cyl. 4.
System Reaction
error memory.
Power Reduction
• No reduction.
• Cable break (cylinder 4).
Actions for Repair
• Check wiring.
replace it.

Diagnostics
7.1.48 KWP Code 571

FMI-NO. 5
Short Description
Injector cyl. 2.
System Reaction
error memory.
Power Reduction
• No reduction.
• Cable break (cylinder 2).
Actions for Repair
• Check wiring.
replace it.

Diagnostics
7.1.49 KWP Code 580

580 651 IVDiaCylShCir_0
FMI-NO. 3
Short Description
• Injector cyl. 1: the current drop measured by ECU is
above the target range.
• Injector 1 (in firing order); short circuit, Short circuit
injector cylinder 1
System Reaction
Power Reduction
• No reduction.
• Short circuit (cylinder 1), injector defective, connection
cable damaged.
Actions for Repair
• Check wiring and counter plugs.
replace it.

Diagnostics
7.1.50 KWP Code 581

FMI-NO. 3
Short Description
injector cylinder 3.
System Reaction
Power Reduction
• No reduction
• Short circuit (cylinder 3), injector defective.
Actions for Repair
replace it.

Diagnostics
7.1.51 KWP Code 582

FMI-NO. 3
Short Description
System Reaction
Power Reduction
• No reduction.
• Short circuit (cylinder 4), injector defective.
damaged.
Actions for Repair
replace it.

Diagnostics
7.1.52 KWP Code 583

FMI-NO. 3
Short Description
System Reaction
Power Reduction
• No reduction
• Short circuit (cylinder 2).
damaged.
Actions for Repair
replace it.

Diagnostics
7.1.53 KWP Code 592

592 523615 MeUnOL
FMI-NO. 5
COMPONENT Fuel high pressure metering Unit
Short Description
• Fuel metering unit: the ECU detects no load or
temperature excess of the ECU component for power
supply of the valve.
• Metering unit (Fuel-System); open load, Open load.
System Reaction
• Warning, Speed pending power reduction, pressure
relief valve may open.
Power Reduction
• 75%.
• Wiring error or ECU output is switched off because of
over temperature.
• Fuel metering unit defective.
pressure release valve can be damaged.
Actions for Repair
• Check wiring , if necessary check FCU.
• Check fuel metering unit and if necessary replace it.
replace it.

Diagnostics
7.1.54 KWP Code 594

594 523615 MeUnShCirHSBatt
FMI-NO. 3
Short Description
• Fuel metering unit: the current drain measured by ECU
is above the target range.
• Metering unit (Fuel-System); short circuit to battery,
HighSide-Shortcut to battery.
System Reaction
• Warning, Speed pending power reduction, pressure
Power Reduction
• 75%
• Short circuit to Ubatt.
Actions for Repair
replace it.

Diagnostics
7.1.55 KWP Code 595

595 523615 MeUnShCirHSGnd
FMI-NO. 4
Short Description
• Metering unit (Fuel-System); short circuit to ground,
HighSide-Shortcut to ground.
System Reaction
• Warning : Speed pending power reduction,
pressure relief valve may open.
Power Reduction
• 75%
• Short circuit to ground.
Actions for Repair
replace it.

Diagnostics
7.1.56 KWP Code 596

596 523615 MeUnShCirLSBatt
FMI-NO. 3
Short Description
• Metering unit (Fuel-System); short circuit to battery,
LowSide-Shortcut to battery.
System Reaction
• Warning : Speed pending power reduction, pressure
Power Reduction
• 75%
• connection cable damaged.
Actions for Repair
replace it.

Diagnostics
7.1.57 KWP Code 597

597 523615 MeUnShCirLSGnd
FMI-NO. 4
Short Description
• Metering unit (Fuel-System); short circuit to ground,
LowSide-Shortcut to ground.
System Reaction
• Warning : Speed pending power reduction, pressure
Power Reduction
• 75%
• Short circuit to ground, fuel metering unit defective,
Actions for Repair
• check fuel metering unit and if necessary replace it.
• check connection cable and if necessary repair or
replace it.

Diagnostics
7.1.58 KWP Code 612

612 523612 MoCADCNTP
FMI-NO. 12
COMPONENT ADC monitoring
Short Description
• ECU reported internal software error, Plausibility check
(MoCADC_uNTP_mp is bigger than
MoCADC_uNTPMax_C).
System Reaction
Power Reduction
• No reduction.
• Short circuit in wiring of analog signals to ECU (Analog
Digital Converter). Defective ECU.
Actions for Repair
• Check wiring.
• Check connected sensors actuators.
• If error is still active replace ECU.

Diagnostics
7.1.59 KWP Code 613

613 523612 MoCADCTst
FMI-NO. 12
Short Description
• ECU reported internal software error, Analysis of test
voltage (Value is out of the target -> ECU internal error).
System Reaction
• Warning: Permanent light, entry into error memory.
Power Reduction
• No reduction.
Actions for Repair
• Check wiring.
• Check connected sensors actuators. If error is still active
replace ECU.

Diagnostics
7.1.60 KWP Code 614

614 523612 MoCADCVltgRatio
FMI-NO. 12
Short Description
• ECU reported internal software error, Analysis of the
ratiometric correction (Value is out of the target -> ECU
internal error).
System Reaction
Power Reduction
• No reduction.
Actions for Repair
• Check wiring.
• Check connected sensors actuators. If error is still active
replace ECU.

Diagnostics
7.1.61 KWP Code 615

615 523612 MoCComErrCnt
FMI-NO. 12
COMPONENT Communication monitoring module
Short Description
• ECU reported internal software error, Error report due to
an error in the plausbility of FC and MM (ECU internal
error).
System Reaction
Power Reduction
• No reduction
• ECU defective, Software erratic
Actions for Repair
• Reflash ECU. If error is still active replace ECU.

Diagnostics
7.1.62 KWP Code 616

616 523612 MoCComSPI
FMI-NO. 12
COMPONENT Communication monitoring module
Short Description
• ECU reported internal software error, Error report due to
an interrupted SPI communication
(ECU internal error)
System Reaction
Power Reduction
• No reduction.
• ROM memory in ECU defective.
Actions for Repair
• Reflash ECU. If error is still activ replace ECU.

Diagnostics
7.1.63 KWP Code 617

617 523612 MoCROMErrXPg
FMI-NO. 12
COMPONENT ROM memory
Short Description
• ECU reported internal software error, multiple error in
complete ROM-test during postdrive detected (ECU
internal error).
System Reaction
• Warning : Not configured.
Power Reduction
• No reduction.
• ECU defective, Software erratic.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.64 KWP Code 618

618 523612 MoCSOPErrMMRespByte
FMI-NO. 12 Test of redundant shut-off paths
COMPONENT
Short Description
• ECU reported internal software error, Too less bytes
received by monitoring memory from CPU as response
(ECU internal error).
• Loss of synchronization sending bytes to the
monitoring memory from CPU.
System Reaction
• Warning : Speed pending power reduction.
Power Reduction
• 75%
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.65 KWP Code 619

619 523612 MoCSOPErrNoChk
COMPONENT
Short Description
• ECU reported internal software error, Error during SOP
test; uncertain cause (defective injector or shut-off
path).
• DFC to set a torque limitation once an error is detected
before MoCSOP's error reaction is set.
System Reaction
• Warning, Speed pending power reduction.
Power Reduction
• 75%
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.66 KWP Code 620

620 523612 MoCSOPErrRespTime
COMPONENT (ECU internal error)
Short Description
• ECU reported internal software error, Error trying to set
MM Response time (ECU internal error).
System Reaction
Power Reduction
• 75%
• ECU defective.
• Software erratic.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.67 KWP Code 621

621 523612 MoCSOPErrSPI
COMPONENT (ECU internal error)
Short Description
• ECU reported internal software error, Error detected in
the internal ECU communication.
System Reaction
Power Reduction
• 75%
• ECU defective.
• Software erratic
• Diagnostic lamp on, no damage on further parts
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.68 KWP Code 623

623 523612 MoCSOPLoLi
COMPONENT
Short Description
• ECU reported internal software error, Error in the check
of the shut-off path test of the under voltage detection
(ECU internal error). Diagnostic fault check to report the
error in undervoltage monitoring.
System Reaction
Power Reduction
• 75%
• ECU defective.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.69 KWP Code 624

624 523612 MoCSOPMM
COMPONENT
Short Description
of the shut-off path of the monitoring module (ECU
internal error).
System Reaction
Power Reduction
• 75%
• ECU defective.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.70 KWP Code 625

625 523612 MoCSOPOSTimeOut
COMPONENT
Short Description
• ECU reported internal software error, Time out error
trying to set or cancelling the alarm task (ECU internal
error). Failure setting the alarm task period.
System Reaction
Power Reduction
• 75%
• ECU defective.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.71 KWP Code 627

627 523612 MoCSOPOSTimeOut
COMPONENT
Short Description
• ECU reported internal software error, Error in time
monitoring of the shut-off path test (ECU internal error).
Diagnostic fault check to report the timeout in the shut
off path test.
System Reaction
Power Reduction
• 75%
• ECU defective.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.72 KWP Code 628

628 523612 MoCSOPUpLi
COMPONENT
Short Description
of the shut-off path test of the over voltage detection
(ECU internal error). Diagnostic fault check to report the
error in overvoltage monitoring.
System Reaction
Power Reduction
• 75%
• ECU defective.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.73 KWP Code 637

637 523612 MoFOvR
FMI-NO. 12
COMPONENT Monitoring Function Overrun
Short Description
reaction.
• ECU reported internal software error, Error in the
plausibility of current energizing time with maximum
permitted energizing time. Diagnostic fault check to
report the error due to Over Run.
System Reaction
• Warning : Errorlamp shows blinking light. Entry in error
memory.
Power Reduction
• No reduction.
• Engine overspeed detected with system reaction.
• Maximum engine speed exceeded.
Actions for Repair

Diagnostics
7.1.74 KWP Code 732

732 100 OilPSwmpSRCMax
Engine Fluid Level/
SPN GROUP SPN NAME Engine Oil Pressure
Pressure 1
FMI-NO. 3
COMPONENT Engine oil pressure sensor
Short Description
• Oil pressure sensor: the voltage of sensor measured by
ECU is out of the target range.
• Sensor error oil pressure; signal range check high, Short
circuit to battery or open load.
System Reaction
• Warning : Default value (4000hPa).
Power Reduction
• No reduction.
• Wiring damaged.
• Diagnostic lamp on, (no damage on engine).
Actions for Repair
replace it.

Diagnostics
7.1.75 KWP Code 733

733 100 OilPSwmpSRCMin
Engine Fluid Level/
Pressure 1
FMI-NO. 4
Short Description
• Oil pressure sensor: the voltage of sensor measured by
• Sensor error oil pressure sensor; signal range check low,
Short circuit to ground.
System Reaction
Power Reduction
• No reduction.
• Wiring damaged.
• Diagnostic lamp on, (no damage on engine).
Actions for Repair
replace it.

Diagnostics
7.1.76 KWP Code 736

736 100 OilPSwmpSysReacLoMax
Engine Fluid Level/
Pressure 1
FMI-NO. 1
Short Description
• Oil pressure is below the target range
(warning threshold).
• Low oil pressure; system reaction initiated, Oilpressure
too low (pressure below warning threshold).
System Reaction
Power Reduction
• 80%
• Low oil level.
• Oil pump defective.
• Oil leackage.
• Suction pipe inlet mash clogged.
• Oil lamp on, engine can be damaged.
Actions for Repair
• Check oil level.
• Check engine for oil leckage, measure oil pressure
external to evaluate sensor value.
• Clean suction pipe inlet mash in oil pump.

Diagnostics
7.1.77 KWP Code 737

737 100 OilPSwmpSysReacLoMin
Engine Fluid Level/
Pressure 1
FMI-NO. 1
Short Description
• Oil pressure is below the target range
(shut off threshold).
• Low oil pressure; system reaction initiated, Oilpressure
too low (pressure below shut off threshold).
System Reaction
• Warning: Power reduction + engine shut off demand.
Power Reduction
• 80%.
• Low oil level.
• Oil pump defective.
• Oil leackage.
• Suction pipe inlet mash clogged.
• Oil lamp on, engine can be damaged.
Actions for Repair
• Check oil level.
• Check engine for oil leckage, measure oil pressure
external to evaluate sensor value.
• Clean suction pipe inlet mash in oil pump.

Diagnostics
7.1.78 KWP Code 747

747 1237 OvrdSwtPlaus
Cruise Control/
SPN GROUP SPN NAME Engine Shutdown Override Switch
Vehicle Speed
FMI-NO. 2
COMPONENT Override Monitoring
Short Description
• Override switch switch: the ECU receives a permanent
signal.
• Override switch; plausibility error, plausbility error
"override switch > 250ms pressed".
System Reaction
Power Reduction
• No reduction.
• Switch is blocked.
• Taster locked.
Actions for Repair
• Check wiring, if sensor is not working.
• Check switch and if necessary replace it.
replace it.

Diagnostics
7.1.79 KWP Code 752

752 107 PAirFltDSysReac
SPN GROUP Inlet/Exhaust Conditions 1 SPN NAME Engine Air Filter 1 Differential Pressure
FMI-NO. 0
COMPONENT Air filter differential sensor
Short Description
• Air filter differential pressure: The pressure difference of
the intake air between the filter inlet and outlet
calculated by ECU is above the target range and the ECU
• Air filter differential pressure; system reaction initiated,
Pressure value above warning threshold.
System Reaction
Power Reduction
• No reduction.
• Pressure loss above target range with system reaction.
• Air filter clogged or defective.
• Sensor not working.
Actions for Repair
• Check airfilter and if necessary clean or renew it.
• Check wiring.
replace it.

Diagnostics
7.1.80 KWP Code 776

776 102 PCACDsSRCMax
FMI-NO. 3
Short Description
• Charge air pressure sensor: The measured voltage of
sensor by ECU is out of the target range.
• Sensor error charged air pressure; signal range check
high, Short circuit to battery or open load.
System Reaction
Power Reduction
• No reduction.
• Emission regulations are not kept.
• High soot load in exhaust gas.
Actions for Repair
• Check wiring, if charge air pressure/temperature sensor
is not working.
replace it.

Diagnostics
7.1.81 KWP Code 777

777 102 PCACDsSRCMin
FMI-NO. 4
Short Description
• Charge air pressure sensor: the measured voltage of
sensor by ECU is out of the target range.
• Sensor error charged air pressure; signal range check
low, Short circuit to ground.
System Reaction
Power Reduction
• No reduction.
• Diagnostic lamp on. E
• Emission regulations are not kept. H
• High soot load in exhaust gas.
Actions for Repair
• Check wiring, if charge air pressure/temperature sensor
is not working.
replace it.

Diagnostics
7.1.82 KWP Code 825

825 523009 PRVctOpnMax
FMI-INFO Abnormal update rated
FMI-NO. 9
COMPONENT Pressure relief valve Rail.
Short Description
• Rail pressure relief valve: is open more frequently than
what the technical specification allows.
• Pressure Relief Valve (PRV) reached maximun allowed
opening count, PRV needs to be exchanged.
System Reaction
Power Reduction
• No reduction.
• Rail pressure relief valve open more than 50 times.
• Rail pressure relief valve defective.
• Diagnostic lamp on, PRV can be damaged
(replace PRV).
Actions for Repair
• Change rail pressure relief valve and remove the error
through Serdia command.

Diagnostics
7.1.83 KWP Code 826

826 523470 PRVFrOpnPresInc
FMI-NO. 2
COMPONENT Pressure relief valve Rail
Short Description
• Rail pressure relief valve will be forced to open.
• Pressure Relief Valve (PRV) forced to open, performed
by pressure rising.
System Reaction
Power Reduction
• No reduction
• Rail pressure relief valve is forced to open by an
increasing rail pressure. This error occurs due to an
supervising error.
PRV can be damaged
Actions for Repair
• Check error memory for other additional errors and
eleminate them first.

Diagnostics
7.1.84 KWP Code 827

827 523470 PRVFrOpnPresShck
FMI-NO. 2
Short Description
• Rail pressure relief valve: is open, will be forced to open,
the forced-open failed.
• Pressure Relief Valve (PRV) forced to open, is forced to
open (pressure shock).
System Reaction
Power Reduction
• No reduction.
• Rail pressure relief valve open or forced open abortive
(interpretation of the rail pressure gradient).
• Operating voltage too low.
• Rail pressure sensor defective.
• Emission regulations are not kept, PRV can be damaged.
Actions for Repair
• Check working voltage and if necessary correct it,
• Check rail-pressure sensor and if necessary replace it,
• Check FCU and if necessary replace it,
• Check rail pressure relief valve and if necessary replace it

Diagnostics
7.1.85 KWP Code 828

828 523470 PRVMonSysReacShOff
FMI-NO. 12
Short Description
• Rail pressure relief valve: is open.
• Pressure Relief Valve (PRV) forced to open; system
reaction initiated, Fault path indicating shutoff
condition in case of open PRV.
System Reaction
• Warning : Speed pending power reduction and engine
shut off demand.
Power Reduction
• No reduction
• Rail pressure relief valve open.
Actions for Repair
• Check PRV opening counter and if necessary replace it.
• Check rail-pressure sensor for plausibility and if
necessary replace it.
• Check FCU and if necessary replace it.

Diagnostics
7.1.86 KWP Code 829

829 523470 PRVMonSysReacWarn
FMI-NO. 12
Short Description
• Rail pressure relief valve: is open.
• Pressure Relief Valve (PRV) forced to open; System
reaction initiated, Fault path indicating warning
condition in case of open PRV.
System Reaction
• Warning : Speed pending power reduction and engine
shut off demand.
Power Reduction
• 75%
• Rail pressure relief valve open.
Actions for Repair
• Check PRV opening counter and if necessary replace
PRV.

Diagnostics
7.1.87 KWP Code 830

830 523470 PRVOpn
SPN GROUP not available SPN NAME Manufacturer Assignable SPN
FMI-NO. 14
Short Description
• Rail pressure relief valve: is open
• Pressure Relief Valve (PRV) is open, Pressure relief valve
(PRV) in rail is open.
System Reaction
Power Reduction
• 75%
• Rail pressure relief valve open
PRV can be damaged.
Actions for Repair
• Check PRV opening counter and if necessary replace it.

Diagnostics
7.1.88 KWP Code 831

831 523470 PRVQBalChk
FMI-NO. 11
Short Description
• Rail pressure relief valve can not be opened due to the
railpressure.
• Pressure Relief Valve (PRV) error; Rail pressure out of
tolerance range, Railpressure out of tolerance range
(PRV can not be opened by a pressure peak in this
operating point).
System Reaction
Power Reduction
• No reduction.
• Rail pressure in abnormal range, FCU defective.
PRV can be damaged.
Actions for Repair
• Check railpressure.
• Check rail pressure sensor for plausibility.
• Check FCU.

Diagnostics
7.1.89 KWP Code 832

832 523470 PRVRPOutOfRng
FMI-NO. 11
Short Description
• Rail pressure is out of the expected average range.
• Rail pressure out of tolerance range.
• Averaged rail pressure is outside the expected tolerance
range.
System Reaction
Power Reduction
• No reduction.
• PRV defective.
PRV can be damaged.
Actions for Repair
• Check PRV and replace if necessary.

Diagnostics
7.1.90 KWP Code 833

833 523009 PRVtiOpnMax
FMI-INFO Abnormal rate of change
FMI-NO. 10
Short Description
• Rail pressure relief valve: is open for a longer time than
what the technical specification allows.
• Pressure relief valve (PRV) reached maximun allowed
open time, PRV open longer than 300 minutes.
System Reaction
Power Reduction
• No reduction.
• Rail pressure relief valve was open for more than 300
minutes.
Actions for Repair
• Change rail pressure relief valve and remove the error
through Serdia command.

Diagnostics
7.1.91 KWP Code 834

834 523906 PSPOL
FMI-NO. 5
COMPONENT Fuel feed pump
Short Description
• ECU detects open load on the electric fuel feed pump
output.
• Electrical fuel pre-supply pump; open load, Cable break,
open load.
System Reaction
• Powerstage in ECU is switched off.
Power Reduction
• No reduction.
• Cable break or loose contact in fuel feed pump wiring,
relay defective.
• Engine shut off due to missing fuel pressure.
• Start function is locked.
(no damage on further parts)
Actions for Repair
• Check wiring of the fuel feed pump circuit including
relay, if necessary repair or replace wiring.

Diagnostics
7.1.92 KWP Code 835

835 523906 PSPOvrTemp
FMI-NO. 12
Short Description
• ECU detects too high temperature in powerstage of fuel
pump circuit.
• Electrical fuel pre-supply pump; powerstage over
temperature, Temperature is over limit.
System Reaction
Power Reduction
• No reduction.
• Relay defective.
• Wiring problem in fuel pump relay circuit.
• Diagnostic lamp on. E
• Start function is locked (no damage on further parts).
Actions for Repair
• Check fuel pump relay if necessary replace it.
• Check wiring of fuel feed pump circuit.

Diagnostics
7.1.93 KWP Code 836

836 523906 PSPSCB
FMI-NO. 3
Short Description
• ECU detects short cut to battery in fuel feed pump
circuit.
• Electrical fuel pre-supply pump; short circuit to battery,
Short cut to battery.
System Reaction
Power Reduction
• No reduction.
• Cable break or loose contact in fuel feed pump wiring.
• Start function is locked (no damage on further parts).
Actions for Repair

Diagnostics
7.1.94 KWP Code 837

837 523906 PSPSCG
FMI-NO. 4
Short Description
• ECU detects short cut to ground in fuel feed pump
circuit.
• Electrical fuel pre-supply pump; short circuit to ground,
Short cut to ground.
System Reaction
Power Reduction
• No reduction.
• Cable break or loose contact in fuel feed pump wiring.
• Engine shut off due to missing fuel pressurestart
function is locked (no damage on further parts).
Actions for Repair

Diagnostics
7.1.95 KWP Code 856

856 523613 RailMeUn0
FMI-NO. 0
COMPONENT Rail pressure metering unit
Short Description
• Rail pressure: the fuel pressure in rail calculated by ECU
is below the target range which is dependant on the
engine speed.
• Rail pressure disrupted, Positive governor deviation.
System Reaction
Power Reduction
• 75 %
• Leakage in high pressure system (external)
• Leakage at rail pressure relief valve (internal)
• Needle clamped in open position.
• Abrasion at high pressure pump.
• Too low primary pressure on low pressure side, sensor
defective, fuel system distur.
Actions for Repair
• Check for leakage.
• Check fuel-primary pressure.
• Change components.
• Check fuel system and if necessary repair it.

Diagnostics
7.1.96 KWP Code 857

FMI-NO. 0
Short Description
engine speed.
• Rail pressure disrupted, maximum positive deviation of
rail pressure exceeded concerning set flow of fuel.
System Reaction
Power Reduction
• No reduction.
• Leakage in high pressure system (external).
• Leakage at rail pressure relief valve (internal).
• Needle clampt in open position.
• Abrasion at high pressure pump.
• Too low primary pressure on low pressure side, sensor
defective, fuel system disturb.
Actions for Repair
• Check for leakage.
• Check fuel-primary pressure.
• Change components.
• Check fuel system and if necessary repair it.

Diagnostics
7.1.97 KWP Code 858

858 523613 RailMeUn10
FMI-NO. 0
Short Description
is above the target range which is dependant on the
engine speed.
• Rail pressure disrupted, leakage is detected based on
fuel quantity balance.
System Reaction
Power Reduction
• 75%
• Metering unit is not working properly
• Fuel return line blocked.
• Injectors do not open.
Actions for Repair
• Check backflow pressure.
• Check Injector function with SerDia.
• Change components (metering unit, injector) if
necessary.

Diagnostics
7.1.98 KWP Code 859

FMI-NO. 0
Short Description
engine speed.
• Rail pressure disrupted, maximum negative rail pressure
deviation with metering unit on lower limit is exceeded.
System Reaction
Power Reduction
• No reduction.
• Metering unit is not working properly.
Actions for Repair
• Check Injector function with SerDia.
• Change components (metering unit, injector) if
necessary.

Diagnostics
7.1.99 KWP Code 861

FMI-NO. 1
Short Description
engine speed.
• Minimum rail pressure exceeded (RailMeUn3),
minimum rail pressure exceeded.
System Reaction
Power Reduction
• No reduction.
• Too low primary pressure on low pressure side.
• Fuel system disturbed.
Actions for Repair
• Check fuel level in tank and low pressure system.

Diagnostics
7.1.100 KWP Code 862

FMI-NO. 0
Short Description
engine speed.
• Rail pressure disrupted, maximum rail pressure
exceeded.
System Reaction
Power Reduction
• No reduction
Actions for Repair
• Check pressure relief valve and metering unit.
• Change components if necessary.

Diagnostics
7.1.101 KWP Code 864

FMI-NO. 2
Short Description
engine speed.
• Setpoint of metering unit in overrun mode not
plausible, setpoint of metering unit in overrun mode
not plausible.
System Reaction
Power Reduction
• 75%
Actions for Repair
• Check metering unit.
• Change components if necessary.

Diagnostics
7.1.102 KWP Code 876

876 523470 RailPRV4
FMI-INFO Mechanical system not responding properly
FMI-NO. 7
Short Description
• Rail pressure is out of the expected average range.
• Maximum rail pressure in limp home mode exceeded
(PRV), Monitoring for maximum rail pressure in limp
home mode with PRV.
System Reaction
Power Reduction
• No reduction.
• Rail pressure relief valve does not open.
• Diagnostic lamp on, engine will be shut off, engine can
be damaged.
Actions for Repair
• Check rail pressure relief valve and replace if necessary.

Diagnostics
7.1.103 KWP Code 877

877 157 RailPSRCMax
Engine Fluid Level/
SPN GROUP SPN NAME Engine Injector Metering Rail 1 Pressure
Pressure 2
FMI-NO. 3
COMPONENT Rail pressure sensor
Short Description
• Rail pressure sensor: the voltage of sensor measured by
• Sensor error rail pressure; signal range check high, Short
cut to battery or open load.
System Reaction
Power Reduction
• No reduction.
• Limp home speed activated.
• Engine shut off in about 5 minutes.
Actions for Repair
• Check wiring.
• Check rail pressure sensor and if necessary replace it.
replace it.

Diagnostics
7.1.104 KWP Code 878

878 157 RailPSRCMin
Engine Fluid Level/
SPN GROUP SPN NAME Engine Injector Metering Rail 1 Pressure
Pressure 2
FMI-NO. 4
COMPONENT Rail pressure sensor
Short Description
• Rail pressure sensor: the voltage of sensor measured by
• Sensor error rail pressure; signal range check low, Short
cut to ground.
System Reaction
Power Reduction
• No reduction.
• Limp home speed activated.
• Engine shut off in about 5 minutes.
Actions for Repair
• Check wiring.
• Check rail pressure sensor and if necessary replace it.
replace it.

Diagnostics
7.1.105 KWP Code 935

935 91 SRCHighAPP1
Electronic Engine
SPN GROUP SPN NAME Accelerator Pedal Position 1
Controller 2
FMI-NO. 3
COMPONENT Accelerator pedal
Short Description
• Analog accelerator pedal sensor 1 or double accelerator
pedal sensor: the voltage measured by ECU is out of the
target range or the calculated pedal position is
implausible compared with the position of the second
pedal.
• Sensor error accelerator pedal; signal range check high,
System Reaction
Power Reduction
• No reduction
• Voltage outside target range.
• Signal implausible compared to signal of redundant
pedal (analog pedal 1).
• Limp home speed is activated if applicated.
Actions for Repair
• Check wiring.
• Check accelator pedal sensor and if necessary replace it.
replace it.

Diagnostics
7.1.106 KWP Code 940

940 91 SRCLowAPP1
Electronic Engine
Controller 2
FMI-NO. 4
COMPONENT Accelerator pedal
Short Description
• Analog accelerator pedal sensor 1 or double accelerator
pedal sensor: the voltage measured by ECU is out of the
target range or the calculated pedal position is
implausible compared with the position of the second
pedal.
• Sensor error accelerator pedal; signal is below the
range, Short cut to ground.
System Reaction
Power Reduction
• No reduction
• Voltage outside target range.
• Diagnostic lamp on, limp home speed is activated if
applicated.
Actions for Repair
• Check wiring.
• Check accelator pedal sensor and if necessary replace it.
replace it.

Diagnostics
7.1.107 KWP Code 946

946 1079 SSpMon1
SPN GROUP Not Available SPN NAME Sensor Supply Voltage 1 (+5V DC) (obsolete)
FMI-INFO Out of Calibration
FMI-NO. 13
COMPONENT Sensor voltage 1 monitoring
Short Description
• Internal hardware monitoring: the ECU detects a
deviation of the target range of the power supply
voltage of sensor output 1.
• Sensor supply voltage monitor 1 error (ECU), Error in
sensor voltage 1.
System Reaction
• Warning : Error lamp shows permanent light. Entry in
error memory.
Power Reduction
• No reduction.
• Wrong voltage of internal 5V reference source 1.
• Operating voltage too high or too low.
• ECU defective.
• Analog connected actuators on ECU may not work.
Actions for Repair
• Check wiring of external components.
• Check working voltage and if necessary correct it.
replace it, if error is not removable, change ECU.

Diagnostics
7.1.108 KWP Code 947

947 1080 SSpMon2
SPN GROUP Not Available SPN NAME Sensor Supply Voltage 2 (+5V DC) (obsolete)
FMI-NO. 13
Short Description
sensor voltage 2.
System Reaction
error memory.
Power Reduction
• No reduction.
• ECU defective.
Actions for Repair

Diagnostics
7.1.109 KWP Code 948

948 523601 SSpMon3
FMI-NO. 13
Short Description
sensor voltage 3.
System Reaction
error memory.
Power Reduction
• No reduction.
• Connection cable damaged, ECU defective.
Actions for Repair

Diagnostics
7.1.110 KWP Code 956

956 677 StrtHSSCB
SPN GROUP Not Available SPN NAME Engine Starter Motor Relay
FMI-NO. 3
COMPONENT Starter control
Short Description
• Start relay (high side power stage): the current drop
measured by ECU is above the target range.
• Starter relay; short circuit, Short cut HighSide-output to
battery.
System Reaction
• Powerstage is switched off.
• permanent light, entry into error memory.
Power Reduction
• No reduction.
• Start relay (high side): short circuit.
• Conncection cable defective.
Actions for Repair
• Check wiring and start relay and if necessary replace it.
replace it.

Diagnostics
7.1.111 KWP Code 957

957 677 StrtHSSCG
FMI-NO. 4
Short Description
• Start relay (high side power stage): the current drain
• Starter relay; short circuit, Short cut HighSide-output to
ground.
System Reaction
Power Reduction
• No reduction.
• Start relay (high side): short circuit.
Actions for Repair
replace it.

Diagnostics
7.1.112 KWP Code 958

958 677 StrtLSOL
FMI-NO. 5
Short Description
• Start relay (low side power stage): the current drop
• Starter relay; no load error, Open circuit/disconnection
LowSide-Output.
System Reaction
• Errorlamp shows permanent light. Entry in error
memory.
Power Reduction
• No reduction
• Start relay (low side): cable break or short circuit.
• Disabled by ECU.
Actions for Repair
replace it.

Diagnostics
7.1.113 KWP Code 959

959 677 StrtLSOvrTemp
FMI-NO. 12
Short Description
• Start relay (low side power stage): the current drop
• Starter relay; powerstage over temperature,
Temperature over limit.
System Reaction
memory.
Power Reduction
• No reduction.
• Start relay (low side): short circuit.
Actions for Repair
replace it.

Diagnostics
7.1.114 KWP Code 960

960 677 StrtLSSCB
FMI-NO. 3
Short Description
• Start relay (high side power stage): the current drain
• Starter relay; short circuit, Short cut LowSide-Output to
battery.
System Reaction
Power Reduction
• No reduction.
• Start relay (high side): short circuit,
• Connection cable defective.
Actions for Repair
replace it.

Diagnostics
7.1.115 KWP Code 961

961 677 StrtLSSCG
FMI-NO. 4
Short Description
• Start relay (high side power stage): the current drop
• Starter relay; short circuit, Short cut LowSide-Output to
ground.
System Reaction
• Error lamp shows permanent light. Entry in error
memory.
Power Reduction
• No reduction.
• Start relay (high side): short circuit,
Actions for Repair
• Check connection cable of terminal 50 and if necessary
repair or replace it.

Diagnostics
7.1.116 KWP Code 973

973 523612 SWReset_0
FMI-NO. 14
COMPONENT Software reset 1
Short Description
• Softwarereset CPU, Visibility of Softwareresets in DSM.
System Reaction
• Warning : Errorlamp shows blinking light. Entry in error
memory.
Power Reduction
• No reduction.
Actions for Repair
• If possible the software update has to be done. Replace
the ECU.

Diagnostics
7.1.117 KWP Code 974

974 523612 SWReset_1
FMI-NO. 14
Short Description
• Softwarereset CPU, Visibility of Softwareresets in DSM.
System Reaction
Power Reduction
• No reduction.
Actions for Repair
the ECU.

Diagnostics
7.1.118 KWP Code 975

975 523612 SWReset_2
FMI-NO. 14
Short Description
• Software reset CPU, Visibility of SoftwareResets in DSM.
System Reaction
• Warning : Error lamp shows blinking light. Entry in error
memory.
Power Reduction
• No reduction.
Actions for Repair
the ECU.

Diagnostics
7.1.119 KWP Code 976

976 91 SyncAPP
Electronic Engine
Controller 2
FMI-NO. 11
COMPONENT Accelerator pedal synchronisation
Short Description
• Plausibility error between APP1 and idle switch.
• Plausibility error between APP1 and APP2 or APP1 and
idle switch, Measured voltage of accelearotor pedal 1 is
out of plausible range.
System Reaction
• Warning: Error lamp shows permanent light. Entry in
error memory.
Power Reduction
• No reduction.
• Broken pedal axle which causes a stacked pedal sensor.
• Defect IVS which causes wrong sensor signal.
• Voltage outside of range.
• Limp home speed is activated.
Actions for Repair
• Check wiring.
• Check accelerator pedal and pedal sensor and if
replace it.

Diagnostics
7.1.120 KWP Code 980

980 523550 T50Err
FMI-NO. 12
COMPONENT Terminal 50
Short Description
• Terminal 50: ECU receives a permanent signal.
• T50 start switch active for too long, Startinformation to
Starter (T50-switch) erratic/defect.
System Reaction
• Warning: Prio 1, permanent light, entry into error
memory.
Power Reduction
• No reduction.
• Engine start switch stuck.
• Start switch clamped.
• T50 switch can be damaged.
Actions for Repair
• Check start switch and if necessary replace it.
replace it.

Diagnostics
7.1.121 KWP Code 994

994 105 TCACDsSRCMax
SPN GROUP Inlet/Exhaust Conditions 1 SPN NAME Engine Intake Manifold 1 Temperature
FMI-NO. 3
COMPONENT Charge air temperature sensor
Short Description
• Charge air temperature sensor: the voltage of sensor
• Sensor error charged air temperature; signal range
check high, Short cut to battery or open load.
System Reaction
• Ramp to default value (60° C).
memory.
• Measurement in case of error: 60° C.
Power Reduction
• No reduction.
Actions for Repair
• Check wiring.
• CAC-sensor not working,
replace it.

Diagnostics
7.1.122 KWP Code 995

995 105 TCACDsSRCMin
FMI-NO. 4
Short Description
• Charge air temperature sensor: the voltage of sensor
• Sensor error charged air temperature; signal range
check low, Short cut to ground.
System Reaction
• Ramp to default value (60° C).
• Error lamp shows permanent light. Entry in error
memory.
• Measurement in case of error: 60° C.
Power Reduction
• No reduction.
• Connection cable / wiring damaged.
Actions for Repair
• Check CAC-sensor and if necessary replace it.
replace it.

Diagnostics
7.1.123 KWP Code 996

996 105 TCACDsSysReacMax
FMI-NO. 0
Short Description
• Charge air temperature downstream calculated by ECU
is above the target range; the ECU activates a system
reaction.
• Charged air cooler temperature; system reaction
initiated, Charge air temperature (downstream) over
warning threshold.
System Reaction
• Warning : Power reduction and engine shut off demand.
Power Reduction
• 185°C-199°C /100% - 80%.
• Charge air cooler is clogged.
• Blocked or dirty piping to CAC.
Actions for Repair
• Check CAC system and clean it.
• Check fan functionality.
• Check cooling perfomance with temperature
measurement.

Diagnostics
7.1.124 KWP Code 997

997 105 TCACDsSysReacMin
FMI-NO. 0
Short Description
• Charge air temperature downstream calculated by ECU
is above the shut down threshold; the ECU activates a
system reaction.
• Charged air cooler temperature; system reaction
initiated, Charge air temperature (downstream) over
shut off threshold.
System Reaction
• Warning : Power reduction and engine shut off demand.
• Error lamp shows blinking light. Entry in error memory.
Power Reduction
• 185°C-199°C /100% - 80%.
• Charge air cooler is clogged.
• Blocked or dirty piping to CAC.
Actions for Repair
• Check CAC system and clean it.
• Check fan functionality.
• Check cooling perfomance with temperature
measurement.

Diagnostics
7.1.125 KWP Code 1014

1014 51 ActrCustCrntMeasSRCMax
SPN GROUP Fuel Economy (Liquid) SPN NAME Engine Throttle Position
FMI-NO. 6
COMPONENT H-Bride Output
Short Description
• Actuator error EGR-Valve; signal range check high.
• Actuator error EGR-Valve: internal error, Short cut to
battery or open load.
System Reaction
Power Reduction
• 60%
• Connecting cable is damaged.
Actions for Repair
• Check wiring and repair or replace if necessary.
• Check actuator with SERDIA test for EGR and if

Diagnostics
7.1.126 KWP Code 1015

1015 51 ActrCustCrntMeasSRCMin
FMI-NO. 5
Short Description
• Actuator error EGR-Valve; signal range check low.
• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(6.1,7.8); internal error, Short cut to ground.
System Reaction
Power Reduction
• 60%
• Short circuit to ground or open load.
• Counter plug is loose.
Actions for Repair
• Check wiring and repair or replace if necessary.
• Check actuator with SERDIA test for EGR and if

Diagnostics
7.1.127 KWP Code 1016

1016 51 ActrCustInvalidPosErr
FMI-NO. 7
Short Description
• Actuator position for EGR valve is not plausible, internal
error, angular misalignement of the flap (deviation from
setpoint > 7%).
• Actuator error EGR-Valve; internal error, Position error of
throttle flap (deviation > 7%).
System Reaction
Power Reduction
• 60%
• incorrect calibration, failed control of ECU.
Actions for Repair
• Troubleshooting with SERDIA 2010 Use Case "EGR
Diagnostic".

Diagnostics
7.1.128 KWP Code 1022

1022 51 ActrCustSRCCrntMax
FMI-NO. 6
Short Description
• Actuator error EGR-Valve; signal range check high,
measured current by ECU is over target.
• Actuator error EGR-Valve; internal error, Short cut to
System Reaction
Power Reduction
• 60%.
• Actuator defective.
Actions for Repair
• Check wiring,
• Check cabels and repair or replace if necessary.
• Check actuator with SERDIA 2010 test for EGR and if

Diagnostics
7.1.129 KWP Code 1023

1023 51 ActrCustSRCCrntMin
FMI-NO. 5
Short Description
• Actuator error EGR-Valve; signal range check low,
measured current is below target.
System Reaction
• Warning: Speed pending power reduction.
Power Reduction
• 60%
Actions for Repair
• Check wiring.
• Check cabels and repair or replace if necessary.
• Check actuator with SERDIA 2010 test for EGR and if

Diagnostics
7.1.130 KWP Code 1024

1024 51 ActrCustSRCMax
FMI-NO. 3
Short Description
• Actuator of the external EGR valve: the ECU detects a
short circuit to battery or open load.
System Reaction
• Warning, Ramp to Not available (50%) and speed
pending power reduction.
• Measurement in case of error: 50%.
Power Reduction
• 60%
Actions for Repair
• Check wiring, actuator defect.
• Check actuator and if necessary replace it.
replace it.

Diagnostics
7.1.131 KWP Code 1025

1025 51 ActrCustSRCMin
FMI-NO. 4
Short Description
• Actuator of the external EGR valve: the ECU detects a
short circuit to ground.
ground.
System Reaction
• Warning, Ramp to Not available (50%) and speed
pending power reduction.
• Measurement in case of error: 50%.
Power Reduction
• 60%
• Short circuit to ground, connection cable damaged.
Actions for Repair
• Check wiring, actuator defect.
• Check actuator and if necessary replace it.
replace it.

Diagnostics
7.1.132 KWP Code 1157

1157 97 WtLvlFlFWLvl
FMI-NO. 12
COMPONENT Water seperator fuel filter
Short Description
• Fuel filter water level sensor: the maximum level is
exceeded.
• Water in fuel level prefilter; maximum value exceeded,
Water level over limit (bad fuel quality).
System Reaction
error memory.
Power Reduction
• No reduction.
• Water level in fuel pre-filter.
Actions for Repair
• Drain water out from pre-filter.

Diagnostics
7.1.133 KWP Code 1170

1170 523612 MoCSOPPsvTstErr
COMPONENT
Short Description
• ECU reported internal software error, Error during
positive test (ECU internal error). Diagnostic fault check
to report that the positive test failed.
System Reaction
Power Reduction
• 75%
• ECU defective.
Actions for Repair
• Reflash ECU.

Diagnostics
7.1.134 KWP Code 1180

1180 168 BattUHi
FMI-NO. 0
Short Description
• Battery voltage: The voltage measured by ECU is out of
the target range.
• Physikal range check high for battery voltage,
Batteryvoltage over limit.
System Reaction
Power Reduction
• No reduction.
• Alternator regulator defective.
• Wiring damaged.
• Diagnostic lamp on for permanent overvoltage, the ECU
can be damaged.
Actions for Repair
• Check alternator regulatorof alternator and if necessary
replace it.
• Check wiring and voltage of alternator.

Diagnostics
7.1.135 KWP Code 1181

1181 168 BattULo
FMI-NO. 1
Short Description
the target range.
• Physical range check low for battery voltage.
• Battery voltage below limit.
System Reaction
Power Reduction
• No reduction
• Voltage below target range.
• battery defective.
• Too low power supply voltage.
• Too high contact resistance.
• Diagnostic lamp on, ECU will reset, no damage to ECU.
Actions for Repair
• Check alternator, wiring, contact resistance, safety fuses,
too high load in energy system.
• Check battery and if necessary replace it.
• Check battery pole and if necessary clean it,
• Check voltage of alternator.

Diagnostics
7.1.136 KWP Code 1223

1223 51 ActrCustHBrgOL
FMI-NO. 5
Short Description
• Actuator EGR-Valve: Open load on ECU output is
detected.
• Actuator error EGR-Valve (2.9;3.6) internal error, Open
circuit to connected actuator.
System Reaction
Power Reduction
• 60%
• Disconnected actuator.
• Broken wiring.
Actions for Repair
• Check wiring and if necessary repair or replace it.
• Check EGR valve function with SerDia 2010 use case.

Diagnostics
7.1.137 KWP Code 1224

1224 51 ActrCustHBrgOvrCurr
FMI-NO. 6
Short Description
• Actuator EGR-valve: too high cuurent is going into the
actuator. Output is switched off.
(6.1,7.8); internal error, Overload.
System Reaction
Power Reduction
• 60%
• Broken wiring.
Actions for Repair
• Check EGR valve function with SerDia 2010 use case, if
necessary replace actuator.

Diagnostics
7.1.138 KWP Code 1226

1226 51 ActrCustHBrgSCB1
FMI-NO. 3
Short Description
• Actuator EGR-valve: short cut to battery on ECU pin A19
is detected.
(6.1,7.8); internal error, Short cut to battery.
System Reaction
Power Reduction
• 60%
• Short circuit or broken wiring on ECU pin A19.
Actions for Repair
• Check actuator with SerDia 2010 use case and replace if
necessary.

Diagnostics
7.1.139 KWP Code 1227

1227 51 ActrCustHBrgSCB2
FMI-NO. 3
Short Description
is detected.
(6.1,7.8); internal error, Short cut to battery.
System Reaction
Power Reduction
• 60%
Actions for Repair
necessary.

Diagnostics
7.1.140 KWP Code 1228

1228 51 ActrCustHBrgSCG1
FMI-NO. 4
Short Description
• Actuator EGR-valve: short cut to ground on ECU pin A19
is detected.
System Reaction
Power Reduction
• 60 %
Actions for Repair
necessary.

Diagnostics
7.1.141 KWP Code 1229

1229 51 ActrCustHBrgSCG2
FMI-NO. 4
Short Description
is detected.
• Actuator error EGR-Valve (2.9;3.6); internal error, Short
cut to ground.
System Reaction
Power Reduction
• 60%
Actions for Repair
necessary.

Diagnostics
7.1.142 KWP Code 1230

1230 51 ActrCustHBrgShCirOvrLd
FMI-NO. 6
Short Description
• Actuator error EGR-valve; Overload by short-circuit.
• Actuator error EGR-Valve (2.9;3.6); internal error, Short
circuit, load over limit.
System Reaction
Power Reduction
• 60%
• Short circuit on H-bridge.
• ECU defective.
Actions for Repair
• Check actuator function with SerDia use case and
replace if necessary.
• Check wiring,
• If the error still occurs replace ECU.

Diagnostics
7.1.143 KWP Code 1231

1231 51 ActrCustHBrgTempOvrCurr
FMI-NO. 11
Short Description
• Actuator EGR-valve: Temperature limit in powerstage of
the actuator is reached due to high current.
(6.1,7.8); internal error, Temperature over limit.
System Reaction
Power Reduction
• 60 %
• EGR throttle flap stuck.
Actions for Repair
• Check actuator function with SerDia 2010 use-case and
repair or replace it if necessary.

Diagnostics
7.1.144 KWP Code 1232

1232 51 ActrCustHBrgUndrVltg
FMI-NO. 4
Short Description
• Actuator EGR-valve: meassured voltage by ECU is under
limit.
(6.1,7.8); internal error, Current over limit.
System Reaction
Power Reduction
• 60%
• Actuator counter plug disconnected.
• Broken wiring, open load, loose contact.
Actions for Repair
• Check wiring and counter plugs in the actuator EGR
circuit and if necessary repair or replace it.

Diagnostics
7.1.145 KWP Code 1505

1505 524057 PSPCtlPresBuildUp
FMI-NO. 2
COMPONENT Fuel feed pump (Pre pressure control)
Short Description
• Electric fuel pump; fuel pressure build up error.
• Electric fuel pump; fuel pressure build up error, Pressure
build up error.
System Reaction
Power Reduction
• No reduction.
• Leakage in fuel system.
• Fuel pump defective.
Actions for Repair
• Check low fuel pressure system (fuel feed pump, relay ,
fuse, wiring, sensor) and if necessary repair or replace it.

Diagnostics
7.1.146 KWP Code 1669

1669 524108 ComEGRTVActrTO
FMI-NO. 9
COMPONENT CAN Message
Short Description
• Missing CAN message of EGR throttle valve.
• Timeout error of CAN-Transmit-Frame ComEGRTVActr,
Timeout Error (Missing CAN Bus message).
System Reaction
Power Reduction
• No reduction.
• Receiver (sender of the message) work inaccurately.
• Parametering inaccurate.
Actions for Repair
• Check CAN Bus wiring (Bus sheduling, polarity, short
• Check actuator.

Diagnostics
7.1.147 KWP Code 1679

1679 524109 ComRxEGRTVActrTO
FMI-NO. 9
Short Description
• Missing message of EGR throttle valve.
• Timeout error of CAN-Receive-Frame ComRxEGRTVActr,
Timeout Error
(Missing CAN Bus message).
System Reaction
Power Reduction
• No reduction.
• Receiver (sender of the message) work inaccurately.
• Parametering inaccurate.
• Engine can be damaged.
Actions for Repair
• Check actuator.

Diagnostics
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Engine Service Manual

July 31, 2014 - A - Original Issue Of Manual

May 16, 2017 - B - Revised front cover.

31211014 TH414C GC, TH417C GC, TH314D, TH417D i

ii TH414C GC, TH417C GC, TH314D, TH417D 31211014

31211014 TH414C GC, TH417C GC, TH314D, TH417D iii

iv TH414C GC, TH417C GC, TH314D, TH417D 31211014

TH414C GC, TH417C GC, TH314D, TH417D i

3.28 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

ii TH414C GC, TH417C GC, TH314D, TH417D

PARAGRAPH TITLE PAGE

TH414C GC, TH417C GC, TH314D, TH417D 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1.2 DISCLAIMER WARNING

1-2 TH414C GC, TH417C GC, TH314D, TH417D

1.7 SAFETY INSTRUCTIONS 1.7.3 General Hazards

TH414C GC, TH417C GC, TH314D, TH417D 1-3

PARAGRAPH TITLE PAGE

TH414C GC, TH417C GC, TH314D, TH417D 2-1

2.1 GENERAL engine. Unauthorised persons are prohibited access to

2-2 TH414C GC, TH417C GC, TH314D, TH417D

TH414C GC, TH417C GC, TH314D, TH417D 2-3

2-4 TH414C GC, TH417C GC, TH314D, TH417D

TH414C GC, TH417C GC, TH314D, TH417D 2-5

This Page Intentionally Left Blank

2-6 TH414C GC, TH417C GC, TH314D, TH417D

PARAGRAPH TITLE PAGE

TH414C GC, TH417C GC, TH314D, TH417D 3-1

3.13 High-Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3-2 TH414C GC, TH417C GC, TH314D, TH417D

3.29 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

3.52 Holder (Engine 458-0043). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158

3-4 TH414C GC, TH417C GC, TH314D, TH417D

3.1 CRANKSHAFT SEALING RING 3.1.1 Crankshaft Sealing Ring Removal

TH414C GC, TH417C GC, TH314D, TH417D 3-5

3. Screw in a self-tapping screw (1) with washer.

3-6 TH414C GC, TH417C GC, TH314D, TH417D

3.1.2 Crankshaft Sealing Ring Installation

4. Mount assembly sleeve (1).

8. Tighten nut to the stop of the assembly sleeve (1)

TH414C GC, TH417C GC, TH314D, TH417D 3-7

3.2 GASKET HOUSING 3.2.1 Gasket Housing Removal

– Safety information / User

3-8 TH414C GC, TH417C GC, TH314D, TH417D

TH414C GC, TH417C GC, TH314D, TH417D 3-9

3.2.2 Gasket Housing Installation

3. Mount gasket housing.

3-10 TH414C GC, TH417C GC, TH314D, TH417D

5. Tighten the screws according to the tightening

TH414C GC, TH417C GC, TH314D, TH417D 3-11

3.2.3 Technical Data

3-12 TH414C GC, TH417C GC, TH314D, TH417D

3.3 CLOSING PARTS

– Safety information / User

1 Screw plug, Torque to 13 Nm (10 ft-lb)

Use a new sealing ring.

TH414C GC, TH417C GC, TH314D, TH417D 3-13

3.4 LUBRICATING OIL PAN 3.4.1 Lubricating Oil Pan Removal

Collect leaking operating substances in suitable

3-14 TH414C GC, TH417C GC, TH314D, TH417D

4. Drive in separating tool (1) to the stop (2).

TH414C GC, TH417C GC, TH314D, TH417D 3-15

3.4.2 Lubricating Oil Pan Installation