Common rail diesel injection (CDI) test of electrical system

AD07.16-S-6000A

Common rail diesel injection (CDI) test of electrical system

16.9.98

 Danger!

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 contact with fuel.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Danger!

Risk of death due to vehicle slipping or toppling from the lifting platform.

Align vehicle between the columns of the lifting platform and position the four brackets at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns when working in engine during starting procedure

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

 

Do not unplug control unit sockets unless ignition switched off



Contents, function descriptions for common rail diesel injection (CDI)

Engine 611.980 in models 638.094/194/294

GF07.16-S-0999A



Wiring diagram of common rail diesel injection (CDI) control unit

Engine 611.980 in models 638.094/194/294

PE07.16-S-2000A



Wiring diagram of common rail diesel injection (CDI) control unit

Engine 611.980 in models 638.094/194/294

PE07.16-S-2000B

Connecting and using test equipment

AD00.00-S-1000AZ

Connect hand-held-tester (HHT) and read out fault memory

AD00.00-S-2000-03A

Common-rail diesel injection (CDI) diagnosis, previous knowledge

AD07.16-S-2000A



Common rail diesel injection (CDI) arrangement of components

GF07.16-S-0001-01A

Information on the location of CDI components and connectors

AD07.16-S-2000-34A

Socket box connection diagram - CDI - testing of electrical system

AD07.16-S-2000-26A

Coupling assignment, diagnosis, CDI

AD07.16-S-2000-07A

CDI diagnosis connector assignment

AD07.16-S-2000-31A

Common rail diesel injection (CDI) diagnosis, fault memory

AD07.16-S-4000A



The CDI control unit and immobilizer control unit are permanently assigned after the first initialization. Therefore, trial installation of a new control unit is not possible



Notes on tester/test connection column

The numbers in brackets, as e.g. in  1.0 (1.23) mean:

1 Coupling 1 in wiring diagram

23 Socket 23 in wiring diagram



Fuses in order on front passenger-side fuse and relay module, connections plugged in



Battery voltage 11 to 14 volts



CDI system complete (all plug connections plugged in)



Ignition: OFF

Check

1

Voltage terminal 87, testing electrical system, CDI

AD07.16-S-6000-01A

2

Voltage terminal 15, testing electrical system, CDI

AD07.16-S-6000-02A

3

Starter signal terminal 50, testing electrical system, CDI

AD07.16-S-6000-03A

4

Starter relay, testing electrical system, CDI

AD07.16-S-6000-04A

5

Relay supply engine control unit, testing electrical system, CDI

AD07.16-S-6000-05A

6

Hot film mass air flow sensor (HFM-SFI), testing electrical system, CDI

With Code MS5, MS6 or MF8

AD07.16-S-6000-06A

7

Charge pressure sensor, testing electrical system, CDI

AD07.16-S-6000-07A

8

Intake air temperature sensor, testing electrical system, CDI

AD07.16-S-6000-08A

9

Intake air temperature sensor, testing electrical system, CDI

With code MQ3 and without code MS5

AD07.16-S-6000-08B

10

Coolant temperature sensor, testing electrical system, CDI

AD07.16-S-6000-09A

11

Fuel temperature sensor, testing electrical system, CDI

AD07.16-S-6000-10A

12

Pedal value sensor, signal 1, testing electrical system, CDI

Up to 31.01.00

AD07.16-S-6000-11A

13

Pedal value sensor, signal 1, testing electrical system, CDI

As of 01.02.00

AD07.16-S-6000-11B

14

Pedal value sensor, signal 2, testing electrical system, CDI

Up to 31.01.00

AD07.16-S-6000-12A

15

Pedal value sensor, signal 2, testing electrical system, CDI

As of 01.02.00

AD07.16-S-6000-12B

16

Rail pressure sensor, testing electrical system, CDI

AD07.16-S-6000-13A

17

Crankshaft position sensor, testing electrical system, CDI

AD07.16-S-6000-14A

18

Camshaft position sensor, testing electrical system, CDI

AD07.16-S-6000-15A

19

Rail pressure regulator valve, testing electrical system, CDI

AD07.16-S-6000-16A

20

Injector 1, testing electrical system, CDI

AD07.16-S-6000-17A

21

Injector 2, testing electrical system, CDI

AD07.16-S-6000-18A

22

Injector 3, testing electrical system, CDI

AD07.16-S-6000-19A

23

Injector 4, testing electrical system, CDI

AD07.16-S-6000-20A

24

Electric shutoff valve, testing electrical system, CDI

AD07.16-S-6000-21A

25

Inlet port shutoff switchover valve, testing electrical system, CDI

Up to 01.11.00 with code MS5

with code MS6

AD07.16-S-6000-22A

26

High-pressure pump element shutoff valve, testing electrical system, CDI

AD07.16-S-6000-23A

27

CAN data bus, testing electrical system, CDI

AD07.16-S-6000-24A

28

Clutch pedal switch, testing electrical system, CDI

Manual transmission

AD07.16-S-6000-25A

29

P/N recognition, testing electrical system, CDI

Automatic transmission (G40)

AD07.16-S-6000-26A

30

Glow output stage, testing electrical system, CDI

AD07.16-S-6000-27A

31

Glow plug failure, testing electrical system, CDI

AD07.16-S-6000-28A

32

Oil sensor, testing electrical system, CDI

AD07.16-S-6000-29A

33

Diagnostic cable, testing electrical system, CDI

Up to 31.01.00

AD07.16-S-6000-30A

34

Diagnostic cable, testing electrical system, CDI

As of 01.02.00

AD07.16-S-6000-30B

35

Cruise control switch, testing electrical system, CDI

With code MD0 or MD9

AD07.16-S-6000-31A

36

Engine radiator fan, testing electrical system, CDI

AD07.16-S-6000-32A

37

EGR/pressure regulating flap transducer, testing electrical system, CDI

Up to 01.11.00 with code MS5

AD07.16-S-6000-33A

38

Exhaust gas recirculation switchover valve, testing electrical system, EGR

Up to 01.11.00 without code MS5

Without code MS6
Without code MF8

Without code MS3

AD14.20-S-6000-08B

39

Charge pressure control transducer, testing electrical system, CDI

AD07.16-S-6000-34A

40

Crash signal, testing electrical system, CDI

AD07.16-S-6000-35A

41

Crankcase ventilation heater, testing electrical system, CDI

AD07.16-S-6000-36A

42

EGR pressure transducer, testing electrical system, CDI

As of 02.11.00 with code MS5

with code MF8

AD07.16-S-6000-37A