AD07.16-S-5000A | Common rail diesel injection (CDI), diagnosis, troubleshooting | 9.6.98 |
ENGINE 611.980 in MODEL 638
Danger! | Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel. | No fire, sparks, naked flames or smoking. Wear protective clothing when handling fuel. | |
Common-rail diesel injection (CDI) diagnosis, previous knowledge | |||
| Common rail diesel injection (CDI) contents function description | ||
Connect hand-held-tester (HHT), read out diagnostic trouble code memory | |||
Troubleshooting | |||
Complaint | Possible cause | Notes | Remedy/test step |
EPC lamp and preglow indicator lamp: | |||
EPC lamp in instrument cluster comes on | Diagnosis, basic knowledge Read out fault code by means of diagnosis tool (e.g. HHT) and proceed on a fault code-related basis | ||
Preglow indicator lamp in instrument cluster does not illuminate when preheating system is switched on. Engine can be started | Bulb | Instrument cluster P15 CAN data bus DTC memory Fault code | |
Preglow indicator lamp in instrument cluster does not illuminate. Engine cannot be started. | Voltage supply of glow output stage defective. Preglow output defective. | DTC memory Fault code | |
Preglow indicator lamp in the instrument cluster illuminates for approx. 1 minute when driving. | Open circuit at glow plugs | DTC memory Fault code | |
Preglow indicator lamp comes on while driving or intermittently | Short circuit at glow output stage. Fault in communication between engine control module and preglow output stage | DTC memory Fault code | |
Start: | |||
Starter does not turn | Terminal 50 Start enable from ETC control module (AT only) Airbag signal Airbag control module Drive authorization signal | DTC memory Fault code DTC memory Fault code DTC memory Fault code DTC memory Fault code |
Drive authorization system DHB 1.2 |
Engine does not start Starter turns Rail pressure < 120 bar | Fuel tank level Hydraulic system Injectors Pressure regulator valve | fueling High-pressure circuit Testing hydraulic system DTC memory Fault codes up to DTC memory Fault codes , | |
Engine does not start. Starter turns. Rail pressure rises at first, then drops back to zero | Restrictions in return line Hydraulic system | any kinks are to be rectified High-pressure circuit Testing hydraulic system | |
Engine does not start. Starter turns Rail pressure > 120 bar | Connectors on injectors interchanged. Crankshaft position sensor Synchronization between camshaft and crankshaft. Camshaft position sensor Injectors | Check assignment, Firing order 1, 3, 4, 2 DTC memory Fault code DTC memory Fault code DTC memory Fault codes up to , , | |
Driving: | |||
Engine stalls when running | Fuel tank level Crankshaft position sensor Leakage on the low-pressure side Pressure regulator valve Injectors Airbag signal | fueling DTC memory Fault code Low-pressure circuit Testing hydraulic system DTC memory Fault codes , DTC memory Fault codes up to , , DTC memory Fault code | |
Driving, load, load change: | |||
Engine stalls under load | Hydraulic system Rail pressure fluctuations Pressure control valve at limit stop Injectors | Low-pressure circuit Testing hydraulic system DTC memory Fault code DTC memory Fault codes , , DTC memory Fault codes up to , , | |
Engine stalls on load change | Leakage on the low-pressure side Rail pressure monitoring | All fuel lines and connections to be checked for constriction and damage Low-pressure circuit Testing hydraulic system High-pressure circuit Testing hydraulic system DTC memory Fault code | |
Insufficient power: | |||
Engine has insufficient power Injection quantity within tolerance Excessive smoke | Incorrect fuel Air cleaner Charge air system AGR transducer/pressure control flap Hot film mass air flow sensor (HFM-SFI) Inlet port shutoff | Replace fuel Visual inspection: DTC memory Fault code Fault memory Fault code DTC memory Fault code | |
Engine has insufficient power Injection quantity within tolerance Smoke in tolerance range | Exhaust system A/C compressor shutoff | Check exhaust system | |
Engine has insufficient power Injection quantity within tolerance Smoke formation no charge pressure | Leak in charge air system Hoses detached, leaking Pressure control flap sticking in closed position Vacuum supply of transducer Charge pressure control Charge pressure sensor Charge pressure control | Visual inspection: Visual inspection Vacuum circuit Testing pneumatic system Fault memory Fault code Fault memory Fault code | |
Engine noise: | |||
Engine knocking Hard engine noise | Injector plug interchanged Engine mechanically defective Injectors | Check assignment, Firing order 1, 3, 4, 2 Compression test to be carried out using diagnosis tool Smooth-running correction to be carried out using diagnosis tool DTC memory Fault codes up to , , |
e.g. HHT: refer to actuations, Compression test e.g. HHT: refer to check actual values, neutral smooth-running correction |
Engine hunts | Engine mechanically defective Injectors Rail pressure control unstable Pressure regulator valve Rail pressure sensor | Compression test to be carried out using diagnosis tool Smooth-running correction to be carried out using diagnosis tool DTC memory Fault codes up to , , DTC memory Fault code DTC memory Fault codes , Fault memory Fault code | e.g. HHT: refer to actuations, Compression test e.g. HHT: refer to check actual values, neutral smooth-running correction |
Referenced documents
- ad0000s200003a Connecting Hand-Held Tester (HHT), reading fault memory
- ad0716p7003i Common rail diesel injection (CDI) high-pressure circuit hydraulic testing
- ad0716s2000a Common rail diesel injection (CDI) diagnosis, previous knowledge
- ad0716s600003a Starter signal terminal 50, testing electrical system, CDI
- ad0716s600006a Hot film mass air flow sensor (HFM-SFI), testing electrical system, CDI
- ad0716s600007a Charge pressure sensor, testing electrical system, CDI
- ad0716s600007b Charge and intake air pressure sensor, testing electrical system, CDI
- ad0716s600013a Rail pressure sensor, testing electrical system, CDI
- ad0716s600014a Crankshaft position sensor, testing electrical system, CDI
- ad0716s600015a Camshaft position sensor, testing electrical system, CDI
- ad0716s600016a Rail pressure control valve, testing electrical system, CDI
- ad0716s600017a Injector 1, testing electrical system, CDI
- ad0716s600018a Injector 2, testing electrical system, CDI
- ad0716s600019a Injector 3, testing electrical system, CDI
- ad0716s600020a Injector 4, testing electrical system, CDI
- ad0716s600022a Inlet port shutoff switchover valve, testing electrical system, CDI
- ad0716s600024a CAN data bus, testing electrical system, CDI
- ad0716s600026a P/N recognition, testing electrical system, CDI
- ad0716s600027a Glow output stage, testing electrical system, CDI
- ad0716s600028a Glow plug failure, testing electrical system, CDI
- ad0716s600033a EGR/pressure regulating flap transducer, testing electrical system, CDI
- ad0716s600034a Charge pressure control transducer, testing electrical system, CDI
- ad0716s7000a Common rail diesel injection (CDI), low-pressure circuit, testing hydraulic system
- ad0716s700302i Rail pressure monitoring, testing hydraulic system, CDI
- ad0716s7003i Common rail diesel injection (CDI) diagnosis, high-pressure circuit, testing hydraulic system
- ad0716s8000a Common rail diesel injection (CDI) diagnosis, vacuum circuit, testing pneumatic system
- ad5430s1003bz Instrument cluster (KIN) diagnosis contents
- ad8340s1001az Tempmatic (TM) diagnosis contents
- ad9160s1000bz Airbag (AB) diagnosis contents
- as4700z000101a Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.
- gf0716s0999a Contents function description common rail diesel injection (CDI)