Nef Eur 5 - F4ae3481-3681

SERIES NEF
Eu 5/EEV
Vehicular application
N40
N40 ENT
N60
N60 ENT
Technical and Repair manual

This publication provides unit and relevant component repair
data, specifications, instructions and methodologies.
This publication has been drawn up for qualified and

specialised personnel.
Before performing any operation check that the part relevant

to the unit on which you must work is available along with all
safety devices for accident-prevention, such as, goggles,
helmet, gloves, shoes, etc. and hoisting and transporting
equipment.
Operations are to be performed by following the indications

included here, using the special equipment indicated and
assuring proper repair, compliance with schedule and
operator's safety requirements.
Each repair must aim to restore operating efficiency and safety

in compliance with the FPT provisions.
FPT cannot be held liable for modifications, alterations or other

interventions non authorised by FPT on the vehicle and if the
unit is warranted the above mentioned interventions will cause
its expiration.
FPT is not liable for repairing interventions.
FPT will provide further details required to carry out the

interventions and all the instructions that are not included on
this publication.
Data included in this publication may not be up-to-date

therefore subject to Manufacturer's modifications that can be
added at any time for technical or commercial purposes and
also to meet new law regulations in other Countries.
If issues on this publication differ from what is actually noticed

on the unit, please get in touch with the FPT network before
starting any intervention.
It is forbidden to copy this text or any of its parts and all

illustrations included.
Publication edited by
FIAT Powerrtrain Technologies
Mkt. Advertising & Promotion
Viale dell'Industria, 15/17
20010 Pregnana Milanese
Milano (Italy)
Print P2D32N020 E - 1st Ed. 05.2012
SERIES NEF Eu 5/EEV INTRODUCTION 1
Introduction
Page
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL

PARTS INSTALLATIONS . . . . . . . . . . . . . . . . 9
CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . 9
KEY OF LECTURE OF THE HEADINGS

AND FOOTNOTES . . . . . . . . . . . . . . . . . . . 10
Print P2D32N020 E Base - May 2012

2 INTRODUCTION SERIES NEF Eu 5/EEV
Base - May 2012 Print P2D32N020 E

PREFACE
Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly's
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
Section 1 describes the engines illustrating its features and working in general.
Section 2 describes the fuel supply type and engine operation.
Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the basis
of their specific use.
Section 4 describes scheduled maintenance and specific overhauling.
Section 5 describes troubleshooting for those who require simple and direct indications in order to locate the cause of the faults
while performing technical assistance.
Section 6 deals with removal and refitting of the main engine components.
Section 7 describes general mechanical servicing of the engine on the revolving stand.
Section 8 gives engine technical characteristics such as data, installation clearances and tightening torques.
Section 9 is about the tools necessary for performing these operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons' safety.
Danger of serious damage for the assembly

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE It indicates an additional explanation for a piece of information.
Service operations
Example
1 1 = Seat of small end bush

Close applying the required torque
Close applying the required torque + angular
2 = Seat of connecting rod bearings.
value
2

Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Number of revolutions
Fitting position check
Measurement
Value to find Temperature
Check
Equipment Pressure
bar
Oversized
Surface for machining
Higher than.
Machine finish
Maximum, peak
Undersized
Interference
Less than.
Strained assembly
Minimum
Selection
Thickness
Classes
Clearance
Oversizing
Lubrication Temperature < 0 C
Damp Cold
Grease Winter
Temperature > 0 C
Sealant
Hot
Adhesive
Summer
Air bleeding Preload

GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
! immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling.
Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is avail
able to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80 C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

GENERAL WARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and star-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR

d. DISTANCE ! 0

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by FPT.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

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

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

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

F4AE ENGINES 1
Part 1
F4AE ENGINES
Section
General specifications 1
Operational diagrams 2
Electrical equipment 3
Scheduled maintenance 4
Diagnostics 5
Removal - refitting of main components 6
General mechanical overhauling 7
Technical specifications 8
Tools 9
Safety prescriptions Appendix

2 F4AE ENGINES

F4AE ENGINES 3
UPDATING
Section Description Page Date of revision

4 F4AE ENGINES

F4AE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Engines F4AE3481 . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engines F4AE3482E*U101 . . . . . . . . . . . . . . . 7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Engines F4AE3681 . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 13
- 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 13
- 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 16

2 SECTION 1 - GENERAL SPECIFICATIONS F4HFE ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code

F4AE3481C*S100
F4AE3481D*S100
F4AE3481B*S100
F4AE3481A*S100
F4AE3481C*U100 N40 ENT
F4AE3481D*U100
F4AE3481B*U100
F4AE3481A*U100
F4AE3482E*U101
F4AE3681C*S100
F4AE3681B*S100
F4AE3681D*S100
F4AE3681E*S100
F4AE3681A*S100
N60 ENT
F4AE3681C*U100
F4AE3681B*U100
F4AE3681D*U100
F4AE3681E*U100
F4AE3681A*U100

ENGINE VIEWS
Engines F4AE3481
Figure 1
176511
LEFT-HAND SIDE VIEW
Figure 2
176513
RIGHT-HAND SIDE VIEW

Figure 3
176512
FRONT VIEW
Figure 4
176514
REAR VIEW

Figure 5
176509
TOP VIEW
Figure 6
176510
PERSPECTIVE VIEW

ENGINE VIEWS
Engines F4AE3482E*U101
Figure 7
171581
LEFT-HAND SIDE VIEW
Figure 8
171583

Figure 9
171582
FRONT VIEW
Figure 10
171580
REAR VIEW

Figure 11
171579
TOP VIEW
Figure 12
171585
PERSPECTIVE VIEW

ENGINE VIEWS
Engines F4AE3681
Figure 13
176504
LEFT-HAND SIDE VIEW
Figure 14
176506

Figure 15
176505
FRONT VIEW
Figure 16
176507
REAR VIEW

Figure 17
176508
TOP VIEW
Figure 18
176503
PERSPECTIVE VIEW

GENERAL CHARACTERISTICS
4-cylinder engines
F4AE3481C*S100 F4AE3481D*S100
Type
F4AE3481C*U100 F4AE3481D*U100
Compression ratio 17 : 1
Maximum power kW 103 118
(hp) (138) (158)
rpm 2700 2700
Maximum torque Nm 460 530

(kgm) (46.89) (54.03)
rpm 1200 1200
Idle speed rpm
Maximum engine
speed rpm
Bore x stroke 102 x 120
Total displacement cm3 3920
TURBOCHARGING With intercooler
Turbocharger type GARRET

Forced by gear pump,
LUBRICATION
pressure relief valve, oil filter
Oil pressure with engine hot:
bar
- at idle speed bar

- at maximum speed bar
COOLING By centrifugal pump, thermostat for regulating, radiator, heat
exchanger, intercooler
Coolant pump control Belt driven
Thermostat:
- start of opening C 79 2
- max. opening C 96
FILLING
- engine sump litres
15W40 ACEA E7/API CI-4 - engine sump
10W30 ACEA E7/API CI-4* + filter litres
10W40 ACEA E9/API CJ-4**
* For ambient temperature < -15 C

** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.
Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

F4AE3481B*S100 F4AE3481A*S100
Type
F4AE3481B*U100 F4AE3481A*U100
(HP) (174) (180)
rpm 2700 2700

(kgm) (58.10) (62.18)
rpm 1250 1300
Idle speed rpm
Maximum engine
speed rpm

Turbocharger type GARRET

LUBRICATION
bar
- at idle speed bar
Thermostat:
- max. opening C 96
FILLING
15W40 ACEA E7/API CI-4
10W30 ACEA E7/API CI-4* - engine sump + filter litres

** Alternatively

Type F4AE3482E*U101
Maximum power kW 110
(HP) (150)
rpm 2500
Maximum torque Nm 600

(kgm) (61.16)
rpm 1300
Idle speed rpm
Maximum engine
speed rpm

Turbocharger type GARRET GT 22

LUBRICATION
bar
- at idle speed bar 1.2
- at maximum speed bar 3.8
Thermostat:
- max. opening C 96
FILLING
- engine sump litres 8.4
10W30 ACEA E7/API CI-4* - engine sump + filter litres 9.4

** Alternatively

6-cylinder engines
F4AE3681C*S100 F4AE3681B*S100
Type
F4AE3681C*U100 F4AE3681B*U100
(hp) (181) (214)
rpm 2700 2700

(kgm) (66.26) (69.32)
rpm 1200 1200
Idle speed rpm
Maximum engine
speed rpm

Turbocharger type CCM HOLSET HX35W

LUBRICATION
bar
- at idle speed bar

Thermostat:
- max. opening C 96
FILLING
15W40 ACEA E7/API CI-4 - engine sump
10W30 ACEA E7/API CI-4* + filter litres

** Alternatively

F4AE3681D*S100 F4AE3681E*S100
Type
F4AE3681D*U100 F4AE3681E*U100
(HP) (248) (275)
rpm 2700 2500

(kgm) (86.65) (96.84)
rpm 1250 1250
Idle speed rpm
Maximum engine
speed rpm


LUBRICATION
bar
- at idle speed bar
Thermostat:
- max. opening C 96
FILLING

** Alternatively

F4AE3681A*S100 F4AE3682C*S100
Type
F4AE3681A*U100 F4AE3682C*U100
(HP) (295) (218)
rpm 2500 2700

(kgm) (107.03) (69.32)
rpm 1300 1200
Idle speed rpm
Maximum engine speed rpm


LUBRICATION
bar
- at idle speed bar
Thermostat:
- start of opening C 79 2 79 2
- max. opening C 96 94
FILLING
Total capacity
- engine sump litres 13.3

** Alternatively

F4AE3682E*S100 F4AE3682A*S100
Type
F4AE3682E*U100 F4AE3682A*U100
(HP) (264) (299)
rpm 2500 2500

(kgm) (101.94) (107.03)
rpm 1400 1250
Idle speed rpm
Maximum engine speed rpm


LUBRICATION
bar
- at idle speed bar
Thermostat:
- max. opening C 94
FILLING
Total capacity

** Alternatively


F4AE ENGINES SECTION 2 - OPERATIONAL DIAGRAMS 1
SECTION 2
Operational diagrams
Page
HIGH PRESSURE ELECTRONIC INJECTION FUEL

SYSTEM (COMMON RAIL) . . . . . . . . . . . . . . 3
- General Specifications . . . . . . . . . . . . . . . . . . . 3
ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
- Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- System functionality . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 5
- Fuel system layout . . . . . . . . . . . . . . . . . . . . . . 7
FUEL SUPPLY SYSTEM COMPONENTS . . . . . . 9
- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Mechanical supply pump . . . . . . . . . . . . . . . . . 10
- CP3 high-pressure pump . . . . . . . . . . . . . . . . . 11
- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 15
- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . . 16
- Pressure limiter for fuel return . . . . . . . . . . . . . 17
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- 4-cylinder engine version . . . . . . . . . . . . . . . . . 18
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 20
- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 21
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 22
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 23
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 SECTION 2 - OPERATIONAL DIAGRAMS F4AE ENGINES
Page
TURBOCHARGING SYSTEM . . . . . . . . . . . . . . . 26
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- 4-cylinder engine version . . . . . . . . . . . . . . . . 26
- 6-cylinder engine version . . . . . . . . . . . . . . . . 26
- Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . 27
- Waste gate . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DeNOx 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 29
- General Information . . . . . . . . . . . . . . . . . . . 29
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Ad Blue fluid level gauge control . . . . . . . . . . 31
- Pump module . . . . . . . . . . . . . . . . . . . . . . . . 31
- Dosing module . . . . . . . . . . . . . . . . . . . . . . . 31
- SCR pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Exhaust gas temperature sensor . . . . . . . . . . 32
- Humidity detecting sensor . . . . . . . . . . . . . . . 33
- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . . 34
- Pin out DCU 15 D2-2 . . . . . . . . . . . . . . . . . . 35

HIGH PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL)

General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
ELECTRIC SYSTEM
Figure 1
107246
1. Injectors connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Crankshaft sensor - 6. EDC7UC31 control unit - 7. Fuel flow rate regulator - 8. Fuel heater and fuel
temperature sensor - 9. Camshaft sensor - 10. Air pressure/temperature sensor - 11. Injector.
Sensors The outlet tension is proportional to the pressure or

Through the sensors, present on the engine, the ECU temperature obtained by the sensor.
controls the engine operation.
Engine oil temperature and pressure sensor
Air pressure/temperature sensor Same as air pressure/temperature sensor, it is fitted on the
It is a component integrating a temperature sensor and a engine oil filter, in a horizontal position.
pressure sensor. It measures engine oil temperature and pressure.
Fitted on the intake manifold, it measures the max. inlet air
capacity to calculate precisely the fuel quantity to inject at
every cycle.

Fuel pressure sensor Injection control

Assembled on a rail end, it measures the fuel pressure in the The control unit, depending on information coming from
rail in order to determine the injection pressure. sensors, controls the flow rate regulator, and changes
pre-injection and main injection modes.
The injection pressure value is used to control the pressure
and to determine the electric injection control length. Closed-loop control for injection pressure
Depending on engine load, measured by processing signals
Fuel temperature sensor
coming from various sensors, the control unit controls the
It is a sensor that is equal to the previous one. regulator in order to always have the optimum pressure.
It measures fuel temperature to provide the control unit with Pilot and main injection spark advance control
an index of the diesel fuel thermal state. The control unit, depending on signals coming from various
sensors, computes the optimum injection point according to
Coolant temperature sensor an internal mapping.
It is a variable-resistance sensor suitable to measure the
coolant temperature to provide the control unit with an Idle speed control
index of the engine thermal state. The control unit processes signals coming from various
sensors and adjusts the amount of injected fuel.
Crankshaft sensor It controls the pressure regulator and changes the injection
It is an inductive sensor placed on the front engine part. time of injectors.
Signals generated through the magnetic flow that is closed on Within certain thresholds, it also takes into account the
the phonic wheel, change their frequencies depending on battery voltage.
output shaft rotation speed. Maximum speed limiting
At 2700 rpm, the control unit limits fuel flow-rate by reducing
Timing sensor the injectors opening time.
It is an inductive sensor placed on the engine rear left part. Over 3000 rpm it deactivates the injectors.
It generates signals obtained from magnetic flow lines that are
closed through holes obtained on the keyed gear on the Cut Off
camshaft. The signal generated by this sensor is used by the Fuel cut off upon release is controlled by the control unit
ECU as injection phase signal. performing the following logics:
- it cuts off injectors supply;
Though being equal to the flywheel sensor, it is NOT - it re-activates the injectors shortly before idle speed is
interchangeable since it has a different outside shape. reached;
- it controls fuel flow rate regulator.
System functionality
Self-diagnosis Smoke control upon acceleration
With strong load requests, the control unit, depending on
The ECU self-diagnostic system checks signals coming from signals received by air inlet meter and engine speed sensor,
sensors by comparing them with threshold data. controls the flow rate regulator and changes the injectors
Engine pre-heating resistance check actuation time, in order to avoid exhaust smokes.
The pre-post heating is activated when even only one of the Fuel temperature control
water, air or fuel temperature sensors signals a temperature When the fuel temperature exceeds 75 C (measured by the
that is less than 5 C. sensor placed on fuel filter) the control unit intervenes by
reducing injection pressure.
Timing recognition If the temperature exceeds 90 C, the power is reduced to
By means of signals coming from camshaft sensor and 60%.
flywheel sensor, the cylinder on which fuel must be injected After Run
is recognised upon startup. The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the
following startup.

HYDRAULIC SYSTEM
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
Figure 2 (D)
High Pressure
Low Pressure
108499
(D) F4AE3481/2
1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump -
6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.

The low-pressure circuit is composed of the following pipings:

- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
Figure 3 (*)
High Pressure
Low Pressure
Fuel outlet
166062
(*) F4AE3681
1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump -
6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.

Fuel system layout The pressure relief valve (2) intervention brings about a fuel
The flow rate regulator (15), placed upstream of the flow increase in the high-pressure pump cooling circuit,
high-pressure pump, adjusts the fuel flow that is necessary on through inlet and drain piping (16) from piping (8).
the low-pressure system. Afterwards, the high-pressure The pressure relief valve housed on the cylinder head,
pump takes care of supplying the rail properly. This assembled on injector return (3), limits the fuel return flow
arrangement, by pressurising the necessary fuel only, from injectors at a pressure of 1.3 to 2 bars.
improves the energetic efficiency and limits fuel heating in the
system. Two by-pass valves are placed in parallel with the mechanical
supply pump.
Function of the pressure relief valve (2), assembled on the
high-pressure pump, is keeping the pressure, at the flow rate The by-pass valve (18) allows fuel to flow from mechanical
regulator inlet, constant at 5 bars, independently from the pump outlet to its inlet, when the fuel filter inlet pressure
efficiency of the fuel filter and of the system set upstream. exceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
Figure 4 (*)
EXHAUST
INTAKE (LOW PRESSURE)
HIGH-PRESSURE PUMP SUPPLY

(LOW PRESSURE)
HIGH PRESSURE
114545
(D) F4AE3481/2
1. High-pressure pump - 2. Pressure relief valve on high-pressure pump, 5 bars - 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars - 4. Rail overpressure valve - 5. Common Rail - 6. Pressure sensor - 7. Injector -
8. Return piping - 9. Control unit heat exchanger - 10. Mechanical priming pump - 11. Prefilter assembled on chassis -
12. Fuel tank - 13. Mechanical supply pump - 14. Fuel filter - 15. Flow rate regulator -
16. High-pressure pump cooling piping - 17. By-pass valve - 18. By-pass valve.

Figure 5 (*)
(LOW PRESSURE)
HIGH-PRESSURE PUMP SUPPLY
INTAKE (LOW PRESSURE)
HIGH PRESSURE
EXHAUST
108608
(*) F4AE3681

FUEL SUPPLY SYSTEM COMPONENTS Fuel filter

Fuel prefilter It is located on engine block in the circuit between feed pump
and high pressure pump (CP3).
On the support there are located: fuel temperature sensor
Figure 6 and heater resistances.
Fuel temperature, signalled by relating sensor to EDC7UC31
central unit, enables a very accurate calculation of the flow
rate of fuel to be injected into the cylinders.
The electrical heater intervenes when fuel temperature is
lower than 5 C.
Figure 7
70494
The fuel filter is of the high water separation type, is 99231

assembled on the vehicle chassis, and has the sensor (4) for
detecting water in fuel placed on the cartridge (3) base.
Manual priming pump (5) and air bleeding screw (2) from 1. Fuel filter support - 2. Fuel temperature sensor -
system are located on filter support. 3. Electric fuel heater - 4. Fuel filter - 5. Adapter -
6. Heater connector - 7. Gasket
The presence of condensate into filter is signalled by sensor
(4) when a warning light on the instrument panel is lit. A. Fitting for fuel drain outlet to tank -
B. Fitting for outlet to high pressure pump -
C. Fitting for drain from high pressure pump -
D. Fitting for fuel drain inlet from rail -
E. Fitting for inlet from feed pump
If the warning light is on, it is necessary to im-

mediately operate to remove its cause; the
common rail system components are quickly
damaged by the presence of water or impurities in
the fuel.

Mechanical supply pump Bleeding conditions

Feed mechanical pump is a gear pump, mounted on high
Figure 10
pressure pump rear side, having the task of feeding high
pressure pump. It is driven by high pressure pump shaft.
Normal operating conditions
Figure 8
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
72592 situation the by-pass valve (1) stays closed whereas by-pass
valve (2) opens due to inlet pressure, and fuel is drained out
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass through B.
valves in close position
Overpressure condition at outlet

NOTE The mechanical supply pump cannot be replaced
individually, therefore it cannot be removed from
Figure 9 the high pressure pump.
72593
The by-pass valve (1) cuts in when overpressure is generated

at outlet B. The existing pressure, overcoming valve spring (1)
elastic strength, makes inlet and outlet communicating
through duct (2).

CP3 high-pressure pump

CP3 high pressure pump is a pump with 3 radial plungers which is driven through a timing system gear. High pressure pump
does not require timing. On high pressure pump rear side, feed mechanical pump is mounted, driven by high pressure pump
shaft.
NOTE The following work must be carried out on the feed pump / high-pressure pump assembly:
- replacing the drive gear;
- replacing the fuel flow rate regulator.
Figure 11
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Fuel flow rate regulator - 4. Control gear - 5. Fuel inlet fitting from
filter - 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from
supply pump to filter - 9.Mechanical supply pump

High-pressure pump - inside structure

Figure 12
Sec. B-B
Sec. C-C
70498
1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft -
7. Low-pressure fuel inlet - 8. Plungers supplying fuel ducts.
Each plunger is made up of:

- one piston (5) driven by a three-lobe element (2) floating on pump shaft (6). Element (2) is floating on a misaligned side
of shaft (6). Therefore, during shaft rotation, the element is not turning together with the shaft, but is just translated, according
to a circular movement, to a wider radius. It results that the three pumping assemblies are driven alternatively;
- one cap intake valve (3);
- one delivery ball valve (4).

Operating principle
Figure 13
Sec. B B
Sec. D D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply duct
- 6. Pressure regulator supply duct - 7. Flow rate regulator.
Plunger (3) is oriented towards the cam that is present on pump shaft (4). During suction stroke, the plunger is fed through feed
duct (5). The quantity of fuel to be sent to the plunger is set by flow rate regulator (7). Flow rate regulator, on the basis of PWM
command received by control unit, partialises fuel inflow to the plunger. During plunger compression stroke, fuel reaches such
a pressure that valve delivering the fuel to common rail (2) is opened and common rail is fed by the plunger through outlet (1).

Figure 14 Figure 15
72601
72598
Sec. C C Sec. A A
1. Plunger inlet - 2. Pump lubrication ducts - 3. Plunger 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
inlet - 4. Main plunger supply duct - 5. Flow rate regulator from pump with high pressure pipe fitting for common rail.
- 6. Plunger inlet - 7. Regulator exhaust duct - 8. 5 bar
pressure relief valve - 9. Fuel drain from regulator inlet.
Figure 15 shows high pressure fuel flow through plunger

outlet ducts.
Figure 14 shows low pressure fuel paths inside the path and
highlights: main plunger supply duct (4), plunger supply ducts
(1 3 6), pump lubrication ducts (2), flow rate regulator
(5), 5 bar pressure relief valve (8) and fuel drain duct (7).
Replacing the pressure regulator
Pump shaft is lubricated by fuel through delivery and return - Greatest cleanliness must be ensured;
ducts (2).
- avoid letting impurities into the pump pressure channels;
Flow rate regulator (5) establishes the fuel amount to send
to plungers; excess fuel is drained out through duct (9). - replace the O-rings and moisten them with Vaseline;
5 bar pressure relief valve acts as fuel return regulator and - tighten to the specified torque:
keeps 5 bar constant pressure at regulator inlet. 1st phase: 3 4 Nm,
2nd phase: 6 7 Nm.

Operation Rail
The cylinder is filled through the cap intake valve only if the Figure 16 (Demonstration)
supply pressure is suitable to open the delivery valves set on
the plungers (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the flow rate regulator, placed on the
low-pressure system; the flow rate regulator is controlled by
the EDC7UC31 control unit through a PWM signal.
When fuel is sent to a plunger, the related piston is moving
downwards (suction stroke). When the piston stroke is
reversed, the intake valve closes and the remaining fuel in the
plunger chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure
107422
circuit.
The plunger compresses the fuel till the top dead center
(delivery stroke) is reached. Afterwards, the pressure 1. Rail - 2. Pressure sensor - 3. Fuel inlet from
decreases till the exhaust valve is closed. high-pressure pump - 4. Overpressure valve.
The plunger piston goes back towards the bottom dead The rail volume is of reduced sizes to allow a quick
center and the remaining fuel is decompressed. pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise use of plenum
When the plunger chamber pressure becomes less than the chambers caused by injectors openings and closings and by
supply pressure, the intake valve is again opened and the the high-pressure pump operation. This function is further
cycle is repeated. enabled by a calibrated hole being set downstream of the
high-pressure pump. A fuel pressure sensor (4) is screwed to
The delivery valves must always be free in their movements,
free from impurities and oxidation. the rail. The signal sent by this sensor to the electronic
control unit is a feed-back information, depending on which
The pressure of fuel delivered to rail is modulated by the rail pressure value is checked and, if necessary, corrected.
electronic control unit through flow rate regulator solenoid
valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump removal refitting time on the engine is
highly reduced in comparison with traditional injection
pumps, because it does not require setting.
Overpressure valve
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are Overpressure valve is mounted at one rail end. Overpressure
absolutely clean. valve task is to protect system components should rail
pressure sensor or CP3 pump pressure regulator
malfunctioning cause a pressure excessive increase in high
pressure system. When pressure in rail is reaching 1800 bar,
the valve at start operates in order to make fuel flow and
consequently decrease pressure to safety values, then
mechanically regulates pressure in rail. The valve enables to
operate engine for long times with limited performance and
prevents fuel excessive overheating, so preserving pipes for
fuel return to tank.

Electro-injector Injection start

The injector is similar as construction to the traditional ones, Figure 18
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position

Figure 17
15
15
70506
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot

valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Control duct -
11. Supply duct - 12. Control fuel outlet - 13. Electric
connection - 14. Spring - 15. High-pressure fuel inlet.
70505
When coil (4) is energised, it makes shutter (6) move
upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot (9). Simultaneously the fuel pressure into pressure chamber
valve - 6. Ball shutter - 7. Control area - 8. Pressure (8) makes plunger (2) lift, with following fuel injection into the
chamber - 9. Control volume - 10. Control duct - cylinder.
11. Supply duct - 12. Control fuel outlet - 13. Electric Injection end
connection - 14. Spring - 15. High-pressure fuel inlet.
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
NOTE The injector cannot be overhauled and therefore

it must not be disassembled.

Pressure limiter for fuel return

It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors at a pressure 1.3 and
2 bars. By guaranteeing this pressure to the return fuel, the
fuel vapours formation inside injectors is avoided, optimising
fuel spraying and combustion.
Figure 19
70507
A To tank B From injectors

LUBRICATION Lubrication involves the heat exchanger as well, the

4-cylinder engine version turbo-blower and the eventual compressor for any eventual
compressed air system.
Lubrication by forced circulation is achieved through oil
rotary expansion pump, placed in the front part of the All these components may often vary according to the
basement, driven by the straight-tooth gear splined to the specific duty and will therefore be examined in the specific
shaft's bar hold. section.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Figure 20 (Demonstration)
Oil recover from the

turbo-blower
To the exchanger
and to the
turbo-blower
Routing of oil return by gravity to sump 108511
Routing of oil return by gravity to sump

Introduction of oil
LUBRICATION SYSTEM LAYOUT

4-cylinder engines

6-cylinder engine version Also in this case, the components such as the oil exchanger,
Even for the 6 cylinders version lubrication is obtained by the turbo-blower and the eventual compressor are
forced circulation and achieved through an oil rotary specifically studied and made out to suit the equipment or the
expansion pump similar to the 4 cylinders' one. duty for which the engine has been developed.
Oil recover from the

turbo-blower
To the exchanger
and to the
turbo-blower
Routing of oil under pressure

108512
Routing of oil return by gravity to sump
Introduction of oil
LUBRICATION SYSTEM LAYOUT

6-cylinder engines

Oil pump Figure 22
NOTE Since the oil pump cannot be overhauled. It shall

be replaced when damaged.
70576
Heat exchanger
Figure 23
166064
1. Heat exchanger body with filter bracket and oil filter - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between
heat exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

Oil pressure relief valve

Figure 24
Loosen the plug (1), withdraw the spring (2) and the relief
valve (3) from the support (4).
Check whether the valve (3) is not scored and is sliding
smoothly into its seat. The spring (2) shall not be broken or
yielded.
Pressure regulation at 100 C oil temperature: 107418
- 1.2 bar min pressure; By-pass valve (5) to cut out clogged oil filter.
- 3.8 bar max. pressure
Figure 25 Figure 26
Flow
70482
107419 Max blow-by:
MAIN DATA TO CHECK OIL PRESSURE RELIEF 20 cm3/1' at 0.83 bar pressure and at 26.7 C oil temperature.
VALVE SPRING

OIL VAPOUR RECYCLING

Figure 27
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

COOLING SYSTEM - Viscous pusher fan, having the duty to increase the heat
4-cylinder engine version dissipating power of the radiator. This component as
The engine cooling system, closed circuit forced circulation well will be specifically equipped based on the engine's
type, generally incorporates the following components: development.
- Expansion tank; placement, shape and dimensions are - Heat exchanger to cool the lubrication oil: even this
subject to change according to the engine's equipment. component is part of the engine's specific equipment.
- Radiator, which has the duty to dissipate the heat - Centrifugal water pump, placed in the front part of the
subtracted to the engine by the cooling liquid. Also this engine block.
component will have specific peculiarities based on the - Thermostat regulating the circulation of the cooling
equipment developed, both for what concerns the liquid.
placement and the dimensions.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Expansion tank
Expansion tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump

74194
COOLING SYSTEM LAYOUT

4-cylinder engines
6-cylinder engine version

The engine cooling system, closed circuit forced circulation
type, is of a similar design as the 4 cylinders engine.
It incorporates necessary components such as the radiator,
the heat exchanger, the expansion tank and some ancillary
components such as the heater or the compressor for the
compressed air.
Such components always vary according to the engine's
equipment and duty.
Expansion tank
Expansion tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump

166066
COOLING SYSTEM LAYOUT

6-cylinder engines
Water Pump The water pump is located in a hollow obtained in the

cylinder block and is driven by and a poly-V belt.
Figure 30
An automatic tensioner keeps the belt tension.
Thermostat
Figure 31
79458
The bypass thermostat (1) is housed in the cylinder head and

needs no adjustment.
Whenever there are doubts as to its condition, replace it.
The thermometric switch/transmitter and coolant
temperature sensor are mounted on the thermostat body.
A = travel start at 77 81 C;
70486
Sec. A-A B = travel at 95 C 7.5 mm

TURBOCHARGER
Description
The turbocharging system is composed of: air filter, turbocharger and intercooler.
The air cleaner is a dry type composed of a filtering cartridge that is periodically changeable.
The function of the turbocharger is to use the energy of the engine's exhaust gas to deliver pressurized air to the cylinders.
The intercooler is composed of a radiator applied to the engine coolant radiator, with the function of lowering the turbocharger
output air temperature before it is sent to the cylinders.
Figure 32
AIR FILTRE TURBOCHARGER
EXHAUST
INTERCOOLER
AIR FILTRE TURBOCHARGER
EXHAUST
INTERCOOLER
74195

Turbocharger The turbocharger is composed of the following main parts:

Figure 33 (D) - a central body in which a shaft is housed, supported by
bushings, the ends of which are connected to: the
turbine rotor and the compressor rotor;
- a turbine casing and a compressor casing mounted on
the end of the central body;
- a boost-pressure regulation valve (when present) fitted
on the turbine casing.
During engine operation, the exhaust gases pass through the
turbine body spinning the turbine rotor.
The compressor rotor is connected by a shaft to the turbine
rotor, which it spins and in doing so compresses the air taken
in through the air filter.
The air is then cooled by the intercooler and sent to the
cylinders via the intake manifold.
intake air
compressed air The engine oil is used to cool and lubricate the turbocharger
166697
exhaust and the bearings.
(D) F4AE3481/2 The turbocharger is fitted with a pressure regulation valve,
mounted on the exhaust manifold before the turbine and
CCM HOLSET HX35W TURBOCHARGER controlled by a pneumatic actuator, connected via a pipe to
the intake manifold.
Its job is to limit the quantity of exhaust gas acting on the
Figure 34 (*) turbine by sending part of it directly into the exhaust pipe
when the boost pressure downstream of the compressor
reaches the maximum value set.
intake air
compressed air
166067
exhaust
(*) F4AE3681
CCM HOLSET HX35W TURBOCHARGER

Apply the magnetic-base dial gauge (2) on the exhaust gas

NOTE Verifying an anomalous operation of the engine, inlet flange in the turbine.
due to the booster system, it is recommended,
before performing controls on the Position the tracer point of the gauge (2) on the tie rod (3)
turbosupercharger, to check the efficiency of the end and set to zero the gauge (2).
sealing gaskets and the fixing of the connection Through the pump (1) let in compressed air, in the actuator
sleeves, making sure of clogging absence inside (6), at the prescribed pressure and make sure that such value
intake sleeves, air cleaner or inside radiators. If the is kept constant for the whole check time, otherwise replace
turbosupercharger damage is due to a lack of the actuator (6).
lubrication, check that the oil circulation pipes are
not broken or obstructed, in such case replace In the above-mentioned conditions, the tie rod must have
them or eliminate the trouble. carried out the prescribe stroke.
NOTE During the operation, beat slightly the actuator (6)

in order to eliminate possible sticking of the
Bearing end play check actuator internal spring.
Position the tracer point of the magnetic-base dial gauge on
the turbocharger shaft end and set to zero the dial gauge.
If a different value is found, loosen the nut (5) and operate
Move the turbocharger shaft axially and check that the properly the knurled ring nut (4).
clearance is not higher than the prescribed value.
Replace the turbocharger if a different value is found.
Waste gate Actuator replacement
Figure 36
Check and adjustment

Figure 35
3 2 1
166070
Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
62873
Remove the nuts (2) and remove the actuator (1) from the
Cover the air, exhaust gas and lubrication oil inlets and supporting bracket. Fit the new actuator following the
outlets. removal operations in reverse order and fitting a new clip (4),
tighten the nuts (2) to 5.6 6.8 Nm torque.
Carry out an accurate external cleaning of the
turbosupercharger, using the anticorrosive and antioxidant Check and adjust the actuator (1), if required, as described
solution and perform the check on the actuator (6). in the relevant chapter.
Clamp the turbosupercharger in a vice. Then, paint the nut (6) with safety paint.
Disconnect the pipe of the actuator (6) and apply to the Before refitting the turbocharger on engine, fill the central
actuator union, the pipe of pump 99367121 (1). body with engine oil.

DeNOx 2 SYSTEM
General Information
To limit the nitrogen oxide exhaust gas values (NOx) within the limits required by Euro 5, with low fuel consumption, the vehicles
have been equipped with a post-treatment system for these substances contained in the exhaust gas, which is essentially an
electronically controlled oxidative catalyst.
Using the Selective Catalytic Reduction (SCR) process, the system transforms the nitrogen oxide (NOx) into inert compounds:
free nitrogen (N2) and water vapour (H2O).
The SCR process is based on a series of chemical reactions that, due to the reaction of ammonia with the oxygen in the exhaust
gas, lead to the reduction of nitrogen oxides (NOx) contained in the exhaust gas.
The system essentially comprises:
- a tank (5) of reagent solution (water - urea: Ad Blue) with a level indicator;
- a pump module (1);
- a mixing and injection module (6);
- a catalytic converter;
- two temperature sensors (9 and 10) at the exhaust gas inlet and outlet to the catalytic converter;
- a humidity sensor fitted on the engine air intake pipe downstream of the air filter.
The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module (1), which
according to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and
humidity in the incoming air, adjusts the flow rate of the Ad Blue solution to be put into the system.
The pump module (1) picks up the reagent solution from the tank (5) and sends it under pressure to the mixing and injection
module (6) to be injected into the exhaust pipe upstream of the catalytic converter.
The first phase of the process takes part in the first part of the catalytic converter: due to the effect of the exhaust gas temperature,
the reagent solution evaporates instantly and, by hydrolysis, converts into ammonia (2NH3) and carbon dioxide (CO2).
Evaporation of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature
required by the process.
The exhaust fumes, additioned with ammonia and at the reaction temperature, are introduced into the catalytic converter, where
the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into
free nitrogen (N2) and water vapour (H2O).

Figure 37
148514
1. Pump module - 2. Tank level sensor - 3. Tank temperature sensor - 4. Ad Blue tank - 5. Prefilter - 6. Return flow valve -
7. Dosing module - 8. MV2 - 9. Exhaust gas temperature sensor - 10. Catalyst - 11. Exhaust gas temperature sensor -
12. NOx detection sensor - 13. Ad Blue pressure sensor - 14. Filter - 15. Diaphgram pump - 16. Reverting valve -
17. Ad Blue temperature sensor

Tank Pump module

Figure 38 Figure 40
108508 148510
The tank with the level indicator command (1) contains the 1. DCU control unit connector - 2. Pressure
reducing substance necessary for the SCR process, compensattion - 3. Ad Blue solution infeed - 4. Prefilter -
comprising a solution of 35% urea and water, known as Ad 5. Ad Blue solution outlet - 6. Ad Blue return pipe from
Blue. dosing module - 7. Ad Blue l tank return - 8. Filter
Dosing module
Figure 41
Ad Blue fluid level gauge control
Figure 39
108129
1. Ad Blue infeed - 2. Electrical connection -

3. Ad Blue outlet
Has the job of dosing the Ad Blue solution to be sent into
the exhaust pipe upstream of the catalytic converter.
SCR pipes
116181
NOTE The SCR pipe harnesses complete with the VOSS
are only available for production.
1. Ad Blue fluid intake pipe - 2. Ad Blue fluid return pipe - In case of repair operations, for the replacement of
3. Inlet pipe for hot engine coolant fluid - 4. NTC sensor - each component (cooling water pipes, AdBlue
5. Outlet pipe for hot engine coolant fluid - 6. Float - pipes, fittings, corrugated pipes, sectioning plates,
7. AdBlue liquid heating coil (only versions equipped with etc.) refer to the supplied spare accessories.
08277 optional) - 8. AdBlue breather

Exhaust gas temperature sensor

Figure 42
102303
Figure 43
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor.
The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to
calculate the amount of urea to be injected into the system.

Humidity detecting sensor

Figure 44
102311
1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply.

This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of
humidity found in sucked air, to determine the calculation of nitric oxide emissions.
Figure 45
102312
ELECTRIC BLOCK DIAGRAM

1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator -
B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter

Nitric oxide sensor
Figure 46
102302
1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare

This sensor has the function to communicate the dosing of AdBlue liquid (Urea) and the catalyst conditions to the control unit.

Pin out DCU 15 D2-2
Figure 47
UDS
DCU15
113576
Pin No Abbrev Name

1 V_V_BAT+R Battery + via main relay (output)
2 V_V_BAT+R Battery + via main relay (output)
3 V_V_BAT+ Battery plus
4 V_V_BAT+ Battery plus
5 B_D_CANH1 Controller Area Network 1 (high)
6 B_D_CANL1 Controller Area Network 1 (low)
7 B_D_CANH2 Controller Area Network 2 (high)
8 B_D_CANL1 Controller Area Network 2 (low)
9 dnc do not connect
10 O_S_CLH Compensation line heating
11 O_S_RAMV Reduction agent metering valve
12 O_V_RAMV Reduction agent metering valve supply (BAT+ )
14 G_G_BAT- Battery minus
15 G_G_BAT- Battery minus
17 G_R_CATTSPRE Catalyst temperature sensor ground (upstream)
18 I_A_RALS Reduction agent level sensor signal
19 G_R_RALS Reduction agent level sensor ground/Reduction agent tank temperature sensor ground

Pin No Abbrev Name

21 O_S_SVS Service soon available
22 O_S_HH1 Hose heating 1 (Suction line heating)
23 O_S_RATH Reduction agent tank heating
24 I_S_T15 Terminal 15 (switched BAT+)
25 G_R_CATTSPOST Post-catalyst temperature sensor ground (downstream)
26 I_A_CATTSPOST Post-catalyst temperature sensor signal (downstream)
28 I_A_CATTSPRE Catalyst temperature sensor signal (upstream)
29 I_A_TRATS Reduction agent tank temperature sensor signal
30 V_V_5VRALS Reduction agent level sensor supply
31 B_D_ISOK ISO-K interface
32 O_S_HH3 Hose heating 3 (Pressure line heating)
34 O_S_HH4 Hose heating 4 (Back flow to supply module line heating)
35 O_S_HH2 Hose heating 2 (Back flow to tank line heating)

Figure 48
148515


F4AE ENGINES SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 3
CABLE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 4
ECU ELECTRONIC CONTROL UNIT

(EDC7UC31) . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Electroinjectors connector (A) . . . . . . . . . . . . 7
- Sensors connector (C) . . . . . . . . . . . . . . . . . . 8
FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS 9
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . 10
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Supercharging air pressure - temperature sensor 11
- Engine oil temperature-pressure sensor . . . . . 11
- Fuel temperature and pressure sensor . . . . . . 12
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . 13
- Pre-post heating resistance and contactor

(if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Coolant temperature sensor . . . . . . . . . . . . . . 15
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 16
- High pressure pump - fuel flow rate regulator 17

2 SECTION 3 - ELECTRICAL EQUIPMENT F4AE ENGINES

LOCATION OF THE MAIN ELECTRICAL COMPONENTS

108641
The NEF F4HFE engines are fully driven by the electronic The electrical and electronic components of the engine are
engine control module, which is assembled directly to the listed here following:
engine by means of a heat exchanger enabling its cooling,
1. Coolant temperature sensor.
utilising rubber buffers to reduce vibration originated by the
engine. 2. Electro-injector.
Through the engine control module it is possible to verify the 3. RAIL pressure sensor.
correct working of the engine. (See SECTION 5 -
4. Air temperature/pressure sensor.
Diagnostics).
5. Starter motor.
6. Timing sensor.
7. Fuel flow rate regulator solenoid valve.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre-post heating.

CABLE ENGINE
All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.
Figure 2
166698
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 4. Engine rpm sensor -
5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor -
8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor -
11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).


All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.
Figure 3
0051064t
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor -
5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor -
8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor -
11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).

ECU ELECTRONIC CONTROL UNIT (EDC7UC31)

Figure 4
102373
A. Injector connector - B. Frame connector (refer to the vehicle which the engine is fitted to) -
C. Sensor connector

Electroinjectors connector (A)

Figure 5 12 16
6 11
50350
1 5
Colour legend
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
4-cylinder engines 6-cylinder engines

Pin
Cable colour Description Cable colour Description
1 HN Cylinder 3 injector LR Cylinder 5 injector
2 HR Cylinder 2 injector BC Cylinder 6 injector
3 - - BL Cylinder 4 injector
4 MB Cylinder 1 injector MB Cylinder 1 injector
5 HV Cylinder 4 injector MV Cylinder 3 injector
6 - - HR Cylinder 2 injector
7 - - - -
8 - - - -
9 V Fuel flow rate regulator V Fuel flow rate regulator
10 C Fuel flow rate regulator C Fuel flow rate regulator
11 - - MN Cylinder 2 injector
12 BL Cylinder 4 injector HN Cylinder 3 injector
13 HG Cylinder 1 injector HG Cylinder 1 injector
14 - - HV Cylinder 4 injector
15 MN Cylinder 2 injector VN Cylinder 6 injector
16 MV Cylinder 3 injector RG Cylinder 5 injector

Sensor connector (C)

6 8 16 9 15 22
Figure 6
Colour legend
C ORANGE
A LIGHT BLUE
4
B WHITE
L BLUE
5
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN 1 3 23 30 36 29
50350
Z PURPLE
Cable colour
Pin Description
code
1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 Signal from sensor of engine revolution counter on timing (phase sensor) B
10 Ground of sensor of engine revolution counter on timing (phase sensor) R
11 - -
12 Fuel pressure sensor ground BN
13 Fuel pressure sensor power supply HN
14 Fuel pressure sensor signal RV
15 Water temperature sensor signal CV
16 - -
17 - -
18 Fuel temperature sensor ground CN
19 Engine revolution counter sensor ground B
20 - -
21 - -
22 - -
23 Signal from engine revolution counter sensor R
24 Oil pressure / temperature sensor ground GV
25 Air pressure / Temperature ground GN
26 Water temperature sensor ground BG
27 Oil pressure sensor signal GR
28 Oil temperature sensor signal NS
29 - -
30 - -
31 - -
32 Oil pressure / temperature sensor supply MN
33 Air pressure / Temperature sensor supply CL
34 Air pressure sensor signal LN
35 Fuel temperature sensor signal BL
36 Air temperature sensor signal BR

FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS

ALTERNATOR
Supplier BOSCH
Rated voltage 28V
Current 90A - 12000 RPM
B
+
W
L 7998
15
PERSPECTIVE VIEW S Characteristics
Figure 8 Rated voltage 28 V
Rated power 2,5kW
Current at room temperature 1800 RPM/35 A
at 25 C and Rated voltage 6000 RPM/70 A
Direction of rotation clockwise, seen from pulley
Weight 6,4 kg
B
A 8003
WIRING DIAGRAM
A. Alternator B. Voltage regulator
Figure 9
8000
VOLTAGE REGULATOR TEMPERATURE CHARACTERISTICS

(6000 RPM)

Crankshaft sensor
This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from
a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is 900 .
Figure 10
50319
Crankshaft sensor
Timing sensor
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a
magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by
the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance
is 900 .
Figure 11
50320
Timing sensor
Figure 12
3 2 1
50342 50288
Connector Wiring diagram
ECU pin
Ref. Description
Camshaft sensor Timing sensor
1 Ground 19C 10C
2 Signal 23C 9C
3 Shield

Supercharging air pressure - temperature sensor

This component incorporates a temperature sensor and a pressure sensor.
Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate
calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C.
The power supply is 5 Volt
Voltage at the sensor output is proportional to the detected pressure or temperature.
Pin 36C Temperature signal
Pin 34C Pressure signal
Engine oil temperature-pressure sensor

This component is analogous to the air temperature-pressure sensor.
The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.
This sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative
device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.
Pin 28C Temperature signal
Pin 27C Pressure signal
Figure 13
50324 50344
Wiring diagram
ECU Pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 NTC signal (temperature) 28C 36C
3 +5 V power input 32C 33C
4 Signal (pressure) 27C 34C

Fuel temperature and pressure sensor

Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 12C - 14C- 13C.
The power supply is 5 Volt.
Figure 14
0051065t
Fuel pressure sensor connector
Ref. Description ECU pin

1 Ground 12C
2 Signal 14C
3 Power supply 13C

Electro-injectors
The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The impedance of the coil of each injector is 0.56 - 0.57 .
1 Cylinder 2 injector 15 A
2 Cylinder 2 injector 2A
CONNECTOR 1
CONNECTOR 2

CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
Figure 15
50343
Figure 16
50349

Pre-post heating resistance and contactor (if present)

The pre-post heating resistance is located on the intake manifold.
The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor.
The resistance impedance is approximately 0.5 .
Figure 17
B
108909
A. - B. Connection terminals
Figure 18
002371t
A. Control contactor
The control contactor is connected to the control unit B connector.

The contactor is tripped with water and/or fuel temperature below 5 C.
The contactor impedance is approximately 15 .
Do not use flammable gases or liquids to provoke the engine ignition.

These substances in contact with the resistance could easily become inflamed creating situations of serious danger.

Coolant temperature sensor

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication
of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
This sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .
Figure 19
107471

Fuel temperature sensor

This sensor is identical to the coolant temperature sensor.
This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C -18C.
The sensor impedance at 20 C is approximately 2.50 .
Figure 20
166060
1. Fuel temperature sensor - 2. Filter heating resistance.
The ECU drives the filter heater contactor at fuel temperature 5 C.
Figure 21
107799 107798
Connector
ECU Pin
Ref. Description
Coolant Fuel
1 Ground 26C 18C
2 Temperature signal 15C 35C

High pressure pump - fuel flow rate regulator

Pump with 3 radial pistons controlled by the timing gears, requiring no phase adjustment, with rotor type feed pump fitted to the
back.
Figure 22
166091
1. Fuel flow rate regulator.
The flow rate regulator is located at the inlet of the high-pressure pump on the low-pressure circuit; its function is to modulate
the quantity of fuel to feed to the high-pressure pump on the basis of commands received from the electronic control unit.
It basically consists of the following parts:
- trapezoidal section shutter;
- valve control pin;
- pre-charging spring;
- coils.
In the absence of the control signal, the flow rate regulator is normally open, and hence the high pressure pump is in its maximum
delivery conditions.
The control unit modulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying the fuel to the
high pressure pump.
This component cannot be replaced individually and hence it cannot be taken down.
The quantity of fuel supplied to the high pressure pump is metered by the flow rate regulator on the low pressure system; the
flow rate regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 and 1600 bar by the electronic control unit by controlling the flow rate
regulator solenoid valve.
- This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on pins 9A - 10A.
- The solenoid valve impedance is approximately 3.2 .


F4AE ENGINES SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled maintenance
Page
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Regular maintenance and inspection planning . 3
- Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE PROCEDURES . . . . . . . . . . . . 4
- Checks and inspections . . . . . . . . . . . . . . . . . . 4

2 SECTION 4 - SCHEDULED MAINTENANCE F4AE ENGINES

SCHEDULED MAINTENANCE
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure,
immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Regular maintenance and inspection planning
Checks and periodical inspections Frequency (hours)
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily

Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . Daily
Checking tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400
EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When anomaly occurs
Replacing the engine oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Fuel pre-filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of blow by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
Changing the alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle's drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES
Checks and inspections
Figure 1
Engine oil level check
The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible
rod.
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing
minimum level, provide filling lubrication of the engine's
components.
Always ensure the oil added has the same characteristics of
the oil contained in the sump.
Mixing is not allowed as this would not guarantee correct
lubrication of the internal parts of the engine.
166058
To provide filling, operate through the upper top or through

the lateral top (2, Figure 1). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier.
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water

and detergent.
Adequately protect the skin and the eyes, operate in

full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

Combustion system inspection Lubricating system inspection

The check must be executed both when the engine The check must be executed both when the engine
disconnected and when it is running. disconnected and when it is running.
The check operation consists in examining the fuel pipelines
running from the tank to the pre-filter (if provided in the Verify the presence of any oil leakage or blow-by from the
specific equipment), to the filter, to the high pressure pump head, from the engine pan of from the heat exchanger.
and to the rail diffuser and from this last one to the head.
Special attention must be paid to the connections on the high

pressure pipelines. The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Due to the high pressure within the pipelines running
from the high-pressure pump to the rail diffuser and
Adequately protect the skin and the eyes, operate in
from this last one to the electro-injectors, special
full compliance with safety regulations.
attention must be aid also in checking presence of any
leakage or blow-by.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
Protect the eyes and the skin from any eventual high
pressure jet: these may deeply penetrate under the
skin surface provoking serious poisoning.
Inspection of water presence within fuel filter or pre-filter
NOTE The components of the common rail system can be

damaged very quickly in presence of water or
Cooling system inspection impurity within the fuel.
The check must be executed both when the engine
disconnected and when it is running. Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the
Check the pipelines from the engine to the radiator, from the drainage of the water within the feed circuit.
expansion tank and vice-versa. Find out any blow-by, verify the
status of the pipes specially close to the holding strips.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit. Inspection of drive belt tensioning
The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
from checking the wear status of the belt itself.
Due to the high temperatures achieved by the
system, do not operate immediately after the engine's
disconnection, but wait for the time deemed
necessary for the cooling. Check of belt's tear and wear status
Protect the eyes and the skin from any eventual high Carefully verify the belt's surface in order to detect any sign
pressure jet of cooling liquid. of incision, crack, excessive wear in correspondence of
toothing; check end and surface grinding.
The density of the cooling liquid must be checked any how

every year before winter season and be replaced in any case Danger: if the engine is switched off but is still hot,
every two year. unexpected motion of the belt may occur.
Wait for engine temperature cooling as a precaution
in order to avoid serious danger injury.
NOTE In case of new filling, proceed bleeding system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious

inconvenience might be caused to the engine due
to the presence of air pockets in the engine's head.

Inspection/replacement of blow-by filter

The filter in subject has been developed and equipped for the NOTE To carry out rocker arm - valve clearance
collection, filtering and condense of the lubricating oil vapours. adjustment more quickly, proceed as follows:
- Rotate the crankshaft, balance cylinder 1 valves
Within the filter unit (1) two cartridge filters are included (2). and adjust the valves marked by the asterisk as
shown in the diagram:
Figure 2
cylinder no. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
- Rotate the crankshaft, balance cylinder 6 valves

and adjust the valves marked by the asterisk as
shown in the diagram:
1 2
intake * * - * - -
74188
exhaust * - * - * -
The check of the filtering element is carried out by removing
the cover and drawing off the cartridges (2).
Inspection tappet clearance
Figure 3
166059
Check the clearance between the rocker arms and valves

using a feeler gauge (1).
Clearance shall be as follows:
- intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.

Oil motor and oil filter replacement Whereas you replace the lubrication oil, it is necessary to
replace the filter.
According to the application the filter can be located in
Warning: We recommend to wear proper different positions: the following procedure is a valid guide for
protections because of high motor service all applications.
temperature.
- The filter is composed by a support and a filtering
The motor oil reaches very high temperature: you cartridge. For the cartridge replacement use the
must always wear protection gloves. 9936076-tool.
Warning: the oil filter contains inside a quantity of oil

Due to the several applications, the pan shape and the oil of about 1 kg.
quantity can change slightly. However, the following
operations are valid for all applications. Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor Warning: avoid the contact of skin with the motor oil:
is hot. in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the The motor oil is very pollutant: it must be disposed
pan connected with the drain plug. of according to the rules.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the
lubrication oil.
- Replace the filtering cartidge with a new one and screw

manually until when the gasket is in contact with the
The oil motor is very pollutant and harmful. support.
In case of contact with the skin, wash with much water - Tighten further using tool 99360076 to a torque of 202
and detergent. Nm.
Protect properly skin and eyes: operate according to - Operate the motor for some minutes and check the level
safety rules. through the dipsick again. If it is necessary, carry out a
topping up to compensate the quantity of oil used for the
Dispose of the residual properly following the rules. filling of the filtering cartridge.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
Use only the recommended oil or oil having the

! requested features for the corrrect motor
functioning.
In case of topping up, don't mix oils having different
features.
If you don't comply with theses rules, the service
warranty is no more valid.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the
dipsick.

Fuel filter replacement Alternator belt replacement (demonstration)

Due to several applications the belt run can change very much.
During this operation don't smoke and don't use free

flames.
Avoid to breathe the vapors coming from filter.
Warning: with switched off motor (but still hot) the

belt can operate without advance notice.
According to the applications the filters position and the
Wait for the motor temperature lowering to avoid
quantity can change.
very serious accidents.
However the following operations are valid for all applications.
- Drain the fuel inside the filter by operating the water
release screw. Collect the fuel in a container without
impurities.
- Unscrew the cartridge by using the 99360076-tool. For applications with automatic belt stretcher, the procedure
- Collect the eventual fuel inside the filtering cartridge. is the following:
- Clean the gasket seat on the support and oil slightly the Figure 4
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 20 2 Nm torque.
176526
- Operate on the tightener (1) and withdraw the belt (2)

from the alternator and water pumps from pulleys and
from the returns pumps.
- Replace the worn belt with a new one.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in
the functioning position.
- Further adjustments are not required.

F4AE ENGINES SECTION 5 - DIAGNOSTICS 1
SECTION 5
Diagnostics
Page
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PT-BOX INSTRUCTIONS . . . . . . . . . . . . . . . . . 5
- Hardware installation . . . . . . . . . . . . . . . . . . . . 5
- Software installation . . . . . . . . . . . . . . . . . . . . . 7
- Software Interface . . . . . . . . . . . . . . . . . . . . . . 18
- Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- ECU diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Active diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 38
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . 40
N40 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . 81
N60 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
GUIDE TO DIAGNOSIS THROUGH

SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2 SECTION 5 - DIAGNOSTICS F4AE ENGINES

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

actually detected, it is necessary to proceed inquiring the
A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed
competence acquired by years of experience and attending with the diagnostic research making trials and tests in order to
training courses. have a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper In case the electronic device is not providing any indication, it
consideration using them to acquire any useful information to will be necessary to proceed relying on the experience,
focus the intervention. adopting traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input an
enquiry relying on memory files, in order to achieve any further
necessary information to identify the origin of the anomaly.
NOTE Any kind of operation on the electronic center unit

must be executed by qualified personnel, duly
authorized by FPT.
Any unauthorized tamper will involve decay of

after-sales service in warranty.

PT - BOX
PT - BOX is a test tool to be connected to a Laptop.
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator - 5. Serial port indicator -
6. Error indicator - 7. CAN line indicator - 8. Line K indicator for automatic management
PT-BOX functions:
- ECU ID reading;
- Failure memory reading;
- Flight recorder reading;
- Parameters reading;
- Failure memory cleaning;
- Active diagnosis: actuators activation/testing;
- Programming of repalced components and parameters/second level;
- Acquisition/Saving of parameters

PT-BOX INSTRUCTIONS Select your user configuration type and then follow the
relevant information.
Hardware installation
1. PT-PLUS configuration
- PC Panasonic user
This Sw may cause engine start-up. Be extremely - PT-BOX module
! careful. - PT-DIAGNOSIS sw
The user is responsible for the correct use of the 2. PT-DIAGNOSIS configuration
PT-DIAGNOSIS software so as not to any cause
injury to people or damage to items. - user with own PC
- PT-BOX module
The user is also responsible for complying with all - PT-DIAGNOSIS sw
the rules relating to security for activities on the
industrial applications (engine, pump, generating The PT-BOX module (Electronic Communication Interface)
set) carried out in the workshop.
Carefully read the user manual before using the PT-BOX is an interface module allowing the communication
diagnostic tool and follow the instructions displayed between the engine ecu's and the PC.
on the screen. - Weight: 500 g;
- Dimension: 175x75x30mm;
General rules for use - Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed: - Thermal tolerance: 0-50 C;
- all instruments ensuring the security must be applied as - Power supply: 6-32V;
indicated in the application; - Connection interfaces: USB and RS232 standard
- ensure that the PT-BOX module is connected to the Bluetooth optional;
diagnostic socket of the engine on which work is to be - Interface for engine electronic systems: 9 KL ISO 9141
carried out; lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O
- in case of emergency, disconnect the PT-BOX module PWM.
from the engine or disconnect the USB cable; The led indicators on the front view allow to check the
- ensure that while using the software, there is nobody communication lines activity with the engine and with the PC
near the engine/vehicle you are working on; to which the instrument is connected.
- if it is necessary for more than one person to be working
on or near the engine/vehicle, they are all responsible for Figure 2
complying with security regulations of the workshop;
- we strongly suggest that the PT-BOX modules be visibly
and uniquely identified (for example by using coloured
adhesive tape, labels with names, etc).
By only accepting the use disposal it is possible to

! access PT-DIAGNOSIS (the green tick icon
becomes active). 156133
1. Led indicators to display the activity of the

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

Connect the PT-BOX module PT-BOX - engine/vehicle connection

On the PT-BOX module there are the communication ports
for the connection to the PC and to the engine / vehicle. Figure 6
Communication ports for the connection to the PC

Figure 3
156138
- connect the module to the engine/vehicle by using the

specific connection cable.
156135
1. serial port - 2. USB port NOTE The module is power-supplied by the diagnostic
cable; for this reason to work correctly it must be
Figure 4 connected to the engine.
System requirements
Minimum
- Processor: 300 MHz Pentium-II CPU;
- Hard disk space: 3 GB available;
- Ram: 256 MB;
156136
- Display: 800 x 600 video adapter and monitor;
Connector for the connection of the engine communication
cable. - Internet connection only needed for rss and pt-diagnosis
software update (eaus): modem;
- External ports: USB connector;
PT-BOX - PC connection
- External reader: DVD-ROM reader;
Figure 5
- Os: Microsoft WindowsTM XP Professional Service Pack
2 - Microsoft Windows 2000 Service Pack 4 plus -
Windows 2000-KB835732-x86-ENU.EXE (login with
administrator privileges);
- Browser: Internet Explorer 5.5.
Recommended
- Processor: 1 GHz Pentium IV - Centrino CPU;
- Hard disk space: 5 GB available;
- Ram: 512 MB;
- Display: 1024 x 768 high colour video adapter and
156137 monitor;
- Internet connection only needed for rss and pt-diagnosis
software update (eaus): high-speed e.g. ADSL;
- connect the USB cable (PT-BOX side marked) to the - External ports: 2 USB 2.0 connectors, Bluetooth;
PT-BOX module (remove the holding screws from the
PT-BOX module, where present); - External reader: DVD-ROM reader;
- connect the USB cable to the PC; - Os: Microsoft WindowsTM XP Professional - Service Pack
3 (login with administrator privileges);
- turn the PC on.
- Browser: Internet Explorer 6.0.

Software installation
Registration
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
The registration procedure is carried out on-line and it is
different according to the user type:
- OEM users
- Dealer users
NOTE For both configurations (PT-PLUS and

PT-DIAGNOSIS) the SW installation is the same.
- A fill-in form is displayed.
Registration>OEM users The activation code received will be requested the

! first time you run the PT-DIAGNOSIS software.
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
Registration form (OEM user)
For this reason:
- Check that the registration card has been delivered The Registration allows you to download the EVCA SYNC
together with the kit. WEB application which allows you to obtain the activation
code:
- Select www.eltrac.it/ivecomotors/default.asp.
- From the starting page, select the language.
- Select pt users registration.
In the registration form:
1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
the identification data and the Network characteristics
areautomatically entered.
3. Enter the serial number of the PT-BOX instrument.

Figure 7
NOTE Before carrying out the registration we suggest to
install the PT-Diagnosis SW.
Installing the EVCA SYNC WEB (OEM users) application

To obtain the activation code it is necessary to install the
EVCA SYNC WEW application, after saving it on the desired
directory:
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module
4. Read the note in compliance with art. 13 of Italian
Legislative Degree 196 dated 30 June 2003 about the
processing of personal data Informative
5. Select the send key (only once!) wait
After sending a summary window is displayed waiting for the
end of the registration procedure.
1. Unzip the evcasyncweb1.2.6.zip (for example using

WinZip: www.winzip.com/downwz.htm).
2. Open the EVCASyncWeb1.2.6 and then
EVCASyncWeb15-09-10 (Rel1.2.6).
3. Run setup.exe and continue with the installation of the
guided application.
NOTE For further information about the installation of

EVCASyncWeb it is possible to read the detailed
guide EVCASyncWeb Setup.pdf in the directory
EVCASyncWeb1.2.6.
Then a link is available to download the EVCA SYNC WEB
application. It will be used to obtain the activation code:
6. Select the print key for printing a summary report 4. At the end of the installation, the icon of the
(registration data and number of registered instrument). EVCASyncWeb application is displayed on the desktop
of the PC.
7. Select the link to download and then select the save key,
to save the application on the PC.

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

PIN.
4. To continue, select the confirm key.
1. Double click on the icon EVCASyncWeb application.

At the start up of the application choose the Internet
connection mode:
- by means of the Proxy Server;
it is necessary to enter the connection parameters; at the
end select the okey. It is possible to pre-set the
connection parameters: read the EVCASyncWeb
manual;
- without Proxy Server;
select the okey.
5. Enter the alpha code supplied with the Registration Card

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

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

Summary of the selected choices (OEM user)

At the end of the activation procedure, the summary of the
selected choices is available. The following data are displayed:
Contract Activation (OEM User)

7. Select a contract type.
The contract types available for the OEM users are indicated
below:
- Fee (annually):
the duration of the contract is for one year, starting from - The type of selected contract.
the activation date of the contract. During this phase it is
- The list of instruments (PT/PB) associated to the contract
only possible to associate one instrument to the contract.
with the generated activation codes
- Token (to be deducted):
- The expire date of the contract (in case of yearly fee) or
it is the payment for a single download of an application;
residual credit (coins):
it is possible to associate to the contract to 4 instruments.
1. We suggest you to print and keep the summary data:
select the key print selections recap.
2. Show and download the list of the available
applications belonging to your profile (FPT
activation): select the applications download key.
The window containing the activation codes is displayed.

9. Print/copy the activation codes and keep them together
with the instruments they are associated to.
10. Select the okey to end.

Download the applications Registration>Dealer users

Before using the PT-DIAGNOSIS diagnosis system you must
register on the FPT web site.
1. Connect to
http://www.fptpowertrain.com/index_main.htm.
The following information for each one of the available
2. Select the language.
applications for downloading is displayed: ECU, license, file
name, Release Date, Release Type and short description.
Each option can be used to sort the list: to sort the list in
ascending/descending order according to a given key, select
the title of the corresponding column.
1. Select the application to be downloaded; the selected line
is highlighted in red.
2. Select the download the selected application key and follow
the system instructions.
3. Identify the path where the packets have been
downloaded.
4. At the end of the download install the packets (double
click) one by one.
3. Select Fiat Powertrain Technologies and then Partner Area.
NOTE The packets must be downloaded/installed one by

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

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

a fill-in form is displayed (on-line registration form).
NOTE For the new customers:
request username and password to
areapartner@fptpowertrain.com.
For the customers already registered:
use username and password received by e-mail.
Registration form (Dealer user)

The Registration allows you to download the EVCA SYNC
WEB application which allows you to obtain the activation
code.
In the registration form:

1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
6. Please follow the indicated instructions the identification data and the Network characteristics are
automatically entered.
After Sales>Various>Diagnostic Instruments>Diagnostic
Tools

3. Fill in the yellow field by entering the alpha code supplied 6. Select the send key (only once!) wait
with the Registration Card (scrap the area on the card).
After sending a summary window is displayed waiting for the
4. Enter the serial number of the pt-box instrument. end of the registration procedure.
Wait for the following window:
- the activation code;
- the link to download the EAUS application (EAsy Update
Software).
7. Print the activation codes (print key) and keep them
together.
8. Select the link to download the EAUS application.
Installation of EAUS application (Dealer user)

The EAUS application is an update utility to automatically
download all SW Updates for all ECU's activated for FPT.
After having selected the link for downloading the EAUS
Figure 8 application, the system asks you to select the file or to directly
run it.
156139
The serial number is type PB-#####-##-##-##; to be

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

Connection
Figure 9
156138
1. Connect the PT-BOX module to the engine/vehicle using

the diagnosis cable.
2. Connect the PT-BOX module to the PC, using one of the
2. Select the end key to exit the installation. two USB cables provided with the module.
NOTE Before carrying out the registration we suggest to The PT-BOX module is supplied by the diagnosis
install the PT-Diagnosis SW. ! cable; therefore it must be connected to the
engine/vehicle to be able to work.
Figure 10
Run the EAUS (Dealer user) application
156140
3. Switch the PC on.
PT-BOX module USB driver set-up

(only for the PT-DIAGNOSIS configuration)
This operation is required only if the PC in use has never been
connected to an PT-BOX module:
1. It is now possible to download the update by using the

Automatic Update Function (tools>software update key).
1. Check that the PT-BOX module is correctly connected to
the PC via the USB cable.
2. The PC acknowledges the presence of a new hardware
component; press the cross button to continue.

5. Select the have disk> button to continue.

3. Automatically (Windows XP) the procedure starts to
set-up the driver; select the Install from a list or specific
location option; select the next> button to continue.
6. Enter the path:

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

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

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

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

9. The procedure is completed; press the finish button.
5. Enter the activation code sent via Web.

6. Select the register button; a message confirms that
registration has taken place.
7. Select the cross button to close the Activation Code
window and go back to the PT-DIAGNOSIS screen.
10. The system informs that the new hardware has been
correctly installed; select the cross button to continue.
11. Re-start the PC.
Activation - first time of use of PT-DIAGNOSIS sw + PT-

BOX module
The first time the PT-DIAGNOSIS Diagnosis System is used,

it is necessary to follow the procedure described below:
1. Make sure you possess the activation codes (Web
access).
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB/BT module.
3. Start the Panasonic PC.
8. Select the stop button and restart PT-DIAGNOSIS.
Now all the software functions are available.

Activating - new PT-BOX module

The activation procedure is necessary every time you want to
use an PT-BOX module that has not yet been paired to the
PT-DIAGNOSIS diagnosis system in use; follow the
operations described below:
6. Enter the activation code received from Field Service.

7. Select the register button; a message confirms that
registration has taken place.
8. Select the cross button to end activation.
9. Re-start the PT-DIAGNOSIS (E.A.SY. icon).
1. Make sure you have requested and obtained the
activating code for the PT-BOX module.
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB cable.
3. Start the PT-DIAGNOSIS software: double click on the
EASY icon (PT-DIAGNOSIS) placed on the desktop of
PC.
4. Select the tools>activations button.
5. Select the entry button.

Software Interface
The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear
and adaptable to various needs.
All windows follow the same design with additional features which depend on the specific working environments.
Each window presents three main areas to which specific functions are univocally associated:
- Keys Area
- Title Area
- Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
The Keys The Operative

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

To go from one environment to another
3. Select the Class and the System under test to which the
engine/ vehicle belongs; then press the navigation key (is
active - green) to continue.
1. The Start Window shows the family.
Start Window
- It is possible to select a new family or to choose a family
from the database;
- green identifies a pull-down menu.
4. The window Choose Activity appears; it is here possible

to choose from four lists.
Window Choose Activity
It is now possible to choose:
- diagnosis;
- test;
- programming;
- specific functions.
Navigation keys
2. Select the fami ly of the engine/vehicle under diagnosis; They allow you to go from one environment to another.
then press the navigation key (is active - green) to Enabled keys are displayed in green and disabled keys are
continue. displayed in grey.
Family Choice Window navigation key forward disabled
- Yellow identifies a selected item in a pull-down menu;
- a paged list is used to display a large amount of navigation key forward enabled
information one page at a time; navigation tools are
available to navigate from page to page. navigation key back enabled
Database key
It allows you to access the Database

environment.
Browse key
To scroll long lists which cannot

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

Detail of Keys area ignition directly via the diagnostic tool. Two positions (stop
In the Start Window the Keys area contains the Keys for and mar) and three states (enabled stop, disabled stop,
accessing the functions which are always available: enabled mar) are possible.
communication panel
It indicates that the communication with the ECU is active or
that the ECU is not present (no ecu).
The lower leds indicate the communication state of the
electronic system as shown below:
Square LEDs: two states (green/red); green indicates that
communication with the electronic system has been initialised;
if red indicates the communication has been interrupted.
Rectangular LEDs: blinking indicate that data exchange
between electronic system and diagnostic system is in
progress.
Utilities key
stop key
To quit PT-DIAGNOSIS application at any time.
engine/vehicle key
It allows you to return to the Family Choice Window.
utilities key
When selected the Key background will be yellow and allows
you to access a menu.
guide to diagnosis key

It allows you to access the environment Guide to Diagnosis
(only available for some ranges). It is available in the Electrical
Control Units environment.

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

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

Acceptance
Environment DataBase key search
From the PT-DIAGNOSIS start window it is possible to select It allows you to search an engine by applying a filter (DATE,
a new engine or to select one from the database. engine mode l, CUSTOMER or NUMBER PLATE).
key delete search

It cancel the filter; it is active only after a search.
key order
It orders the list according to the selected ordering criterion.
key report
It gives access to the summary environment; enabled after
selecting an engine.
key delete
1. Select the database button: you access the DataBase
environment (it contains the list of accepted engines). It deletes the selected engine from the database; it is active
only after selecting an engine.
2. The list of accepted engines is available.

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

How to order the engines list 3. If required, enter the word or the code to be searched
and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive
select the cancel search key.
For the selection of a new engine see ECU Diagnosis.

!
1. Select the order key.

2. Select the order method.
- DATE
- ENGINE MODEL
- CUSTOMER
- NUMBER PLATE
Environment Report
How to search for an engine from the database
When the engine sheet of the engine under test has been
saved in the Report Environment, the engine has been
accepted.
You access the Report environment in the following ways:
1. Select the search key.

2. Select the search method.
- DATE
- from the Buttons area at any time by selecting the
- ENGINE MODEL corresponding button;
- CUSTOMER - from the DataBase environment by selecting the
required engine and the report button.
- NUMBER PLATE

Environment Report
DIAGNOSIS REPORT LIST

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

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

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

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

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

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

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

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

3. Select the button automatic acceptance.
1. Sselect the Family, the Class and then the System of engine
under diagnosis.
2. Press the navigation button forward (enabled - green) to
continue.
4. By means of the automatic acceptance the system tries to
communicate with the engine ECU: confirm the displayed
message by pressing the tick icon; wait until the ECU is
ready.

3. The window Choose Activity appears; it is here possible 2. PT-DIAGNOSIS system presents a pop-up window
to choose from four lists: where to select the automatic or the manual activation of
Window Choose Activity the ignition key; select the required mode; the key button
is disabled.
- diagnosis
Under the automatic mode all activation of the ignition key are
- test controlled by the diagnosis instrument (key button working).
- programming Under the manual mode all activation of the ignition key are
- specific functions controlled by the operator on the engine.
4. The present Repair Guide describes the diagnosis

environment and the specific functions to which it is
associated:
- Identification Code Reading
- Faults Memory Reading
- Parameters Reading
Identification code reading

3. Confirm the new message by pressing the tick icon.
1. To access the Read Identification environment select the

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

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

the electronic system under test is read:
- identification code
- HW version
- SW version 1. Select the button ecu's area>add ecu; the Choose Vehicle
- production date window will appear, where you can select the desired
ECU.
-
Managing more ecu's
After identification code reading it is possible to carry out
other activities (step 5) or to return to the window Choose It is possible to operate with two or more connected ECU's
engine (step 6). at the same time.
1. Select the button ecu's area>desired ecu.

The activity remains interrupted for the not selected ECU's
and can be started again at any time.
Cancel an ecu
5. To access the other activities from the environment It is possible to stop the activity on one of the connected
Identification Code Reading, select the choose activities ECU's.
buttons: choose an activity; the system automatically
access the selected activity.
The choose activities buttons are shown in yellow when
selected.
6. To exit the diagnosis of the engine under test select the 1. Slect the button ecu's area>required ecu>cancel.
button ecu's area>ecu under test>cancel.
2. Select the required ECU.

Ignition Key Button Modes - on line/off line Read faults memory

At the system start up the on/off button is on-line if the
PT-BOX module is activated and connected to the PC,
otherwise is disabled (off-line).
On line mode
The function Ignition Key is active; it can be managed in
automatic or manual mode; the ignition key screen appears
only after the selection of a function that requires it (e.g.
diagnosis functions).
In automatic mode all ignition key activations are managed by
the diagnosis instrument.
In manual mode all ignition key activations are managed by the
operator on the engine.
The automatic activation depends on the type of engine; make
sure the engine supports the function before selecting 1. To access the Read Faults Memory environment select the
automatic mode. item Faults Memory Reading from the list Diagnosis and
then press the navigation button forward.
1. After selecting the automatic mode a test procedure is

carried out.
2. Switch the ignition off. 2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation of
3. The engine chassis may move. the ignition key; select the required mode; the key button
The PT-DIAGNOSIS SW activates the ignition key and is disabled.
displays a screen page in which it asks to check the dashboard;
if it is turned on the diagnosis procedure can be continued;
otherwise the system asks for position of the key to ON in
manual mode.
Both in manual and in automatic mode:
1. Before ignition key activation a message is always
displayed: request (manual mode) or warning
(automatic).
2. When the ECU is cancelled a message indicates that it is
necessary to interrupt the communication and then to
confirm the operation.
3. The chosen mode remains until the engine under test is
changed.
Off line mode
The basis diagnosis is simulated and it is possible to read some
information about the electronic system under test.
3. Confirm the new message by pressing the tick icon.

cancel faults memory key

It cancels the faults selected in the list; it is possible to cancel
a fault at a time; the cancel operation will be effective when you
confirm it by pressing the tick icon displayed in the next
pop-up-window.
faults key
It allows you to access the Faults environment; it can be yellow
(the faults list is displayed) or gray (environment Faults
disabled).
4. Wait until the ECU is ready; the list and faults type
occurred during the working are displayed.
There are two types of failures:
- failures present during the reading procedure (red);
- intermittent failures not present during the reading
operation but which occurred at least once before
(black).
Detail of Buttons area of the Faults Memory area

New icons appear in the window Read Faults Memory for
accessing specific functions:
On line Mode
Faults Memory Reading Icons
environmental condi tions key

Active when the communication with the ECU has been
interrupted this is used to examine environmental conditions
when the failure occurred. It can be gray (default status) or
yellow (when selected).
repair guide key

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

Off line Mode 2. Select the button environmental conditions.

Faults Memory Reading Icons It examines the present environmental conditions at time of
the fault.
blink code search key
Appears only if the communication with the ECU interrupted
is (under OFF LINE Mode) recognize the fault where blink
code or required word appear.
To go from one function to another (faults, environmental
conditions, troubleshooting) select the corresponding button.
Operations like Read and Cancel Faults Memory are very
important: they are automatically stored and need the engine
acceptance.
How to get information about a fault

1. Interrupt the communication with the ECU (button
on/off) and select an item from the faults list: the fault is
described in the below blank area; in particular the
following information is available:
3. Select the repair guide button; the following information
is available:
- the blink code
- the failure code (DTC)
- the failure mode (FMI)
Appears a new icon, the measures key
measures key
The Measurements pop-up window opens with a list of

possible measurements and the relevant operating
suggestions.
- the fault
- the signal type
- the repetition type
The button faults appears on yellow background because it
is selected.

Parameters reading 3. The read parameters are shown and the values assumed
4. Select the groups key.
The groups key allows you to access the groups management
functions (see group Management).
Detail of parameters buttons area

New icons appears on the window Parameters Reading for
accessing specific functions:
1. To access the Parameters Reading environment select

the item Parameters Reading from the Diagnosis List and
then press the navigation button forward.
on key
The communication between the system and the ECU is
active: select the button to interrupt the reading.
off key
The communication with the ECU has been interrupted; select
the button to start again the electronic system reading.
groups key
2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation It opens the GROUPS window showing the list of created
of the ignition key; select the required mode; the key group (A) and the keys to create/modify the groups (B).
button is disabled.
Pay close attention to the displayed messages and wait until
the ECU is ready.
parameters acquisition key

It allows to record the trend in time of the measurable
parameters.
report key
It allows you to save the report of carried out operations.
print key
It allows you to print the displayed window.

Groups Management 9. From the drop down menu (above on the left), select one
of the available parameter groups, excluding the
parameter you are changing.
10. On the left-hand list the parameters of the selected group
are shown; on the right-hand list the parameter of the
group you are changing are shown.
The parameters with a gray background on the left-hand list
are parameters that have already been added and can not be
selected.
5. The Groups window opens.

The pre-defined parameter groups are first displayed then
the customized ones; the pre-defined parameters
(measurable and status) can not be modified.
11. To a parameter to the right-hand group, select it and

confirm by pressing the right arrow key ( ).
12. To remove a parameter (from the right-hand list select it
and confirm by pressing the left hand arrow key ( ).
Select the save key to save and exit the groups management
environment.
Modify a parameters group

Create a new parameters group
6. Select create.
7. Enter the name of the group you want to create.
8. Confirm by selecting the green tick icon.
1. Select a customized parameters group.

2. Select modify; the window for parameters groups
management opens.
3. Select the group you want to change and continue with
step 9 (link).

Cancel a parameters group Window Store Parameter
2. Select the sample time by using the arrows on the

Sampling active area.
3. Select the duration of registration by using the arrows key
1. Select a group of customized parameters on the active area Duration.
2. Select delete; confirm or cancel the request.
Appendix parameter acquisition key
4. Select the key start/stop to start the registration (a new

window open Notes where you can add a comment).
5. Close the Notes window, the registration starts.
6. Wait for the end of registration procedure (it is also
possible to interrupt the registration, by using the stop
key).
1. Select the parameters acquisition key; the window Store

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

Archive window
- To display tables (horizontal or vertical).
- To colour display the area indicated by the diagram.
- Print.
- To go back
Programming
The consultation can be started
To access the programming area of the ECU under test
proceed as follows:
1. From the Archive windows, select a registration; it is

possible:
- to cancel it (cancel key)
- to read data (report key)
- to show data (show key, opens the Data Reading
window)
- to print data (print key)
- to save data in text format (save as key)
- to go back (cross key)
Data Reading window
1. Select the Engine Family under diagnosis.

continue.
2. From the Archive window, select a registration and the

show key; the Data Reading window opens; it is possible:
- To select all parameters (fast selection key).
- Deselect all parameters (fast deselection key).
- To show the diagram with full-screen.
- Increase, reduce or to bring back to the original 3. Select the Class and the System under test to which the
display the time range (x-axle, seconds). engine belongs; select the forward navigation key
(enabled - green) to continue.

4. Select the programming option from the Programming 7. Read the displayed messages and select the green tick
list; select the forward navigation key (enabled - green). icon to continue.
5. If required, enter the required data, by following the 8. At the end the system permits access to the
indicated procedure. Programming environment; the components list is
displayed, on which tests can be carried out.
It is possible to carry out a programming only in During the programming do not disconnect the
! online mode. In case of error check the connections ! USB cable. Before carrying out the ECU
ECU/PT-BOX/PT-DIAGNOSIS. programming verify the charge left in the
computer's battery.
It is recommended to plug the PC in (connect it to
the engine/vehicle or to the mains supply).
Programming environment
It is possible to use specific functions, by selecting the
corresponding key:
6. Select the ignition key management (automatic/manual): - Data Reading

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

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

print key
- station type and number;
If enabled, select to print a report. - programming date;
- ECU software release.
cancel key
If enabled, select to re-establish a configuration.
navigation keys
If enabled, select to move between different environments.
cross key
If enabled, select to cancel an operation.

The system views the following data classes:
- supplying data;
- factory data (never updated);
- service data (updated after each programming
event).
scroll keys
If enabled, select to scroll the list step by step.
fast scroll keys

If enabled, select to scroll the list step by step.

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

continue.
5. Select the ignition key management (automatic/manual):
if the electronic system engine under test is fitted with
this function, select the automatic key.
- PT-DIAGNOSIS displays some information about
the activity in progress.
- The ignition key ON is automatically activated.
- The ECU connection starts.
6. Read the displayed messages and select the green tick

icon to continue.
3. Select the Class and the System under test to which the
engine belongs; select the forward navigation key (enabled
- green) to continue.
7. At the end the system permits access to the Active

Diagnosis environment; the components list is displayed,
on which tests can be carried out.
4. From the Test list select the option acti ve diagnosis;

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

Active Diagnosis environment

The components of the selected electronic system are indicated in a list; use the browse keys to display all the elements of the list.
1. Select the component on which the test will be carried out.
2. Select the forward navigation key to continue and carry out the test.
Help key Components:

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

It allows you to move one
step back; if selected at
this level it allows you to
exit the Active Diagnosis
environment.

Base - May 2012
40
NOTE
N40 ENGINE
FAULT CODES
Reason of Possible failure Long Term-
Dfp Name Description DTC OBD-System Power Red. Mil.
Failure correction Failure
SECTION 5 - DIAGNOSTICS
Vehicle 1 (Sensors/Plausibility checks)
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
Due to a short
circuit in the ignition Check wiring for
switch the EDC is correct installation
T15CD Terminal 15 failure $ 119 Non No "Mil OFF"
switched on, and for short
although T15 has circuits
not been activated.
Check wiring and
signal of
temperature sensor.
Ensure complete
Temperature
cool down of
sensor downstream
vehicle (>10 hours)
of catalyst is
without sun
inaccurate or
exposure and and
defective, defect in
measure all 3
wiring (also check
sensors signals. If
connectors)
temperature
differences are Failure is a NOx
above 20C replace dependent
SCR Temperatures defective sensor (potentially)
SCRCatPlausIv $ 11F "catalyst monitoring" yes (OBD) "Mil ON"
plausibility Check wiring and longterm failure (via
signal of LTF group5 SCR
temperature sensor. System)
Ensure complete
Temperature cool down of
sensor upstream of vehicle (>10 hours)
catalyst is inaccurate without sun
or defective, defect exposure and and
in wiring (also check measure all 3
connectors) sensors signals. If
temperature
differences are
above 20C replace
defective sensor
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
Possible failure Long Term-
Dfp Name Description DTC OBD-System Reason of Failure Power Red. Mil.
correction Failure
If the ambient
temperature sensor is
inaccurate it is likely
that the urea pump
module (DTC $E4)
and urea tank
temperature (DTC
Ambient temperature $E5) are also
sensor or both reported implausible
Failure is a NOx
upstream and by the DCU. Check
dependent
SCR Temperatures downstream catalyst wiring and signal of
SCRCatPlausIv $ 11F "catalyst monitoring" (potentially) longterm yes (OBD) "Mil ON"
plausibility temperature sensors temperature sensors.
failure (via LTF group5
are inaccurate, defect Ensure complete cool
SCR System)
in wiring (also check down of vehicle (>10
connectors) hours) without sun
exposure and and
measure all 3 sensors
signals. If temperature
differences are above
20C replace the
sensors which seem
implausible.
Defective or incorrect
Check speed
functioning speed
measuring device for
Vehicle Speed Sensor measuring device, see
VSSCD2 $ 211 "non" proper functioning No "Mil OFF"
failure CAN message
and for its CAN
Tachograph Output
configuration
(TCO1).
Failure is a NOx
Replace catalyst and
SCR Catalyst Thermal dependent
Excessive ageing of reset EEPROM value
SCRCatAgeingIv Ageing Limit $ 21D "non" (potentially) longterm "Mil OFF"
SCR-Catatlyst of catalyst ageing time
exceeded failure (via LTF group5
via tester
SCR System)
Base - May 2012
41
Base - May 2012
42
correction Failure
Measured catalyst
efficiency lower than
the estimated (NH3
Check urea dosing
slip present),
system for correct
inaccurate NOx
dosing amount
measurement (value
(perform UDST and
too high) downstream
Dosing Valve Check,
of catalyst, incorrect
check DCU error
NOx estimation
memory for leakage
(value too low)
failures), check
upstream of catalyst, Failure is a NOx
accuracy of
estimated catalyst dependent
SCR Catalyst Efficiency NOx-sensor and
SCRCatNOxLvl1Iv $ 21E catalyst monitoring efficiency too high (potentially) longterm "Mil ON"
below first threshold NOx-model
(due to inaccuracies in failure (via LTF group5
(humidity, boost
the exhaust mass flow SCR System)
pressure and
calculation, the
temperature) for
estimated NH3
plausible values, check
storage, temperature
NOx-conversion
measurements up-
efficiency of catalyst,
and downstream of
check exhaust system
the catalyst) or
for excessive urea
catalyst degradation,
deposits
excessive urea
deposits in exhaust
system
Read out failure
Failure is a NOx
memory of the DCU
Defect or abnormal dependent
and perform
SCRCatDCUStateIv DCU State Monitoring $ 31D "catalyst monitoring behaviour of urea (potentially) longterm yes (OBD) "Mil ON"
troubleshooting, check
dosing system failure (via LTF group5
behaviour of urea
SCR System)
dosing system closely
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Measured catalyst
the estimated (NH3
Check urea dosing
slip present),
system for correct
inaccurate NOx
dosing amount
measurement (value
(perform UDST and
Dosing Valve Check,
check DCU error
NOx estimation
memory for leakage
(value too low)
failures), check
accuracy of
SCR Catalyst Efficiency estimated catalyst dependent
NOx-sensor and
SCRCatNOxLvl2Iv below second $ 31E "catalyst monitoring efficiency too high (potentially) longterm yes (OBD) "Mil ON"
NOx-model
threshold (due to inaccuracies in failure (via LTF group5
(humidity, boost
the exhaust mass flow SCR System)
pressure and
calculation, the
temperature) for
estimated NH3
NOx-conversion
measurements up-
and downstream of
the catalyst) or
for excessive urea
deposits
excessive urea
deposits in exhaust
system
Base - May 2012
43
Base - May 2012
44
correction Failure
Measured catalyst
efficiency higher than
the estimated (danger
Check urea dosing
of NH3 slip),
system for correct
inaccurate NOx
dosing amount
measurement (value
(perform UDST and
too low) downstream
Dosing Valve Check,
check DCU error
NOx estimation
memory for leakage
(value too high) Failure is a NOx
failures), check
upstream of catalyst, dependent
SCR Catalyst System accuracy of
SCRCatHiEffIv $ 31F "non" estimated catalyst (potentially) longterm "Mil OFF"
Efficiency too high NOx-sensor and
efficiency too low failure (via LTF group5
NOx-model
(due to inaccuracies in SCR System)
(humidity, boost
the exhaust mass flow
pressure and
calculation, the
temperature) for
estimated NH3
exhaust system for
measurements up-
excessive urea
and downstream of
deposits
the catalyst), excessive
urea deposits in
exhaust system
Vehicle 2 (Lamps/relays/actuators)
Check the wiring and
Short circuit of main
all components
relay 2 output to
connected to main
external source,
relay 2, if defect
defect in one of the
remains main relay
connected
Main Relay 2 failure inside ECU could be
components or
(Grid Heater 1, Fan 1, defective, replace
defective main relay 2
VGT, Lambda Heater, ECU
MRlyCD $ 125 "non" No "Mil OFF"
EGR Bypass Valve, Check the wiring and
EGR Actuator, Blow Short circuit of main
all components
By Valve)) relay 2 output to
connected to main
ground, defect in one
relay 2, if defect
of the connected
remains main relay
components or
inside ECU could be
defective main relay
defective, replace
2o
ECU
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Replace alternator
Alternator voltage
govenror device or
governor defect alternator
Battery defect,
BattCD Battery Voltage failure $ 126 "non" alternator defect, No "Mil OFF"
wiring problems (too Replace battery or
high resistance) or alternator. Check ECU
ECU defect. and wiring.
Occurence possible
during cold start.
all components
relay 1 output to Failure is a NOx
connected to main
Main Relay 1 (High external source, dependent
relay 1, if defect
MnRly1_SCB Pressure Pump) Short $ 128 "non" defect in one of the (potentially) longterm "Mil OFF"
remains main relay
to Battery connected failure (via LTF group1
inside ECU could be
components or Fuel System)
defective, replace
ECU
all components
relay 3 output to
connected to main
external source,
relay 3, if defect
Main Relay 3 failure defect in one of the
remains main relay
(A/C Compressor, connected
inside ECU could be
Fuel Filter Heater, components or
defective, replace
Intercooler Bypass defective main relay 3
ECU
MRlyCDMnRly3 Valve, Additive Valve, $ 129 "non" No "Mil OFF"
Grid Heater 2, Fan 2, Check the wiring and
OBD/Cold Start/ all components
relay 3 output to
Adjustable Speed connected to main
ground, defect in one
Limiter Lamp) relay 3, if defect
of the connected
remains main relay
components or
inside ECU could be
defective main relay
defective, replace
3o
ECU
Base - May 2012
45
Base - May 2012
46
correction Failure
Short circuit of wiring
to external source or
Check of wiring or
inside relay, broken or
Engine-Brake Exhaust replace relay
disconnected wiring
EVCD Valve (Main Relay 4) $ 12A "non" or defective relay No "Mil OFF"
failure
Check of wiring or
to ground or inside
relay replace relay

Check of wiring or
inside relay replace relay

Air Heater 1 Power Check of wiring or
ArHt1 $ 12B "non" to ground or inside No "Mil OFF"
Stage failure relay replace relay
Broken or
Check of wiring or
disconnected wiring
or defective relay replace relay
Short circuit to ground Check grid heater

AirHtStickOnIv Air Heater always on $ 12E "non" No "Mil OFF"
of grid heater switch and replace it
The ECU is switched
off by main electrical Inform driver about
Main Relay failure
"comprehensive switch instead of correct vehicle shut
MRlyCDAftRun (Interrupted $ 225 No "Mil ON"
components" terminal 15, defective off, check wiring,
Afterrun))
main relay, wiring replace main relay
problem
Short circuit of main all components
Failure is a NOx
relay 1 output to connected to main
Main Relay 1 (High dependent
ground, defect in one relay 1, if defect
MnRly1_SCG Pressure Pump) Short $ 228 "non" (potentially) longterm "Mil OFF"
of the connected remains main relay
to Ground failure (via LTF group1
components or inside ECU could be
Fuel System)
defective main relay 1 defective, replace
ECU
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Engine 1 (Temperature and Pressure Sensors)

Sensor defective or
Check wiring or
short circuit to
external source replace sensor
Coolant Temperature Sensor defective or Check wiring or

CTSCD $ 131 "non" No "Mil OFF"
Sensor failure short circuit to ground replace sensor
See OTS plausibility See OTS plausibility
check check
(Dfp_OTSCD.Npl) (Dfp_OTSCD.Npl)
Ensure that engine
Extreme ambient
was not running in
conditions. Or
extreme ambient
Coolant Temperature inaccurate sensor
Clg_DynTst $ 132 "non" conditions. Check No "Mil OFF"
Dynamic failure (although sensor does
wiring and accuracy of
not exceed its signal
sensor, replacement
range)
of sensor
Sensor defective or Failure is a NOx
Check wiring or
Boost Air short circuit to dependent
IATSCD Temperature Sensor $ 133 "non" (potentially) longterm "Mil OFF"
failure Sensor defective or Check wiring or failure (via LTF group5
short circuit to ground replace sensor SCR System)
Sensor defective or
Check wiring or
short circuit to
Failure is a NOx
dependent
Boost Pressure Sensor Sensor defective or Check wiring or
BPSCD $ 134 "non" (potentially) longterm "Mil OFF"
failuree short circuit to ground replace sensor
Difference of ambient Check ambient and Air System)
and boost pressure is boost pressure sensor
out of range.. for accuracy
Sensor defective or
Check wiring or
short circuit to
Fuel Temperature external source replace sensor
FTSCD $ 135 "non" No "Mil OFF"
Sensor failure
Sensor defective or Check wiring or
short circuit to ground replace sensor
Base - May 2012
47
Base - May 2012
48
correction Failure
to external source or Check wiring and
defective pressure proper functioning of Failure is a NOx
sensor, rail pressure rail pressure sensor dependent
Rail Pressure Sensor
RailCD $ 136 "non" overshoot (potentially) longterm "Mil OFF"
failure
Short circuit of wiring Check wiring and Fuel System)
to ground or defective proper functioning of
pressure sensor rail pressure sensor
Check rail pressure
Defective rail pressure
sensor for plausible
sensor, defect in other
values, ensure proper
injection relevant
functioning of the
component
injection components
PRV does not open
once the pressure Check application
Common Rail
limit is reached: value of maximum rail
PRVMon Pressure Limiting $ 137 "non" No yes (technical) "Mil OFF"
Mechanical defect or pressure, check
Valve failure
wrong application functioning of the PRV
parameter
PRV does not open
Check application
even after pressure
value of maximum rail
shock: Stuck PRV or
pressure, check
wrong application
functioning of the PRV
parameter
Sensor defective or
Check wiring or
short circuit to

Oil Pressure Sensor Monitoring function
OPSCD $ 138 "non" for ADC Sig-error not No "Mil OFF"
failure
explained in
documentation????
Inaccurate oil pressure
Check oil pressure
sensor or defect (e.g.
sensor for accuracy
blocked piping) in the
and check oil system
oil system.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Sensor defective or
Check wiring or
short circuit to

OTSCD Oil Temperature $ 13A "non" No "Mil OFF"
Sensor failure Inaccurate oil or Check oil and coolant
coolant temperature temperature sensor
sensors or insufficient for accuracy and
oil or coolant check oil and coolant
recirculation (low system for proper
coolant level etc.). functioning
Ambient Air Check wiring or
short circuit to dependent
Temperature Sensor external source replace sensor
EATSCD $ 13C "non" (potentially) longterm "Mil OFF"
failure (of Humidity
Sensor defective or Check wiring or failure (via LTF group5
Sensor) SCR System)
Ensure that engine
Extreme ambient
was not running in
conditions. Or
extreme ambient
ClgAbsTst $ 232 "non" conditions. Check No "Mil OFF"
Test failure (although sensor does
sensor, replacement
range)
of sensor
Ensure correct wiring
and proper
Rail pressure sensor
functioning of rail
inaccurate Failure is a NOx
pressure sensor,
replace sensor dependent
Rail Pressure Sensor "comprehensive
RailCDOfsTst $ 236 (potentially) longterm yes (technical) "Mil ON"
Offset Monitoring components" Ensure correct wiring failure (via LTF group1
and proper Fuel System)
functioning of rail
inaccurate
pressure sensor,
replace sensor
Base - May 2012
49
Base - May 2012
50
correction Failure
sensor or defect (e.g. Check oil pressure
OPSCD1 Oil Pressure too low $ 238 "non" too low oil level, sensor for accuracy No "Mil OFF"
leakage...) in the oil and check oil system
system
Inaccurate oil
temperature sensor or
Check oil temperature
Temperatura olio defect (e.g. blockage,
OTSCD1 $ 23A "non" sensor for accuracy No "Mil OFF"
eccessivamente alta insufficient
recirculation) in the oil
system.
Engine 2 (Speed sensing/actuators)

Signal interrupted do
Check wiring, sensor
to wiring problem,
installation and proper
defective or
functioning of
incorrectly installed Failure is a NOx
crankshaft sensor
crankshaft speed dependent
(evaluate raw signals)
Crankshaft Speed sensor (potentially) longterm
EngMCrS1 $ 141 "non" yes (technical) "Mil ON"
Signal failure Signal interrupted do failure (via LTF group2
Check wiring, sensor Injection Timing
to wiring problem,
installation and proper System)
defective or
functioning of
incorrectly installed
crankshaft sensor
crankshaft speed
sensor
to wiring problem,
Engine runs with defective or
EngMBackUp $ 142 "non" functioning of No yes (technical) "Mil OFF"
Camshaft Speed only incorrectly installed
crankshaft sensor
crankshaft speed
(evaluated raw signals)
sensor
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Signal interrupted do Check wiring, sensor
to wiring problem, installation and proper
defective or functioning of
incorrectly installed camshaft phase sensor
Camshaft Speed Signal camshaft phase sensor (evaluate raw signals)
EngMCaS1 $ 143 "non" No yes (technical) "Mil OFF"
failure Signal interrupted do Check wiring, sensor
camshaft phase sensor (evaluate raw signals)
Signal interrupted do Check wiring, sensor Failure is a NOx
to wiring problem, installations and dependent
Offset between
defective or proper functioning of (potentially) longterm
EngMOfsCaSCrS Camshaft and $ 144 "non" "Mil ON"
incorrectly installed camshaft and failure (via LTF group2
Crankshaft
camshaft or crankshaft crankshaft sensors Injection Timing
sensor (evaluate raw signals) System)
No reactions
necessary only if this
fault/information status
reoccurs frequently. In
this case check driving
conditions of vehicle,
Info: Engine Engine overspeed has engine speed
EngPrtOvrSpd $ 14D "non" No "Mil OFF"
Overspeed Protection occurred acquisition and
injection system for
quantity setpoint and
actual value during
fault recognition,
check also for ECU
errors
Base - May 2012
51
Base - May 2012
52
correction Failure
Advice operator not
A defect has occurred
Info: OBD to press button too
(in the EDC or DCU)
Performance Limiter long, check device for
CoVehPrflmAct $ 14F "non" which triggered a No "Mil OFF"
Intervention by mechanical and
performance limitation
Legislation electrical defects,
via corresponging Fids
check wiring
Wrong manipulation
Advice operator not
of operator, button
to press button too
mechanically stuck in
Engine Compartment long, check device for
ECBtCDStop $ 24A "non" actuated position, No "Mil OFF"
Stop Button stuck mechanical and
electrical defect in
electrical defects,
device, defective
check wiring
wiring
Fuel metering CR Systems

High pressure side:
Leakage in high
pressure section,
injection nozzle stuck
in open position, worn
high pressure pump, Failure is a NOx
Rail Pressure Positive
worn injector, leaking Check for defects dependent
Deviation High and
RailMeUn1 $ 152 "non" pressure relieve valve according to 'reason (potentially) longterm yes (technical) "Mil OFF"
High Fuel Flow
Low pressure side: of failure' list. failure (via LTF group1
Setpoint Value
Pressure before gear Fuel System))
pump too low, gear
pump output too low
(fuel filter clogged,
leakage in low
pressure side).
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Metering unit stuck in
open position,
zero-delivery throttle
clogged, metering unit
without power due to
Failure is a NOx
electricel error.
Rail Pressure Negative Check for defects dependent
Low pressure side:
RailMeUn2 Deviation too High on $ 153 "non" according to 'reason (potentially) longterm yes (technical) "Mil OFF"
Pressure before gear
Minimum Metering of failure' list. failure (via LTF group1
pump too high (e.g. by
Fuel System)
pressure relieve
valve), pressure after
too high.
High pressure side:

Leakage in the high
pressure section,
high pressure pump,
PRail Pressure below Check for defects
worn injector, leaking
RailMeUn3 Minimum Limit in $ 154 "non" according to 'reason No "Mil OFF"
pressure relieve valve.
Controlled Mode of failure' list.
Low pressure side:
pump too low or gear
pump output too low
(clogged fuel filter,
leak on output side).
Base - May 2012
53
Base - May 2012
54
correction Failure
open position,
Rail Pressure above electricel error. Check for defects
RailMeUn4 Maximum Limit in $ 155 "non" Low pressure side: according to 'reason No "Mil OFF"
Controlled Mode Pressure before gear of failure' list
pump too high (e.g. by
pressure relieve
too high.
Leakage in the high
pressure section,
in open position, worn Check for defects
Rail Pressure Drop
RailMeUn6 $ 156 "non" high pressure pump, according to 'reason No yes (technical) "Mil OFF"
Rate too High of failure' list.
pressure relieve valve,
injector reflux too
high.
High pressure system:
Leakage in the high
pressure section,
or defective high
Setpoint of Rail Check for defects
pressure pump, worn
RailMeUn7 Metering Unit not $ 157 "non" according to 'reason No yes (technical) "Mil OFF"
injector, leaking
plausible in Overrun of failure' list.
Low pressure system:
'Zero delivery' is not
active in metering unit
(excessve leakage in
metering unit).
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
inaccurate, high
pressure pump
Fuel Flow Setpoint of defective. Check for defects
RailMeUn10 Common Rail $ 158 "non" Low pressure system: according to 'reason No yes (technical) "Mil OFF"
Metering Unit too low Metering unit reflux of failure' list.
too low, fuel system
leakage, metering unit
jammed in closed
position.
Broken or
Check of wiring or Failure is a NOx
disconnected wiring
Common Rail or defective relay replace relay dependent
MeUnCDNoLoad Metering Unit Power $ 159 "non" (potentially) longterm "Mil OFF"
Stage failure Defective wiring, ECU, Check wiring, ECU, failure (via LTF group1
powerstage or power stage and Fuel System)
metering unit metering unit
Info Fault: High
The 'High Pressure Wait until the 'High
Pressure Test (Rail
HpTst $ 15B "non" Test' is requested via Pressure Test' has No "Mil OFF"
Pressure Monitoring
a diagnostic tester terminated
deactivated)
Identify the defect
triggering this fault
High NOx emissions Failure is a direct
Info: Long Term Fuel path and follow the
OBDGFClct1 $ 15F "non" due to various longterm failure (via "Mil ON"
system Failure troubleshooting
possible defects counter 576000 mins)
procedure of that
failure.
Failure is a NOx
Common Rail Short circuit of wiring dependent
Check of wiring or
MeUnCDSCBat Metering Unit Power $ 259 "non" to external source or (potentially) longterm "Mil OFF"
Stage Short to Battery inside relay replace relay
Fuel System)
Identify the defect
Info: Long Term path and follow the
Injection timing Failure troubleshooting
procedure of that
failure
Base - May 2012
55
Base - May 2012
56
correction Failure
Failure is a NOx
Common Rail
Short circuit of wiring dependent
Metering Unit Power Check of wiring or
MeUnCDSCGnd $ 359 "non" to ground or inside (potentially) longterm "Mil OFF"
Stage Short to replace relay
relay failure (via LTF group1
Ground
Fuel System)
Identify the defect
Info: Long Term air path and follow the
system failurea troubleshooting
procedure of that
failure.
Identify the defect
Info: Long Term NOx path and follow the
Sensor Failure troubleshooting
procedure of that
failure.
Identify the defect
Info: Long Term SCR path and follow the
System FailureR troubleshooting
procedure of that
failure.
Injectors 1
Short circuit in wiring Check the wiring or
with external source replace injector
BDefective coil of Check the wiring and Failure is a NOx
injector replace injector. dependent
Injector Cylinder 1
InjVlvCyl1A $ 161 "fuel system" (potentially) longterm "Mil ON"
failure Depending on the failure (via LTF group1
pattern, various Check the wiring and Fuel System)
reasons can cause the the injection signals,
defect, internal ECU replace ECU
problems also possible
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Defective coil of Check the wiring and Failure is a NOx
Injector Cylinder 2
Injector Cylinder 3
njector Cylinder 4
Base - May 2012
57
Base - May 2012
58
correction Failure
Defective coil of Check the wiring and
injector replace injector.
Injector Cylinder 5
InjVlvCyl5A $ 165 "non" No "Mil OFF"
failure Depending on the
pattern, various Check the wiring and
injector replace injector.
Injector Cylinder 6
InjVlvCyl6A $ 166 "non" No "Mil OFF"
failure Depending on the
Failure is a NOx
Broken wire or
dependent
Injector Cylinder 1 disconnection of Check the wiring or
InjVlvCyl1B $ 167 "fuel system" (potentially) longterm "Mil ON"
warning wiring or inside replace injector.
injector
Fuel System)
Failure is a NOx
Broken wire or
dependent
injector
Fuel System)
Failure is a NOx
Broken wire or
dependent
injector
Fuel System)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Failure is a NOx
Broken wire or
dependent
InjVlvCyl4B $ 16A "fuel system" (potentially) longterm "Mil ON"
injector
Fuel System)
Broken wire or
InjVlvCyl5B $ 16B "non" No "Mil OFF"
injector
Broken wire or
InjVlvCyl6B $ 16C "non" No "Mil OFF"
injector
See individual injector See individual injector
and injection-bank and injection-bank
errors (InjVlvCyl... and errors (InjVlvCyl... and
Minimum Injections
InjVlvNumMinInj $ 16E "non" InjVlvBnk...) which InjVlvBnk...) which No "Mil OFF"
Number not reached
have triggerd the have triggerd the
shut-off or error in the shut-off or error in the
component component
Iniettori 2
Short circuit of
Check the wiring or
high-side to battery or
ground. replace injector.
Short circuit of Failure is a NOx

Check the wiring or
low-side to ground in dependent
injector cable replace injector. (potentially) longterm
InjVlvBnk1A Injector Bank 1 failure $ 171 "fuel system" "Mil ON"
Depending on the Fuel System)
problem
Base - May 2012
59
Base - May 2012
60
correction Failure
Short circuit of
Check the wiring or
high-side to battery or

Check the wiring or
low-side to ground in dependent
injector cable. replace injector.. (potentially) longterm
Depending on the Fuel System)
problem
Clock error or Check the power
irrupton of the power supply or replace ECU
supply voltage if problem reoccurs.
Reset ECU. If no
Defective ECU recovery, replace
ECU.
ECU Hardware for
InjVlvChipA Injection: CY33X Chip $ 17C "non" Check 'TESTMODE' No "Mil OFF"
Internal failure of ECU
specific failure (1) parameters or replace
or 'TESTMODE' takes
ECU if problem
too long
reoccurs
Defective SPI-bus Replace ECU if
participant, timing problem reoccurs
problem due to (Send in ECU for
software bug investigation)
Replace ECU if
Defective ECU
problem reoccurs
ECU Hardware for Replace ECU if

Defective ECU
Injection: CY33X problem reoccurs
InjVlvChipB $ 27C "non" No "Mil OFF"
Chip specific failure Replace ECU if
(2) Defective ECU
problem reoccurs
Replace ECU if
Defective ECU
problem reoccurs
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Air inlet system / EGR

Differential Pressure
Sensor Failure "comprehensive
IEDPCDPDiff $ 181 No "Mil ON"
between Exhaust and componentsi"
Intake (EGR Valve)
Boost system and turbine speed

No actions necessary
due to this failure
alone. If
powerreduction
occurred due to
Torque Reduction Active power actual defect, the
SmkTrqLim due to Smoke $ 19E "non" redcution due to failure triggering the No "Mil OFF"
Limitation smoke limitation torque limitation
should also be in the
failure memory.
Follow
troubleshooting of this
root error.
Application Determine what
dependent: defect has set the Fid
NOx Estimation
NOxEstIv $ 19F "non" Implausible sensor and resolve the No "Mil OFF"
failure
signals or defective problem causing this
sensors etc. original defect.
due to this failure
alone. If
powerreduction
occurred due to
Info: Torque Active power
actual defect, the
Limitation due to redcution due to
NTCTrqLim $ 29D "non" failure triggering the No "Mil OFF"
Negative Torque engine break shut off
torque limitation
Coordinator event
failure memory.
Follow
root error.
Base - May 2012
61
Base - May 2012
62
correction Failure
due to this failure
alone. If
powerreduction
occurred due to
actual defect, the
BstPrtTrqLim $ 39E "non" failure triggering the No "Mil OFF"
Turbo Charger turbo charger
torque limitation
Protection protection
failure memory.
Follow
root error.
due to this failure
alone. If
Info: Torque powerreduction
Limitation due to occurred due to
Active power
Engine Protection actual defect, the
redcution due to
EngPrtTrqLim (against Excessive $ 49E "non" failure triggering the No "Mil OFF"
engine mechanics
Torque, Engine torque limitation
protection
Overspeed and should also be in the
Overheat) failure memory.
Follow
root error.
due to this failure
alone. If
powerreduction
Active power occurred due to
Info: Torque
redcution due to actual defect, the
Limitation due to SCR
SCRPrtTrqLim $ 59D "non" excessive failure triggering the No "Mil OFF"
Catalyst Overheat
temperatures in the torque limitation
Protection
SCR catalyst should also be in the
failure memory.
Follow
root error.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
due to this failure
alone. If
powerreduction
occurred due to
Info: Torque Active power actual defect, the
NsCtlTrqLim Limitation due to $ 59E "non" redcution due to failure triggering the No "Mil OFF"
Noise Limitation noise control torque limitation
failure memory.
Follow
root error.
due to this failure
alone. If
powerreduction
Info: Torque occurred due to
Limitation due to Fuel Active power actual defect, the
QLimTrqLim Quantity Limitation $ 69E "non" redcution due to failure triggering the No "Mil OFF"
because of Injection limiting fuel quantity torque limitation
System Errors should also be in the
failure memory.
Follow
root error.
Exhaust system (Aftertreatment)

Check for proper
Failure is a NOx
CAN communication CAN communication
dependent
FrmMngNOxSensNO NOx Sensor "comprehensive disturbed, defective or and check accuracy
$ 1A2 (potentially) longterm yes (OBD) "Mil ON"
xIv Plausiblity failure componentsi" inaccurate NOx and proper
sensor functioning of NOx
NOx Sensor)
sensor.
Base - May 2012
63
Base - May 2012
64
correction Failure
Check wiring of NOx
Disconnected cable in
sensor and its proper
the wiring of the NOx
functioning. If
sensor or defective
necessary replace
NOx sensor.
NOx sensor.
Check wiring of NOx Failure is a NOx
Short circuit in the
sensor and its proper dependent
"comprehensive wiring of the NOx
FrmMngNOxSensIv NOx Sensor Failure $ 1A3 functioning. If (potentially) longterm yes (OBD) "Mil ON"
components" sensor or defective
necessary replace failure (via LTF group4
NOx sensor. NOx sensor. NOx Sensor)
Strange driving cycle Check installation
or inproper (including wiring) and
installation of the functionality of sensor.
sensor, defective If necessary change
NOx sensor NOx sensor
Defective CAN
controller of NOx Check presence and
Sensor , undervoltage correct connection of
of NOx Sensor, the NOx Sensor to Failure is a NOx
CAN Message missing NOx Sensor, the network, Check dependent
FrmMngTONOxSensIv timeout Nox (from $ 1A4 "non" CAN cable correct functioning of (potentially) longterm yes (OBD) "Mil ON"
Nox Sensor) connecting the NOx the NOx Sensor failure (via LTF group4
Sensor is CAN controller and NOx Sensor)
disconnected or its voltage supply.
broken. Short circuit Check wiring.
in wiring.
Check presence and
Defective CAN
correct connection of
controller of DCU,
the DCU to the Failure is a NOx
undervoltage of DCU,
CAN Message network, check dependent
missing DCU, CAN
FrmMngTODM1DCUIv timeout DM1DCU $ 1A5 "catalyst monitoring" correct functioning of (potentially) longterm yes (OBD) "Mil ON"
cable connecting the
(from DCU) the DCU CAN failure (via LTF group5
DCU is disconnected
controller and its SCR System)
or broken. Short
voltage supply. Check
circuit in wiring
wiring.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Defective CAN Check presence and
controller of Dosing correct connection of
Control Unit , the DCU to the Failure is a NOx
CAN Message undervoltage of DCU, network, Check dependent
FrmMngTOSCR1Iv timeout SCR1 (from $ 1A6 "catalyst monitoring missing DCU, CAN correct functioning of (potentially) longterm yes (OBD) "Mil ON"
DCU) cable connecting the the DCU CAN failure (via LTF group5
DCU is disconnected controller and its SCR System)
or broken. Short voltage supply. Check
circuit in wiring wiring.
Failure due to engine
switch off after a high
load period, leading to LRead out the DCU
high temperatur in failure memory and
exhaust system. perform
A defect occurred in troubleshooting
the urea dosing according to DCU
nfo: SCR Dosing Valve system which can support.
FrmMngSCR1ProtIv $ 1A8 "non" impair the cooling of No "Mil OFF"
Overheat ProtectionR
the urea dosing valve
Read out the DCU
A defect occurred in
failure memory and
the urea dosing
perform
system which can
troubleshooting
impair the cooling of
according to DCU
support.
Check wiring. Replace
short circuit to dependent
Humidity Sensor external source sensor if necessary
IAHSCDStrtDly $ 1AE "non" (potentially) longterm "Mil OFF"
Signal Ratio failure
Sensor defective or Check wiring. Replace failure (via LTF group5
short circuit to ground sensor if necessaryo SCR System)
Check what SPN and

A certain error has corresponding DCU
Info: DCU Error1 via occured in the DCU error is active and
FrmMngDM1SPN1Iv CAN message $ 1AF "non" System and is perform No yes (OBD) "Mil OFF"
DM1DCU reported via CAN to troubleshooting
the EDC. according to DCU
support.
Base - May 2012
65
Base - May 2012
66
correction Failure
Check NOx sensor
for correct functioning
(dismount sensor ->
NOx value should be
0ppm during driving),
NOx sensor
check wiring of sensor,
inaccurate or
check fuel injectors,
check urea dosing
wiring, urea injection Failure is a NOx
system for correct
valve or fuel injector dependent
NOx Sensor Drift "comprehensive dosing amount
SCRCatNOxDrIv $ 2A2 jammed open, (potentially) longterm yes (OBD) "Mil ON"
failure components" (perform UDST and
excessive urea failure (via LTF group4
Dosing Valve Check,
deposits in exhaust NOx Sensor)
check DCU error
system, strange
memory for leakage
behaviour of SCR
failures), check SCR
catalyst
catalyst for correct
functioning, check
exhaust system for
excessive urea
deposits
FrmMngTOSCR2Iv timeout SCR2 (from $ 2A6 "catalyst monitoring missing DCU, CAN correct functioning of (potentially) longterm yes (OBD) "Mil ON"
DCU) cable connecting the the DCU CAN failure (via LTF group5
DCU is disconnected controller and its SCR System)
circuit in wiring. wiring.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
If failure 1AE
'IAHSCDStrDly' also
stored in memory:
proceed according
that description
If failure ACTIVE: run

engine at medium
speed > 10 min, if
failure does NOT get
INACTIVE: check
wiring harness and
replace sensor if
Sensor possibly necessary Failure is a NOx
Info: Humidity Sensor saturated with water dependent
IAHSCD possibly saturated $ 2AE "non" droplets If failure not active (potentially) longterm "Mil OFF"
with water droplets AND ratio 'active failure (via LTF group5
time' / 'occurrence' < SCR System)
10 min/occurrence: no
action needed
If failure not active

AND ratio 'active
time' / 'occurrence' >
10 min/occurrence:
possible short circuit:
check wiring harness
or replace sensor, if
necessary
Sensor defective or Check wiring. Replace
short circuit to ground sensor if necessaryo
Verificare quale SPN e
A certain error has
relativo errore DCU
Info: DCU Error2 via occured in the DCU
attivo ed individuare
FrmMngDM1SPN2Iv CAN message $ 2AF "non" System and is No yes (OBD) "Mil ON"
ed eliminare il
DM1DCU reported via CAN to
problema secondo il
the EDC.
supporto DCU.
Base - May 2012
67
Base - May 2012
68
correction Failure
Check urea dosing
system for correct
dosing amount
(perform UDST and
Dosing Valve Check,
check DCU error
NOx sensor
memory for leakage
inaccurate or
failures), check NOx
sensor for correct Failure is a NOx
wiring, inaccurate
functioning, check dependent
NOx Sensor "comprehensive NOx estimation, urea
SCRCatNOxPlIv $ 3A2 wiring of sensor, check (potentially) longterm yes (OBD) "Mil ON"
Plausibility failure componentsi" injection valve jammed
NOx estimation failure (via LTF group4
open or excessive
(humidity, boost NOx Sensor)
urea deposits in
pressure and
exhaust system,
temperature) for
defective SCR catalyst
SCR catalyst for
correct functioning,
for excessive urea
deposits
Check what SPN and
FrmMngDM1SPN4Iv CAN message $ 4AF "non" System and is perform No yes (OBD) "Mil ON"
support.
Check what SPN and
support.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Interfaces 1 (CAN-Bus)
Check timing
Wrong configuration
configuration with
of CAN timing
hardware
(Prescaler,
compatibility, check
synchronization jump
termination resistors
width, sampling,
and network
propagation and
connection and
NetMngCANAOff CAN A Bus off $ 1B1 "non" phase segments), bad No "Mil OFF"
contacts. Short circuits
termination resistors,
to external source,
defective network
ground or CAN High
connection and
to Low.Monitor CAN
contacts or defective
communication for
CAN controller with
erroneous behaviour
erroneous messages.
of a participant.
Check timing
Wrong configuration
configuration with
of CAN timing
hardware
(Prescaler,
width, sampling,
and network
propagation and
connection and
NetMngCANBOff CAN B Bus off $ 1B2 "non" phase segments), bad No "Mil OFF"
to external source,
defective network
ground or CAN High
connection and
to Low.Monitor CAN
communication for
CAN controller with
erroneous behaviour
erroneous messages.
of a participant.
Base - May 2012
69
Base - May 2012
70
correction Failure
Check timing
Wrong configuration
configuration with
of CAN timing
hardware
(Prescaler,
width, sampling,
and network
propagation and
connection and
NetMngCANCOff CAN C Bus off $ 1B3 "non" phase segments), bad No "Mil OFF"
to external source,
defective network
ground or CAN High
connection and
to Low.Monitor CAN
communication for
CAN controller with
erroneous behaviour
erroneous messages.
of a participant.
controller of Body correct connection of
Computer , the BC to the
CAN Message
undervoltage of BC, network, Check
FrmMngTOBC2EDC1 timeout BC2EDC1
$ 1B4 "non" missing BC, CAN correct functioning of No "Mil OFF"
Iv (from Body
cable connecting the the BC CAN
Computer)
BC is disconnected or controller and its
broken. Short circuit in voltage supply. Check
wiring. wiring.
controller of Vehicle correct connection of
Control Module , the VCM to the
CAN Message undervoltage of VCM, network, Check
FrmMngTOVM2EDCI
timeout VM2EDC $ 1B5 "non" missing VCM, CAN correct functioning of No "Mil OFF"
v (from VCM) cable connecting the the VCM CAN
VCM is disconnected controller and its
Check CAN
Disturbed CAN,
communication, check
incorrect configuration
CAN configuration,
CAN Transmit of the CAN, EDC is
FrmMngTxTO $ 1B7 "non" ensure proper No yes (OBD) "Mil OFF"
Message timeout disconnected from the
connection of the
network, EDC CAN
EDC to the network,
controller defective
replace EDC
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Consult trouble
Defective MIL/Body shooting of body
Info: MIL visualization "comprehensive Controller or controller and check
FrmMngBC1MILIv $ 1B9 No "Mil ON"
not available components" disturbed CAN correct functioning of
communication the CAN
communication.
FrmMngTODashDsplIv timeout Dash Display $ 1BA "non" missing VCM, CAN correct functioning of No "Mil OFF"
(from VCM) cable connecting the the VCM CAN
FrmMngTORxAMCONIv timeout AMCON $ 1BC "non" missing VCM, CAN correct functioning of No "Mil OFF"
(from VCM) cable connecting the the VCM CAN
Defective CAN
controller of Body Check presence and
Computer or Vehicle correct connection of
Control Module , the BC or VCM to
CAN Message
undervoltage of BC the network, check
timeout CCVS (from
FrmMngTORxCCVS $ 1BD "non" or VCM, missing BC correct functioning of No "Mil OFF"
Body Computer or
or VCM, CAN cable the BC or VCM CAN
VCM)
connecting the BC or controller and its
VCM is disconnected voltage supply. Check
or broken. Short wiring.
circuit in wiring.
Base - May 2012
71
Base - May 2012
72
correction Failure
CAN Message
timeout BC2EDC2
FrmMngTOBC2EDC2Iv $ 2B4 "non" missing BC, CAN correct functioning of No "Mil OFF"
(from Body
Computer)
broken. Short circuit voltage supply. Check
in wiring. wiring.
Interfaces 2 (CAN messages timeout)

controller of Gearbox correct connection of
CAN Message Control Unit , the ETC to the
timeout ETC1 (from undervoltage of ETC, network, check
FrmMngTOETC1 Electronic $ 1C2 "non" missing ETC, CAN correct functioning of No "Mil OFF"
Transmission cable connecting the the ETC CAN
Controller) ETC is disconnected controller and its
controller of correct connection of
Tachograph Output , the TCO to the
CAN Message undervoltage of TCO, network, check
FrmMngTOTCO1 timeout TCO1 (from $ 1C3 "non" missing TCO, CAN correct functioning of No "Mil OFF"
Tachograph Output) cable connecting the the TCO CAN
TCO is disconnected controller and its
controller of Power correct connection of
CAN Message
Take Off , the PTO to the
timeout active
undervoltage of PTO, network, Check
FrmMngTOTSC1 TSC1-PE
$ 1C6 missing PTO, CAN correct functioning of No "Mil OFF"
PEActIv (Torque/Speed
cable connecting the the PTO CAN
Control Request from
PTO is disconnected controller and its
PTO to Engine)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Defective CAN
controller of Vehicle
Check presence and
Control Module or
CAN Message Body Computer ,
the VCM/BC to the
timeout active undervoltage of
network, Check
FrmMngTOTSC1VEA TSC1-VE VCM/BC, missing
$ 1C8 "non" correct functioning of No "Mil OFF"
ctIv (Torque/Speed VCM/BC, CAN cable
the VCM/BC CAN
Control Request from connecting the
controller and its
VCM/BC to Engine) VCM/BC is
disconnected or
wiring.
broken. Short circuit in
wiring.
timeout ETC2 (from undervoltage of ETC, network, Check
CAN Message
timeout inactive
FrmMngTOTSC1PEPa TSC1-PE
$ 2C6 "non" missing PTO, CAN correct functioning of No "Mil OFF"
sIv (Torque/Speed
PTO to Engine)
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
network, Check
FrmMngTOTSC1VRA TSC1-VR VCM/BC, missing
the VCM/BC CAN
controller and its
VCM/BC to Retarder) VCM/BC is
disconnected or
wiring.
broken. Short circuit in
wiring.
Base - May 2012
73
Base - May 2012
74
correction Failure
Tachograph , the TC to the
Time/Date CAN undervoltage of TC, network, Check
FrmMngTOTimeDateIv timeout (from $ 2C9 "non" missing TC, CAN correct functioning of No "Mil OFF"
Tachograph or VCM) cable connecting the the TC CAN
TC is disconnected or controller and its
in wiring wiring.
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
timeout inactive undervoltage of
network, Check
FrmMngTOTSC1 TSC1-VE VCM/BC, missing
VEPasIv (Torque/Speed VCM/BC, CAN cable
the VCM/BC CAN
controller and its
disconnected or
wiring.
broken. Short circuit
in wiring
Defective CAN
controller of Check presence and
Tachograph - High correct connection of
CAN Message Resolution Vehicle the BC to the
timeout HRVD (from Distance , network, Check
FrmMngTOHRVDIv Tachograph - High $ 3C9 "non" undervoltage of BC, correct functioning of No "Mil OFF"
Resolution Vehicle missing BC, CAN the BC CAN
Distance) cable connecting the controller and its
BC is disconnected or voltage supply. Check
broken. Short circuit wiring.
in wiring.
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
network, Check
FrmMngTOTSC1 TSC1-VR VCM/BC, missing
VRPasIv (Torque/Speed VCM/BC, CAN cable
the VCM/BC CAN
controller and its
disconnected or
wiring.
in wiring.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
ECU 1 (internal checks)

Electric disturbances,
internal defect of the
ECU Hardware: SPI Replace ECU if failure
HWEMonCom $ 1D1 "non" ECU leading to a SPI No "Mil OFF"
Communication failure remains present
bus communication
error
Try to flash the EDC
Wrong
correctly with a
programming/flashing
proper dataset, if
of the EDC, internal
defect persists:
defect of the EDC.
replace EDC.
Wrong
correctly with a
ECU Hardware: programming/flashing
HWEMonEEPROM $ 1D2 "non" proper dataset, if No "Mil OFF"
EEPROM failure of the EDC, internal
defect persists:
defect of the EDC.
replace EDC.
Wrong
correctly with a
proper dataset, if
defect persists:
defect of the EDC.
replace EDC.
Analyze what error
triggered the recovery
(Read out label
Electronic
HWEMon_numRecov
disturbances, various
ery and compare the
ECU recovery - hardware defects
HWEMonRcyLocked $ 1D3 "non" value with the No "Mil OFF"
locked (ECU internal) or
according table). If
configuration
error occurs
problems
repeatedly, reprogram
EDC. If error remains,
replace EDC.
If error exists only
temporary (i.e.
injection reoccurs)
Defective monitoring
error can be ignored
module or CPU (e.g.
ECU Hardware: and error deleted in
impaired functioning
Montr Microcontroller $ 1D4 "non" the fault memory. In No "Mil OFF"
of the CPU clock) of
Watchdog failure case of a permanent
the EDC. Disturbed
error the injection
SPI-Bus.
remains blocked and
the ECU has to be
replaced
Base - May 2012
75
Base - May 2012
76
correction Failure
If failure remains after
Watch dog switch off
ECU initialisation:
path defect replace ECU
Electronic If failure remains after
ECU Hardware: Shut
SOPTst $ 1D5 "non" disturbances, internal ECU initialisation: No yes (technical) "Mil OFF"
off during Initialization ECU problem replace ECU
disturbances, internal ECU initialisation:
ECU problem replace ECU
Electronic
ECU Hardware: TPU If failure persists:
TPUMon $ 1D6 "non" disturbances, wrong No "Mil OFF"
Monitoring TPU timebase Replace ECU
ECU Software: Variant See general remarks See general remarks

VarMngCodDs $ 1D7 "non" No "Mil OFF"
Dataset failure See general remarks See general remarks
If ECU functions
correctly after
recovery only
temporary SPI error
occurred and fault
ECU Hardware:
memory can be
WdCom Controller Watchdog $ 1D8 "non" Disturbed SPI-Bus No "Mil OFF"
deleted and error
failure
ignored. If permanent
SPI error is present
and the ECU does not
leave boot block -->
Replace ECU
ADC Monitoring
ADCMon $ 1D9 "non" Buffer overrun No "Mil OFF"
failure
Analyze what error
(Read out label
Electronic
HWEMon_numRecov
ery and compare the
HWEMonRcy ECU recovery - hardware defects
$ 2D3 "non" value with the No "Mil OFF"
Suppressed suppressed (ECU internal) or
configuration
error occurs
problems
replace EDC.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Analyze what error
(Read out label
Electronic
HWEMon_numRecov
ery and compare the
hardware defects
HWEMonRcyVisible ECU recovery - visible $ 3D3 "non" value with the No "Mil OFF"
(ECU internal) or
configuration
error occurs
problems
replace EDC.
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)

ECU Hardware: High
Side Power Stage Check of wiring or
StrtCDHS $ 1E1 "non" to ground or inside No yes (technical) "Mil OFF"
Short to Ground or replace relay
relay
Battery
1) Defective CAN or
immobilizer and new
control unit (here no 1) Ensure correct
PIN entry is possible) CAN functioning
OR T15 was toggled (timeout errors),
more than a unlock fuel release via
calibratable value OR a tester request,
number of allowed replace immobilizer
Immobilizer failure (no
ImmCtl $ 1E2 "non" incorrect PIN entries 2) Enter PIN code via No "Mil OFF"
fuel release)
is exceeded. accelerator pedal or
2) Defective CAN or instrument cluster,
immobilizer OR ensure correct CAN
wrong code AND functioning (timeout
code is kown by the errors), replace
EDC AND T15 has immobilzer
not been toggeled
excessively
Electronic
disturbances,
requested torque Check injection
Overrun Monitoring increase via tester, relevant application, if
OvRMon $ 1E3 "non" No "Mil OFF"
failure wrong application of failure persists replace
injection relevant ECU
parameters, defective
ECU
Redundant Engine Electronic If failure persists after
OvRMonSigA Speed in Overrun $ 1E4 "non" disturbances, internal reinitialization replace No "Mil OFF"
Monitoring ECU problem ECU
Base - May 2012
77
Base - May 2012
78
correction Failure
Excessive battery Check battery voltage,
voltage, defect in check wiring for
wiring harness, correct voltage supply
electrical failure of the of the sensor and the
ECU Hardware: EDC EDC, replace EDC
SSpMon12V Sensor 12V Supply $ 1E5 "non" No "Mil OFF"
Voltage failure Insufficient battery Check battery voltage,
EDC EDC, replace EDC
Excessive battery
Check battery voltage,
voltage, defect in
check wiring for
wiring harness,
correct voltage supply
electrical failure in
of the sensor and the
connected sensors or
ECU Hardware: EDC, replace EDC
"comprehensive in the EDC
SSpMon1 Sensor Supply Voltage $ 1E6 No yes (technical) "Mil ON"
1 failure components" Insufficient battery
voltage, defect in
check wiring for
wiring harness,
electrical failure
EDC, replace EDC
in the EDC
Excessive battery
voltage, defect in
check wiring for
wiring harness,
in the EDC
SSpMon2 Sensor Supply Voltage $ 1E7 "non" No yes (technical) "Mil OFF"
2 failure Insufficient battery
voltage, defect in
check wiring for
wiring harness,
electrical failure
EDC, replace EDC
in the EDC
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Excessive battery
voltage, defect in
check wiring for
wiring harness,
in the EDC
voltage, defect in
check wiring for
wiring harness,
electrical failure
EDC, replace EDC
in the EDC
Excessive voltage
supply of a CJ940 Check the battery for
component: High correct voltage supply,
HWEMonUMaxSuppl ECU internal Supply
$ 1E9 "non" battery voltage, check wiring. If defect No "Mil OFF"
y Voltage too high
defective wiring, remains replace EDC
internal defect of the (internal defect)
EDC
Insufficient voltage
component: Low sufficient voltage
ECU internal Supply
HWEMonUMinSupply $ 1EA "non" battery voltage, supply, check wiring. If No "Mil OFF"
Voltage too low
defective wiring, defect remains replace
internal defect of the EDC (internal defect)
EDC
Base - May 2012
79
Base - May 2012
80
correction Failure
Replace ECU (not
Ambient pressure necessary if never
sensor inside ECU is running in high altitude
defect and if turbocharger
without VGT)
Replace ECU (not
Atmospheric Pressure
APSCD $ 1EB "non" sensor inside ECU is running in high altitude No "Mil OFF"
Sensor failure defect and if turbocharger
without VGT)
Replace ECU (not
sensor inside ECU is running in high altitude
defect and if turbocharger
without VGT)
ECU Hardware: Low
Side Power Stage Check wiring or
StrtCDLS $ 2E1 "non" to external source or No yes (technical) "Mil OFF"
inside relay
Battery
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
NOTE
N60 ENGINE
FAULT CODES
Reason of Possible failure Long Term-
Dfp Name Description DTC OBD-System Power Red. Mil.
Failure correction Failure
Vehicle 1 (Sensor/Plausibility checks)
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
Due to a short Check wiring for
circuit in the correct installation
ignition switch the and for short
T15CD Terminal 15 failure $ 119 "non" EDC is switched circuits No "Mil OFF"
on, although T15
has not been
activated.
Check wiring and
signal of
temperature
sensor. Ensure
Temperature complete cool
sensor downstream down of vehicle
of catalyst is (>10 hours)
inaccurate or without sun
defective, defect in exposure and and
wiring (also check measure all 3
temperature
differences are Failure is a NOx
above 20C replace dependent
SCR Temperatures "catalyst defective sensor (potentially)
SCRCatPlausIv plausibility $ 11F monitoring" yes (OBD) "Mil ON"
Check wiring and longterm failure (via
signal of LTF group5 SCR
temperature System)
sensor. Ensure
Temperature complete cool
sensor upstream of down of vehicle
catalyst is (>10 hours)
inaccurate or without sun
defective, defect in exposure and and
wiring (also check measure all 3
temperature
differences are
above 20C replace
defective sensor
Base - May 2012
81
Base - May 2012
82
correction Failure
If the ambient
temperature sensor is
inaccurate it is likely
that the urea pump
module (DTC $E4)
and urea tank
temperature (DTC
Ambient temperature $E5) are also
sensor or both reported implausible
upstream and by the DCU. Check
downstream catalyst wiring and signal of
temperature sensors temperature sensors.
are inaccurate, defect Ensure complete cool
in wiring (also check down of vehicle (>10 Failure is a NOx
connectors) hours) without sun dependent
SCR Temperatures
SCRCatPlausIv $ 11F "catalyst monitoring" exposure and and (potentially) longterm yes (OBD) "Mil ON"
plausibility
measure all 3 sensors failure (via LTF
signals. If temperature group5 SCR System)
differences are above
20C replace the
sensors which seem
implausible.
Temperature sensor
Check both sensor
up- or downstream of
signals and their
the catalyst or both
wiring, look for static
are inaccurate, defect
implausibility, check
in wiring (also check
for oil leakages,
connectors), oil
replace one or both
leakage into exhaust
sensors
system
Defective or incorrect Check speed
functioning speed measuring device for
Vehicle Speed Sensor measuring device, see
VSSCD2 $ 211 "non" proper functioning No "Mil OFF"
failure CAN message and for its CAN
Tachograph Output configuration
(TCO1).
Failure is a NOx
Replace catalyst and
SCR Catalyst Thermal dependent
Excessive ageing of reset EEPROM value
SCRCatAgeingIv Ageing Limit $ 21D "non" (potentially) longterm "Mil OFF"
SCR-Catatlyst of catalyst ageing time
exceeded failure (via LTF
via tester
group5 SCR System)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Measured catalyst
the estimated (NH3
Check urea dosing
slip present),
system for correct
inaccurate NOx
dosing amount
measurement (value
(perform UDST and
Dosing Valve Check,
check DCU error
NOx estimation
memory for leakage
(value too low)
failures), check
accuracy of
SCR Catalyst estimated catalyst dependent
NOx-sensor and
SCRCatNOxLvl1Iv Efficiency below first $ 21E "catalyst monitoring" efficiency too high (potentially) longterm "Mil ON"
NOx-model
threshold (due to inaccuracies in failure (via LTF
(humidity, boost
the exhaust mass flow group5 SCR System)
pressure and
calculation, the
temperature) for
estimated NH3
NOx-conversion
measurements up-
and downstream of
the catalyst) or
for excessive urea
deposits
excessive urea
deposits in exhaust
system
Measured catalyst
the estimated (NH3
Check urea dosing
slip present),
system for correct
inaccurate NOx
dosing amount
measurement (value
(perform UDST and
Dosing Valve Check,
check DCU error
NOx estimation
memory for leakage
(value too low)
failures), check
accuracy of
estimated catalyst dependent
DCU State NOx-sensor and
SCRCatDCUStateIv $ 31D "catalyst monitoring" efficiency too high (potentially) longterm yes (OBD) "Mil ON"
Monitoring NOx-model
(due to inaccuracies in failure (via LTF
(humidity, boost
pressure and
calculation, the
temperature) for
estimated NH3
NOx-conversion
measurements up-
and downstream of
the catalyst) or
for excessive urea
deposits
excessive urea
deposits in exhaust
Base - May 2012
system
83
Base - May 2012
84
correction Failure
Measured catalyst
the estimated (NH3
Check urea dosing
slip present),
system for correct
inaccurate NOx
dosing amount
measurement (value
(perform UDST and
Dosing Valve Check,
check DCU error
NOx estimation
memory for leakage
(value too low)
failures), check
accuracy of
SCR Catalyst estimated catalyst dependent
NOx-sensor and
SCRCatNOxLvl2Iv Efficiency below $ 31E "catalyst monitoring" efficiency too high (potentially) longterm yes (OBD) "Mil ON"
NOx-model
second threshold (due to inaccuracies in failure (via LTF
(humidity, boost
pressure and
calculation, the
temperature) for
estimated NH3
NOx-conversion
measurements up-
and downstream of
the catalyst) or
for excessive urea
deposits
excessive urea
deposits in exhaust
system
Measured catalyst
efficiency higher than
the estimated (danger
of NH3 slip), Check urea dosing
inaccurate NOx system for correct
measurement (value dosing amount
too low) downstream (perform UDST and
of catalyst, incorrect Dosing Valve Check,
NOx estimation check DCU error
(value too high) memory for leakage
Failure is a NOx
upstream of catalyst, failures), check
dependent
SCR Catalyst System estimated catalyst accuracy of
SCRCatHiEffIv $ 31F "non" (potentially) longterm "Mil OFF"
Efficiency too high efficiency too low NOx-sensor and
failure (via LTF
(due to inaccuracies in NOx-model
group5 SCR System)
the exhaust mass flow (humidity, boost
calculation, the pressure and
estimated NH3 temperature) for
storage, temperature plausible values, check
measurements up- exhaust system for
and downstream of excessive urea
the catalyst), deposits
excessive urea
F4AE ENGINES
deposits in exhaust
Print P2D32N020 E
system
Print P2D32N020 E
F4AE ENGINES
correction Failure
Vehicle 2 (Lamps/relays/actuators)
all components
relay 2 output to
connected to main
external source,
relay 2, if defect
defect in one of the
remains main relay
connected
Main Relay 2 failure inside ECU could be
components or
(Grid Heater 1, Fan 1, defective, replace
VGT, Lambda Heater, ECU
MRlyCD $ 125 "non" No "Mil OFF"
EGR Bypass Valve, Check the wiring and
EGR Actuator, Blow Short circuit of main all components
By Valve) relay 2 output to connected to main
ECU
Replace alternator
Alternator voltage govenror device or
governor defect alternator
Battery defect,
BattCD Battery Voltage failure $ 126 "non" alternator defect, No "Mil OFF"
wiring problems (too Replace battery or
high resistance) or alternator. Check
ECU defect. ECU and wiring.
Occurence possible
during cold start.
all components
relay 1 output to Failure is a NOx
connected to main
Main Relay 1 (High external source, dependent
relay 1, if defect
MnRly1_SCB Pressure Pump) Short $ 128 "non" defect in one of the (potentially) longterm "Mil OFF"
remains main relay
to Battery connected failure (via LTF
inside ECU could be
components or group1 Fuel System)
defective, replace
ECU
Base - May 2012
85
Base - May 2012
86
correction Failure
all components
relay 3 output to
connected to main
external source,
relay 3, if defect
Main Relay 3 failure defect in one of the
remains main relay
(A/C Compressor, connected
inside ECU could be
Fuel Filter Heater, components or
defective, replace
Intercooler Bypass defective main relay 3
ECU
MRlyCDMnRly3 Valve, Additive Valve, $ 129 "non" No "Mil OFF"
Grid Heater 2, Fan 2, Check the wiring and
OBD/Cold Start/ Short circuit of main all components
Adjustable Speed relay 3 output to connected to main
Limiter Lamp) ground, defect in one relay 3, if defect
ECU
Check of wiring or
inside relay, broken or
Engine-Brake Exhaust replace relay
disconnected wiring
EVCD Valve (Main Relay 4) $ 12A "non" or defective relay No "Mil OFF"
failure
to ground or inside Check of wiring or
relay replace relay

to external source or Check of wiring or
inside relay replace relay

Air Heater 1 Power to ground or inside Check of wiring or
ArHt1 Stage failure $ 12B "non" replace relay No "Mil OFF"
relay
Broken or
disconnected wiring Check of wiring or
or defective relay replace relay
Short circuit to Check grid heater

AirHtStickOnIv Air Heater always on $ 12E "non" No "Mil OFF"
ground of grid heater switch and replace it
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
The ECU is switched
off by main electrical Inform driver about
Main Relay failure "comprehensive switch instead of correct vehicle shut
MRlyCDAftRun $ 225 No "Mil ON"
(Interrupted Afterrun) components" terminal 15, defective off, check wiring,
main relay, wiring replace main relay
problem
Short circuit of main all components
Failure is a NOx
relay 1 output to connected to main
Main Relay 1 (High dependent
MnRly1_SCG Pressure Pump) Short $ 228 "non" (potentially) longterm "Mil OFF"
to Ground failure (via LTF
group1 Fuel System)
ECU
Engine 1 (Temperature and Pressure Sensors)
Sensor defective or
short circuit to Check wiring or
Coolant Temperature Sensor defective or Check wiring or

CTSCD Sensor failure $ 131 "non" short circuit to ground replace sensor No "Mil OFF"
See OTS plausibility See OTS plausibility

check check
(Dfp_OTSCD.Npl) (Dfp_OTSCD.Npl)
Ensure that engine
Extreme ambient
was not running in
conditions. Or
extreme ambient
Clg_DynTst $ 132 "non" conditions. Check No "Mil OFF"
Dynamic failure (although sensor does
sensor, replacement
range)
of sensor
Boost Air replace sensor dependent
IATSCD Temperature Sensor $ 133 "non" external source (potentially) longterm "Mil OFF"
failure Sensor defective or Check wiring or failure (via LTF
short circuit to ground replace sensor group5 SCR System)
Base - May 2012
87
Base - May 2012
88
correction Failure
Sensor defective or
Failure is a NOx
dependent
Boost Pressure Sensor Sensor defective or Check wiring or
BPSCD $ 134 "non" (potentially) longterm "Mil OFF"
failure short circuit to ground replace sensor
failure (via LTF
Difference of ambient Check ambient and group5 SCR System)
and boost pressure is boost pressure sensor
out of range. for accuracy
Sensor defective or
Fuel Temperature external source replace sensor
FTSCD Sensor failure $ 135 "non" No "Mil OFF"
to external source or Check wiring and
defective pressure proper functioning of Failure is a NOx
sensor, rail pressure rail pressure sensor dependent
RailCD Rail Pressure Sensor $ 136 "non" overshoot "Mil OFF"
(potentially) longterm
failure
Short circuit of wiring failure (via LTF
Check wiring and group1 Fuel System)
to ground or
proper functioning of
defective pressure
rail pressure sensor
sensor
Check rail pressure
Defective rail pressure
sensor for plausible
sensor, defect in other
values, ensure proper
injection relevant
functioning of the
component
injection components
PRV does not open
once the pressure Check application
Common Rail value of maximum rail
limit is reached:
PRVMon Pressure Limiting $ 137 "non" No yes (technical) "Mil OFF"
Mechanical defect or pressure, check
Valve failure functioning of the PRV
wrong application
parameter
PRV does not open
Check application
even after pressure
value of maximum rail
shock: Stuck PRV or
pressure, check
wrong application
functioning of the PRV
parameter
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Sensor defective or

Oil Pressure Sensor Monitoring function

OPSCD failure $ 138 "non" for ADC Sig-error not No "Mil OFF"
explained in
documentation????
Check oil pressure
sensor or defect (e.g.
sensor for accuracy
blocked piping) in the
oil system.
Sensor defective or

OTSCD Oil Temperature $ 13A "non" No "Mil OFF"
Sensor failure Inaccurate oil or Check oil and coolant
coolant temperature temperature sensor
sensors or insufficient for accuracy and
oil or coolant check oil and coolant
recirculation (low system for proper
coolant level etc.). functioning
Ambient Air short circuit to Check wiring or
Temperature Sensor external source (potentially) longterm
EATSCD $ 13C "non" "Mil OFF"
failure (of Humidity failure (via LTF
Sensor) Sensor defective or Check wiring or
short circuit to ground replace sensor group5 SCR System)
Ensure that engine

Extreme ambient
was not running in
conditions. Or
extreme ambient
ClgAbsTst $ 232 "non" conditions. Check No "Mil OFF"
Test failure (although sensor does
sensor, replacement
range)
of sensor
Base - May 2012
89
Base - May 2012
90
correction Failure
Ensure correct wiring
and proper
functioning of rail
inaccurate Failure is a NOx
pressure sensor,
Rail Pressure Sensor "comprehensive
RailCDOfsTst $ 236 (potentially) longterm yes (technical) "Mil ON"
Offset Monitoring components" Ensure correct wiring failure (via LTF
and proper group1 Fuel System)
functioning of rail
inaccurate
pressure sensor,
replace sensor
sensor or defect (e.g. Check oil pressure
OPSCD1 Oil Pressure too low $ 238 "non" too low oil level, sensor for accuracy No "Mil OFF"
leakage...) in the oil and check oil system
system.
Inaccurate oil
temperature sensor Check oil
Oil Temperature too or defect (e.g. temperature sensor
OTSCD1 $ 23A "non" No "Mil OFF"
high blockage, insufficient for accuracy and
recirculation) in the check oil system
oil system.
Engine 2 (Speed sensing/actuators)

to wiring problem,
defective or
functioning of
incorrectly installed Failure is a NOx
crankshaft sensor
crankshaft speed dependent
Crankshaft Speed sensor (potentially) longterm
EngMCrS1 Signal failure $ 141 "non" yes (technical) "Mil ON"
Signal interrupted do failure (via LTF
Check wiring, sensor group2 Injection
to wiring problem,
installation and proper Timing System)
defective or
functioning of
incorrectly installed
crankshaft sensor
crankshaft speed
sensor
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Engine runs with defective or functioning of
EngMBackUp $ 142 "non" No yes (technical) "Mil OFF"
Camshaft Speed only incorrectly installed crankshaft sensor
crankshaft speed (evaluated raw
sensor signals)
Camshaft Speed camshaft phase sensor (evaluate raw signals)
EngMCaS1 Signal failure $ 143 "non" No yes (technical) "Mil OFF"
camshaft phase sensor (evaluate raw signals)
Signal interrupted do Check wiring, sensor Failure is a NOx
to wiring problem, installations and dependent
Offset between
defective or proper functioning of (potentially) longterm
EngMOfsCaSCrS Camshaft and $ 144 "non" "Mil ON"
incorrectly installed camshaft and failure (via LTF
Crankshaft
camshaft or crankshaft crankshaft sensors group2 Injection
sensor (evaluate raw signals) Timing System)
Base - May 2012
91
Base - May 2012
92
correction Failure
No reactions
necessary only if this
fault/information
status reoccurs
frequently. In this case
check driving
conditions of vehicle,
Info: Engine Engine overspeed has
EngPrtOvrSpd $ 14D "non" engine speed no "Mil OFF"
Overspeed Protection occurred
acquisition and
injection system for
quantity setpoint and
actual value during
fault recognition,
check also for ECU
errors
Check what faiure
A defect has occurred
evoked the
Info: OBD (in the EDC or DCU)
performance
Performance Limiter which triggered a
CoVehPrflmAct $ 14F "non" limitation and perform No "Mil OFF"
Intervention by performance
troubleshooting on
Legislation limitation via
the basis of this
corresponging Fids
defect.
Wrong manipulation
Advice operator not
of operator, button
to press button too
mechanically stuck in
Engine Compartment long, check device for
ECBtCDStop $ 24A "non" actuated position, No "Mil OFF"
Stop Button stuck mechanical and
electrical defect in
electrical defects,
device, defective
check wiring
wiring
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Fuel metering CR Systems
High pressure side:
Leakage in high
pressure section,
in open position,
worn high pressure
Failure is a NOx
Rail Pressure Positive pump, worn injector,
Check for defects dependent
Deviation High and leaking pressure
RailMeUn1 $ 152 "non" according to 'reason (potentially) longterm yes (technical) "Mil OFF"
High Fuel Flow relieve valve
of failure' list. failure (via LTF
Setpoint Value Low pressure side:
group1 Fuel System)
pump too low, gear
pump output too low
(fuel filter clogged,
leakage in low
pressure side).
open position,
without power due to Failure is a NOx
Rail Pressure Negative electricel error. Check for defects dependent
RailMeUn2 Deviation too High $ 153 "non" Low pressure side: according to 'reason (potentially) longterm yes (technical) "Mil OFF"
on Minimum Metering Pressure before gear of failure' list. failure (via LTF
pump too high (e.g. group1 Fuel System)
by pressure relieve
too high.
Base - May 2012
93
Base - May 2012
94
correction Failure
High pressure side:
Leakage in the high
pressure section,
in open position,
worn high pressure
Rail Pressure below pump, worn injector, Check for defects
RailMeUn3 Minimum Limit in $ 154 "non" leaking pressure according to 'reason No "Mil OFF"
Controlled Mode relieve valve. of failure' list.
Low pressure side:
pump too low or gear
pump output too low
(clogged fuel filter,
leak on output side).
open position,
Rail Pressure above electricel error. Check for defects
RailMeUn4 Maximum Limit in $ 155 "non" Low pressure side: according to 'reason No "Mil OFF"
Controlled Mode Pressure before gear of failure' list.
pump too high (e.g.
by pressure relieve
too high.
Leakage in the high
pressure section,
in open position, Check for defects
Rail Pressure Drop according to 'reason
RailMeUn6 $ 156 "non" worn high pressure No yes (technical) "Mil OFF"
Rate too High of failure' list.
pump, worn injector,
leaking pressure
relieve valve, injector
reflux too high.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Leakage in the high
pressure section,
in open position,
worn or defective
Setpoint of Rail Check for defects
high pressure pump,
RailMeUn7 Metering Unit not $ 157 "non" according to 'reason No yes (technical) "Mil OFF"
plausible in Overrun of failure' list.
Low pressure system:
'Zero delivery' is not
active in metering unit
(excessve leakage in
metering unit).
inaccurate, high
pressure pump
Fuel Flow Setpoint of defective. Check for defects
RailMeUn10 Common Rail $ 158 "non" Low pressure system: according to 'reason No yes (technical) "Mil OFF"
Metering Unit too low Metering unit reflux of failure' list.
too low, fuel system
leakage, metering unit
jammed in closed
position.
Broken or
disconnected wiring Check of wiring or Failure is a NOx
Common Rail or defective relay replace relay dependent
MeUnCDNoLoad Metering Unit Power $ 159 "non" (potentially) longterm "Mil OFF"
Stage failure Defective wiring, Check wiring, ECU, failure (via LTF
ECU, powerstage or power stage and group1 Fuel System)
metering unit metering unit
Info Fault: High
The 'High Pressure Wait until the 'High
Pressure Test (Rail
HpTst $ 15B "non" Test' is requested via Pressure Test' has No "Mil OFF"
Pressure Monitoring
a diagnostic tester terminated
deactivated)
Base - May 2012
95
Base - May 2012
96
correction Failure
Identify the defect
Info: Long Term Fuel path and follow the
system Failure troubleshooting
procedure of that
failure.
Failure is a NOx
Common Rail Short circuit of wiring dependent
Metering Unit Power to external source or Check of wiring or
MeUnCDSCBat $ 259 "non" (potentially) longterm "Mil OFF"
Stage Short to Battery inside relay replace relay
failure (via LTF
group1 Fuel System)
Identify the defect
Info: Long Term path and follow the
Injection timing Failure troubleshooting
procedure of that
failure.
Failure is a NOx
Common Rail
Short circuit of wiring dependent
Metering Unit Power Check of wiring or
MeUnCDSCGnd $ 359 "non" to ground or inside (potentially) longterm "Mil OFF"
Stage Short to replace relay
relay failure (via LTF
Ground
group1 Fuel System)
Identify the defect
Info: Long Term air path and follow the
system failure troubleshooting
procedure of that
failure.
Identify the defect
Info: Long Term NOx path and follow the
Sensor Failure troubleshooting
procedure of that
failure.
Identify the defect
Info: Long Term SCR path and follow the
System Failure troubleshooting
procedure of that
failure.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Injectors 1
injector replace injector. Failure is a NOx
dependent
Injectors 1 Injector Cylinder 1 $ 161 "fuel system" "Mil ON"
Depending on the (potentially) longterm
failure
pattern, various failure (via LTF
Check the wiring and group1 Fuel System)
reasons can cause the
the injection signals,
defect, internal ECU
replace ECU
problems also
possible
dependent
InjVlvCyl2A Injector Cylinder 2 $ 162 "fuel system" "Mil ON"
failure
replace ECU
problems also
possible
dependent
failure
replace ECU
problems also
possible
Base - May 2012
97
Base - May 2012
98
correction Failure
dependent
failure
replace ECU
problems also
possible
dependent
failure
replace ECU
problems also
possible
dependent
failure
replace ECU
problems also
possible
Failure is a NOx
Broken wire or
dependent
failure (via LTF
injector
group1 Fuel System)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Failure is a NOx
Broken wire or
dependent
failure (via LTF
injector
group1 Fuel System)
Failure is a NOx
Broken wire or
dependent
failure (via LTF
injector
group1 Fuel System)
Failure is a NOx
Broken wire or
dependent
InjVlvCyl4B $ 16A "fuel system" (potentially) longterm "Mil ON"
failure (via LTF
injector
group1 Fuel System)
Failure is a NOx
Broken wire or
dependent
InjVlvCyl5B $ 16B "fuel system" (potentially) longterm "Mil ON"
failure (via LTF
injector
group1 Fuel System)
Failure is a NOx
Broken wire or
dependent
InjVlvCyl6B $ 16C "fuel system" (potentially) longterm "Mil ON"
failure (via LTF
injector
group1 Fuel System)
See individual injector See individual injector
and injection-bank and injection-bank
errors (InjVlvCyl... and errors (InjVlvCyl... and
Minimum Injections
InjVlvNumMinInj $ 16E "non" InjVlvBnk...) which InjVlvBnk...) which No "Mil OFF"
Number not reached
have triggerd the have triggerd the
shut-off or error in shut-off or error in
the component the component
Base - May 2012
99
Base - May 2012
100
correction Failure
Injectors 2
Short circuit of
high-side to battery or Check the wiring or

low-side to ground in Check the wiring or dependent
injector cable. replace injector. (potentially) longterm
failure (via LTF
Depending on the group1 Fuel System)
problem
Short circuit of
high-side to battery or Check the wiring or

low-side to ground in Check the wiring or dependent
injector cable. replace injector. (potentially) longterm
failure (via LTF
Depending on the group1 Fuel System)
problem
Check the power
Clock error or
supply or replace
irrupton of the power
ECU if problem
supply voltage.
reoccurs.
Reset ECU. If no
Defective ECU recovery, replace
ECU Hardware for ECU.
Injection: CY33X
InjVlvChipA $ 17C "non" Check 'TESTMODE' No "Mil OFF"
Chip specific failure Internal failure of ECU
(1) parameters or replace
or 'TESTMODE' takes
ECU if problem
too long
reoccurs
Defective SPI-bus Replace ECU if
participant, timing problem reoccurs
problem due to (Send in ECU for
software bug investigation)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Replace ECU if
Defective ECU
problem reoccurs
ECU Hardware for Replace ECU if

Defective ECU
Injection: CY33X problem reoccurs
InjVlvChipB $ 27C "non" No "Mil OFF"
Chip specific failure Replace ECU if
(2) Defective ECU
problem reoccurs
Replace ECU if
Defective ECU
problem reoccurs
Air inlet system / EGR
Differential Pressure
Sensor Failure "comprehensive
IEDPCDPDiff $ 181 No "Mil ON"
between Exhaust and components"
Intake (EGR Valve)
Boost system and turbine speed

due to this failure
alone. If
powerreduction
occurred due to
Torque Reduction Active power actual defect, the
SmkTrqLim due to Smoke $ 19E "non" redcution due to failure triggering the No "Mil OFF"
Limitation smoke limitation torque limitation
failure memory.
Follow
troubleshooting of
this root error.
Application Determine what
dependent: defect has set the Fid
NOx Estimation
NOxEstIv $ 19F "non" Implausible sensor and resolve the No "Mil OFF"
failure
signals or defective problem causing this
sensors etc. original defect.
Base - May 2012
101
Base - May 2012
102
correction Failure
due to this failure
alone. If
powerreduction
occurred due to
actual defect, the
NTCTrqLim $ 29D "non" failure triggering the No "Mil OFF"
Negative Torque engine break shut off
torque limitation
Coordinator event
failure memory.
Follow
troubleshooting of
this root error.
due to this failure
alone. If
powerreduction
occurred due to
actual defect, the
BstPrtTrqLim $ 39E "non" failure triggering the No "Mil OFF"
Turbo Charger turbo charger
torque limitation
Protection protection
failure memory.
Follow
troubleshooting of
this root error.
due to this failure
alone. If
Info: Torque powerreduction
Limitation due to occurred due to
Active power
Engine Protection actual defect, the
redcution due to
EngPrtTrqLim (against Excessive $ 49E "non" failure triggering the No "Mil OFF"
engine mechanics
Torque, Engine torque limitation
protection
Overspeed and should also be in the
Overheat) failure memory.
Follow
troubleshooting of
this root error.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
due to this failure
alone. If
powerreduction
Active power occurred due to
Info: Torque
redcution due to actual defect, the
Limitation due to SCR
SCRPrtTrqLim $ 59D "non" excessive failure triggering the No "Mil OFF"
Catalyst Overheat
temperatures in the torque limitation
Protection
SCR catalyst should also be in the
failure memory.
Follow
troubleshooting of
this root error.
due to this failure
alone. If
powerreduction
occurred due to
Info: Torque Active power actual defect, the
NsCtlTrqLim Limitation due to $ 59E "non" redcution due to failure triggering the No "Mil OFF"
Noise Limitation noise control torque limitation
failure memory.
Follow
troubleshooting of
this root error.
due to this failure
alone. If
powerreduction
Info: Torque occurred due to
Limitation due to Fuel Active power actual defect, the
QLimTrqLim Quantity Limitation $ 69E "non" redcution due to failure triggering the No "Mil OFF"
because of Injection limiting fuel quantity torque limitation
System Errors should also be in the
failure memory.
Follow
troubleshooting of
this root error.
Base - May 2012
103
Base - May 2012
104
correction Failure
Exhaust system (Aftertreatment)
Check for proper
Failure is a NOx
CAN communication CAN communication
dependent
FrmMngNOxSensNO NOx Sensor "comprehensive disturbed, defective or and check accuracy
$ 1A2 (potentially) longterm yes (OBD) "Mil ON"
xIv Plausiblity failure components" inaccurate NOx and proper
failure (via LTF
sensor functioning of NOx
group4 NOx Sensor)
sensor.
Disconnected cable in Check wiring of NOx
the wiring of the sensor and its proper
NOx sensor or functioning. If
defective NOx necessary replace
sensor. NOx sensor.
Check wiring of NOx Failure is a NOx
Short circuit in the sensor and its proper dependent
"comprehensive wiring of the NOx
FrmMngNOxSensIv NOx Sensor Failure $ 1A3 functioning. If (potentially) longterm yes (OBD) "Mil ON"
components" sensor or defective necessary replace failure (via LTF
NOx sensor. NOx sensor. group4 NOx Sensor)
Strange driving cycle Check installation
or inproper (including wiring) and
installation of the functionality of sensor.
sensor, defective If necessary change
NOx sensor NOx sensor
Defective CAN
controller of NOx Check presence and
Sensor , undervoltage correct connection of
of NOx Sensor, the NOx Sensor to Failure is a NOx
CAN Message missing NOx Sensor, the network, Check dependent
FrmMngTONOxSensI timeout Nox (from CAN cable
$ 1A4 "non" correct functioning of (potentially) longterm yes (OBD) "Mil ON"
v Nox Sensor) connecting the NOx the NOx Sensor failure (via LTF
Sensor is CAN controller and group4 NOx Sensor)
disconnected or its voltage supply.
broken. Short circuit Check wiring.
in wiring.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Check presence and
Defective CAN
controller of DCU,
the DCU to the Failure is a NOx
undervoltage of DCU,
CAN Message network, check dependent
FrmMngTODM1DCU missing DCU, CAN
timeout DM1DCU $ 1A5 "catalyst monitoring" correct functioning of (potentially) longterm yes (OBD) "Mil ON"
Iv cable connecting the
(from DCU) the DCU CAN failure (via LTF
DCU is disconnected
controller and its group5 SCR System)
or broken. Short
circuit in wiring
wiring.
FrmMngTOSCR1Iv timeout SCR1 (from $ 1A6 "catalyst monitoring" missing DCU, CAN correct functioning of (potentially) longterm yes (OBD) "Mil ON"
DCU) cable connecting the the DCU CAN failure (via LTF
DCU is disconnected controller and its group5 SCR System)
Failure due to engine
switch off after a high
load period, leading to Read out the DCU
high temperatur in failure memory and
exhaust system. perform
A defect occurred in troubleshooting
the urea dosing according to DCU
Info: SCR Dosing system which can support.
FrmMngSCR1ProtIv Valve Overheat $ 1A8 "non" impair the cooling of No "Mil OFF"
Protection the urea dosing valve
Read out the DCU
A defect occurred in
failure memory and
the urea dosing
perform
system which can
troubleshooting
impair the cooling of
according to DCU
support.
Base - May 2012
105
Base - May 2012
106
correction Failure
short circuit to Check wiring. Replace
sensor if necessary dependent
Humidity Sensor external source
IAHSCDStrtDly $ 1AE "non" (potentially) longterm "Mil OFF"
Signal Ratio failure
Sensor defective or Check wiring. Replace failure (via LTF
short circuit to ground sensor if necessary group5 SCR System)
Check what SPN and Check what SPN and

A certain error has corresponding DCU corresponding DCU
Info: DCU Error1 via occured in the DCU error is active and error is active and
FrmMngDM1SPN1Iv CAN message $ 1AF "non" System and is perform perform yes (OBD) "Mil OFF"
DM1DCU reported via CAN to troubleshooting troubleshooting
the EDC. according to DCU according to DCU
support. support.
Check NOx sensor
for correct functioning
(dismount sensor ->
NOx value should be
0ppm during driving),
NOx sensor
check wiring of
inaccurate or
sensor, check fuel
injectors, check urea
wiring, urea injection Failure is a NOx
dosing system for
valve or fuel injector dependent
NOx Sensor Drift "comprehensive correct dosing
SCRCatNOxDrIv $ 2A2 jammed open, (potentially) longterm yes (OBD) "Mil ON"
failure components" amount (perform
excessive urea failure (via LTF
UDST and Dosing
deposits in exhaust group4 NOx Sensor)
Valve Check, check
system, strange
DCU error memory
behaviour of SCR
for leakage failures),
catalyst
check SCR catalyst for
for excessive urea
deposits
FrmMngTOSCR2Iv timeout SCR2 (from $ 2A6 "catalyst monitoring" missing DCU, CAN correct functioning of (potentially) longterm yes (OBD) "Mil ON"
DCU) cable connecting the the DCU CAN failure (via LTF
DCU is disconnected controller and its group5 SCR System)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
If failure 1AE
'IAHSCDStrDly' also
stored in memory:
proceed according
that description
If failure ACTIVE: run

engine at medium
speed > 10 min, if
failure does NOT get
INACTIVE: check
wiring harness and
replace sensor if
Sensor possibly necessary Failure is a NOx
Info: Humidity Sensor saturated with water dependent
IAHSCD possibly saturated $ 2AE "non" droplets If failure not active (potentially) longterm "Mil OFF"
with water droplets AND ratio 'active failure (via LTF
time' / 'occurrence' < group5 SCR System)
10 min/occurrence:
no action needed
If failure not active

AND ratio 'active
time' / 'occurrence' >
10 min/occurrence:
possible short circuit:
check wiring harness
or replace sensor, if
necessary
Sensor defective or Check wiring. Replace
short circuit to ground sensor if necessary
Check what SPN and
support.
Base - May 2012
107
Base - May 2012
108
correction Failure
Check urea dosing
system for correct
dosing amount
(perform UDST and
Dosing Valve Check,
NOx sensor check DCU error
inaccurate or memory for leakage
defective, defect in failures), check NOx
wiring, inaccurate sensor for correct Failure is a NOx
NOx estimation, urea functioning, check dependent
NOx Sensor "comprehensive injection valve
SCRCatNOxPlIv $ 3A2 wiring of sensor, (potentially) longterm yes (OBD) "Mil ON"
Plausibility failure components"
jammed open or check NOx failure (via LTF
excessive urea estimation (humidity, group4 NOx Sensor)
deposits in exhaust boost pressure and
system, defective SCR temperature) for
catalyst plausible values, check
SCR catalyst for
for excessive urea
deposits
Check what SPN and
support.
Check what SPN and
support.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Interfaces 1 (CAN-Bus)
Check timing
Wrong configuration
configuration with
of CAN timing
hardware
(Prescaler,
width, sampling,
and network
propagation and
connection and
NetMngCANAOff CAN A Bus off $ 1B1 "non" phase segments), bad No "Mil OFF"
to external source,
defective network
ground or CAN High
connection and
to Low.Monitor CAN
communication for
CAN controller with
erroneous behaviour
erroneous messages.
of a participant.
Check timing
Wrong configuration
configuration with
of CAN timing
hardware
(Prescaler,
width, sampling,
and network
propagation and
connection and
NetMngCANBOff CAN B Bus off $ 1B2 "non" phase segments), bad No "Mil OFF"
to external source,
defective network
ground or CAN High
connection and
to Low.Monitor CAN
communication for
CAN controller with
erroneous behaviour
erroneous messages.
of a participant.
Base - May 2012
109
Base - May 2012
110
correction Failure
Check timing
Wrong configuration
configuration with
of CAN timing
hardware
(Prescaler,
width, sampling,
and network
propagation and
connection and
NetMngCANCOff CAN C Bus off $ 1B3 "non" phase segments), bad No "Mil OFF"
to external source,
defective network
ground or CAN High
connection and
to Low.Monitor CAN
communication for
CAN controller with
erroneous behaviour
erroneous messages.
of a participant.
CAN Message
Iv (from Body
Computer)
in wiring. wiring.
FrmMngTOVM2EDCI timeout VM2EDC $ 1B5 "non" missing VCM, CAN correct functioning of No "Mil OFF"
Disturbed CAN,
Check CAN
incorrect
communication, check
configuration of the
CAN configuration,
CAN Transmit CAN, EDC is
FrmMngTxTO $ 1B7 "non" ensure proper No yes (OBD) "Mil OFF"
Message timeout disconnected from
connection of the
the network, EDC
EDC to the network,
CAN controller
replace EDC
defective
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Consult trouble
Defective MIL/Body shooting of body
Info: MIL visualization "comprehensive Controller or controller and check
FrmMngBC1MILIv $ 1B9 No "Mil ON"
not available components" disturbed CAN correct functioning of
communication the CAN
communication.
FrmMngTODashDsplI timeout Dash Display $ 1BA "non" missing VCM, CAN correct functioning of No "Mil OFF"
FrmMngTORxAMCO timeout AMCON $ 1BC "non" missing VCM, CAN correct functioning of No "Mil OFF"
NIv (from VCM) cable connecting the the VCM CAN
Defective CAN
controller of Body Check presence and
Computer or Vehicle correct connection of
Control Module , the BC or VCM to
CAN Message
undervoltage of BC or the network, check
timeout CCVS (from
FrmMngTORxCCVS $ 1BD "non" VCM, missing BC or correct functioning of No "Mil OFF"
Body Computer or
VCM, CAN cable the BC or VCM CAN
VCM)
connecting the BC or controller and its
VCM is disconnected voltage supply. Check
or broken. Short wiring.
circuit in wiring.
Base - May 2012
111
Base - May 2012
112
correction Failure
CAN Message
Iv (from Body
Computer)
in wiring. wiring.
Interfaces 2 (CAN messages timeout)
timeout ETC1 (from undervoltage of ETC, network, check
Tachograph Output , the TCO to the
CAN Message undervoltage of TCO, network, check
FrmMngTOTCO1 timeout TCO1 (from $ 1C3 "non" missing TCO, CAN correct functioning of No "Mil OFF"
Tachograph Output) cable connecting the the TCO CAN
TCO is disconnected controller and its
CAN Message
timeout active
FrmMngTOTSC1PEA TSC1-PE
ctIv (Torque/Speed
PTO to Engine)
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
network, Check
FrmMngTOTSC1VEA TSC1-VE VCM/BC, missing
the VCM/BC CAN
controller and its
disconnected or
wiring.
in wiring.
timeout ETC2 (from undervoltage of ETC, network, Check
CAN Message
timeout inactive
FrmMngTOTSC1PEPa TSC1-PE
sIv (Torque/Speed
PTO to Engine)
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
network, Check
FrmMngTOTSC1VRA TSC1-VR VCM/BC, missing
the VCM/BC CAN
controller and its
disconnected or
wiring.
in wiring.
Base - May 2012
113
Base - May 2012
114
correction Failure
Tachograph , the TC to the
Time/Date CAN undervoltage of TC, network, Check
FrmMngTOTimeDateI timeout (from $ 2C9 "non" missing TC, CAN correct functioning of No "Mil OFF"
v Tachograph or VCM) cable connecting the the TC CAN
TC is disconnected or controller and its
in wiring. wiring.
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
network, Check
FrmMngTOTSC1VEP TSC1-VE VCM/BC, missing
asIv (Torque/Speed VCM/BC, CAN cable
the VCM/BC CAN
controller and its
disconnected or
wiring.
in wiring.
Defective CAN
controller of Check presence and
Tachograph - High correct connection of
CAN Message Resolution Vehicle the BC to the
timeout HRVD (from Distance , network, Check
FrmMngTOHRVDIv Tachograph - High $ 3C9 "non" undervoltage of BC, correct functioning of No "Mil OFF"
Resolution Vehicle missing BC, CAN the BC CAN
Distance) cable connecting the controller and its
BC is disconnected or voltage supply. Check
broken. Short circuit wiring.
in wiring.
Defective CAN
Check presence and
Control Module or
the VCM/BC to the
network, Check
FrmMngTOTSC1VRP TSC1-VR VCM/BC, missing
asIv (Torque/Speed VCM/BC, CAN cable
the VCM/BC CAN
controller and its
disconnected or
wiring.
in wiring.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
ECU 1 (internal checks)
Electric disturbances,
ECU Hardware: SPI internal defect of the
Communication Replace ECU if failure
HWEMonCom $ 1D1 "non" ECU leading to a SPI No "Mil OFF"
failure remains present
bus communication
error
Wrong
correctly with a
proper dataset, if
defect persists:
defect of the EDC.
replace EDC.
Wrong
correctly with a
ECU Hardware: programming/flashing
HWEMonEEPROM $ 1D2 "non" proper dataset, if No "Mil OFF"
EEPROM failure of the EDC, internal
defect persists:
defect of the EDC.
replace EDC.
Wrong
correctly with a
proper dataset, if
defect persists:
defect of the EDC.
replace EDC.
Analyze what error
(Read out label
Electronic
HWEMon_numRecov
ery and compare the
ECU recovery - hardware defects
HWEMonRcyLocked $ 1D3 "non" value with the No "Mil OFF"
locked (ECU internal) or
configuration
error occurs
problems
replace EDC.
If error exists only
temporary (i.e.
injection reoccurs)
Defective monitoring
error can be ignored
module or CPU (e.g.
ECU Hardware: and error deleted in
impaired functioning
Montr Microcontroller $ 1D4 "non" the fault memory. In No "Mil OFF"
of the CPU clock) of
Watchdog failure case of a permanent
the EDC. Disturbed
error the injection
SPI-Bus.
remains blocked and
the ECU has to be
replaced
Base - May 2012
115
Base - May 2012
116
correction Failure
If failure remains after
Watch dog switch off ECU initialisation:
path defect replace ECU
ECU Hardware: Shut disturbances, internal ECU initialisation:
SOPTst off during Initialization $ 1D5 "non" No yes (technical) "Mil OFF"
disturbances, internal ECU initialisation:
Electronic
ECU Hardware: TPU disturbances, wrong If failure persists:
TPUMon $ 1D6 "non" No "Mil OFF"
Monitoring TPU timebase Replace ECU
ECU Software: See general remarks See general remarks

VarMngCodDs Variant Dataset failure $ 1D7 "non" No "Mil OFF"
See general remarks See general remarks
If ECU functions
correctly after
recovery only
temporary SPI error
occurred and fault
ECU Hardware:
memory can be
WdCom Controller Watchdog $ 1D8 "non" Disturbed SPI-Bus No "Mil OFF"
deleted and error
failure
ignored. If permanent
SPI error is present
and the ECU does
not leave boot block
--> Replace ECU
ADC Monitoring
ADCMon $ 1D9 "non" Buffer overrun No "Mil OFF"
failure
Analyze what error
(Read out label
Electronic
HWEMon_numRecov
ery and compare the
HWEMonRcySuppres ECU recovery - hardware defects
$ 2D3 "non" value with the No "Mil OFF"
sed suppressed (ECU internal) or
configuration
error occurs
problems
replace EDC.
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Analyze what error
(Read out label
Electronic
HWEMon_numRecov
ery and compare the
hardware defects
HWEMonRcyVisible ECU recovery - visible $ 3D3 "non" value with the No "Mil OFF"
(ECU internal) or
configuration
error occurs
problems
replace EDC.
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)

ECU Hardware: High
Side Power Stage Check of wiring or
StrtCDHS $ 1E1 "non" to ground or inside No yes (technical) "Mil OFF"
relay
Battery
1) Defective CAN or
immobilizer and new
control unit (here no 1) Ensure correct
PIN entry is possible) CAN functioning
OR T15 was toggled (timeout errors),
more than a unlock fuel release via
calibratable value OR a tester request,
number of allowed replace immobilizer
Immobilizer failure
ImmCtl $ 1E2 "non" incorrect PIN entries 2) Enter PIN code via No "Mil OFF"
(no fuel release)
is exceeded. accelerator pedal or
2) Defective CAN or instrument cluster,
immobilizer OR ensure correct CAN
wrong code AND functioning (timeout
code is kown by the errors), replace
EDC AND T15 has immobilzer
not been toggeled
excessively
Electronic
disturbances,
requested torque Check injection
Overrun Monitoring increase via tester, relevant application, if
OvRMon $ 1E3 "non" No "Mil OFF"
failure wrong application of failure persists replace
injection relevant ECU
parameters, defective
ECU
Redundant Engine Electronic If failure persists after
OvRMonSigA Speed in Overrun $ 1E4 "non" disturbances, internal reinitialization replace No "Mil OFF"
Monitoring ECU problem ECU
Base - May 2012
117
Base - May 2012
118
correction Failure
Excessive battery Check battery voltage,
ECU Hardware: EDC EDC, replace EDC
SSpMon12V Sensor 12V Supply $ 1E5 "non" No "Mil OFF"
Voltage failure Insufficient battery Check battery voltage,
EDC EDC, replace EDC
Excessive battery
voltage, defect in
check wiring for
wiring harness,
"comprehensive in the EDC
SSpMon1 Sensor Supply Voltage $ 1E6 No yes (technical) "Mil ON"
1 failure components" Insufficient battery
voltage, defect in
check wiring for
wiring harness,
electrical failure
EDC, replace EDC
in the EDC
Excessive battery
voltage, defect in
check wiring for
wiring harness,
in the EDC
voltage, defect in
check wiring for
wiring harness,
electrical failure
EDC, replace EDC
in the EDC
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
correction Failure
Excessive battery
voltage, defect in
check wiring for
wiring harness,
in the EDC
voltage, defect in
check wiring for
wiring harness,
electrical failure
EDC, replace EDC
in the EDC
Excessive voltage
component: High correct voltage supply,
HWEMonUMaxSuppl ECU internal Supply
$ 1E9 "non" battery voltage, check wiring. If defect No "Mil OFF"
y Voltage too high
defective wiring, remains replace EDC
internal defect of the (internal defect)
EDC
Insufficient voltage
Check the battery for
supply of a CJ940
sufficient voltage
component: Low
ECU internal Supply supply, check wiring. If
HWEMonUMinSupply $ 1EA "non" battery voltage, No "Mil OFF"
Voltage too low defect remains
defective wiring,
replace EDC (internal
internal defect of the
defect)
EDC
Base - May 2012
119
Base - May 2012
120
correction Failure
Replace ECU (not
necessary if never
Ambient pressure
running in high
sensor inside ECU is
altitude and if
defect
turbocharger without
VGT)
Replace ECU (not
Atmospheric Pressure sensor inside ECU is running in high
APSCD Sensor failure $ 1EB "non" No "Mil OFF"
defect altitude and if
VGT)
Replace ECU (not
necessary if never
Ambient pressure
running in high
sensor inside ECU is
altitude and if
defect
VGT)
ECU Hardware: Low
Side Power Stage Check wiring or
StrtCDLS $ 2E1 "non" to external source or No yes (technical) "Mil OFF"
inside relay
Battery
F4AE ENGINES
Print P2D32N020 E
Print P2D32N020 E
F4AE ENGINES
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS
RECOMMENDED TESTS OR
ANOMALY POSSIBLE CAUSE INTERVENTION REMARKS
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact that,
in case of insufficient fuel feeding, the
Possible exessive smoke. engine control module tries to
compensate prolonging the injectors
working time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of is working correctly.
overheating.
If the pump plunger is permanently
depressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filter's obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct Unless the leakage is significant, no
valve. connection of the pipe fittings under the performance failures will be detected.
feeding pump (the lockers must stay To verify O-rings integrity, extract from the
outside and the fittings must be well tank the fuel recycling pipeline, seal the end
locked). and activate the priming pump driving the
Visually check the low pressure pipeline low pressure circuit.
integrity.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace the
valve.
The engine suddenly stops (with no Obstructed fuel filter. Replace the fuel filter. Solve the cause of the filter's obstruction
previous problems) and does not start (empty and clean the tank and the part of
again. the circuit over the filter, refill with clean
fuel).
Base - May 2012
121
Base - May 2012
122
RECOMMENDED TESTS OR
ANOMALY POSSIBLE CAUSE INTERVENTION REMARKS
The engine disconnects or does not start. EDC7UC31 burned by short circuit on Eliminate the short circuit and replace the Verify that the wire line, close to the pedal,
the wiring harness of the friction clutch. EDC7UC31. is not exposed to.
Difficult start and low performance in all Inefficient high pressure pump. After having excluded any other possible
conditions. cause, replace the high pressure pump
.
Difficult start, low performance and engine Injector with obstructer or solenoid The non-working injector is easily In case of low entity blow-by, inficiating the
running with one cylinder less. (mechanical part) blocked open. recognisable detecting by feeling the mechanical working of the injector but not
absence of pulsing within the relevant high involving flow limiter activation, there is no
pressure pipe. error memorisation in the engine control
module.
Starting requires in excess of ten seconds, Injector blocked in open position (with no The non-working injector is easily Usually, whether such symptoms appear, it
followed by huge white exhaust fumes, and return). recognisable detecting by feeling the is instinctive to give up engine start.
a fuel smell. absence of pulsing within the relevant high However, by insisting, it is possible to start
pressure pipe. the engine.
As a matter of facts, by insisting, if within the
rail the pressure makes the flow limiter
close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the
screws. original position.
The engine works with one cylinder less, Injector blocked in closed position. Identify the injector that is not working any The non-working injector is easily
without memorising failure blink codes in more and the relating high pressure filler. recognisable detecting by feeling the
the engine control module. absence of pulsing within the relevant high
pressure pipe.
F4AE ENGINES
Print P2D32N020 E
F4AE ENGINES SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS 1
SECTION 6
Removal and installation of main
components
Page
REMOVAL AND INSTALLATION AUXILIARY DRIVE

BELT (DEMONSTRATION) . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL AND INSTALLATION

(DEMONSTRATION) . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLANT PUMP REMOVAL AND INSTALLATION

(DEMONSTRATION) . . . . . . . . . . . . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION STARTER

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE CABLE REMOVAL AND INSTALLATION 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL AND INSTALLATION LOW-PRESSURE

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS F4AE ENGINES
Page Page
REMOVAL AND INSTALLATION FUEL HOSE INJECTOR REMOVAL AND INSTALLATION . . 17

FROM HIGH PRESSURE PUMP TO
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . 8 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TURBOCHARGER REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE CONTROL UNIT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 EXHAUST MANIFOLD REMOVAL-
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL FILTER REMOVAL AND REFITTING . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD REMOVAL AND
FUEL FILTER REMOVAL AND REFITTING . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL AND INSTALLATION COMMON CYLINDER HEAD REMOVAL AND

RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OIL VAPOUR RECIRCULATION (BLOW-BY) ENGINE OIL FILTER REMOVAL AND

SYSTEM REMOVAL AND INSTALLATION . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TAPPET COVER REMOVAL AND INSTALLATION 13 REMOVAL AND INSTALLATION ENGINE OIL
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . 25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INJECTOR WIRING SUPPORT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14 OIL SUMP REMOVAL AND INSTALLATION
(DEMONSTRATION) . . . . . . . . . . . . . . . . . . . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL AND INSTALLATION ROCKER ARM
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

REMOVAL AND INSTALLATION ALTERNATOR REMOVAL AND

AUXILIARY DRIVE BELT INSTALLATION (DEMONSTRATION)
(DEMONSTRATION) Removal
Removal Disconnect the electrical connections of the alternator.
Figure 1 Remove the auxiliary components drive belt as described in
the relative procedure.
Figure 2
176526
Operate on the belt tensioner (1) and extract the belt (2)
from the alternator pulleys, the coolant pump and the return
pumps.
176527
Installation Undo the screws (1) and disconnect the alternator (2).
Turn the automatic belt tensioner (2) to fit the belt (1) on
pulleys and guide rollers.
Installation
Place the alternator (2) in position, fasten the screws (1) and
tighten them to the specified torque.
Install the auxiliary components drive belt as described in the
relative procedure.
Connect the alternator electrical connections.

COOLANT PUMP REMOVAL AND Figure 5

INSTALLATION (DEMONSTRATION)
Removal
Position a suitable container to catch any coolant.
Remove the auxiliary components drive belt as described in
Figure 3
176528
Place the coolant pump (2) in position, fasten the screws (1)
and tighten them to the specified torque.
relative procedure.
176528
Undo the screws (1) and remove the water pump (2).
Installation
Figure 4
70221
Apply a new seal ring (2) to the coolant pump (1).

THERMOSTAT REMOVAL AND REMOVAL AND INSTALLATION STARTER

INSTALLATION MOTOR
Removal Removal
Disconnect the starter motor electrical connections.
Figure 6 (D)
Figure 8
2
74166
Unscrew the flywheel cover fastening screws (1) and remove

176519
the starter motor (2).
(D) 4-cylinder engine
Figure 7 (*) Installation

Position the starter motor (2) on the internal part of the
flywheel cover (1).
Screw down the retaining screws and tighten them to the
specified torque.
Connect the starter motor electrical connections.
176529
(*) 6-cylinder engine

Unscrew the fastening screws (1) and remove the coolant
outlet coupling (2).
Then remove the thermostat (3) with its gasket.
Installation
Place the thermostat in position.
Place the coolant outlet coupling (1) in position with a new
gasket, screw in the retaining screws and tighten them to the
specified torque.

ENGINE CABLE REMOVAL AND INSTALLATION

Removal
Figure 9
107246
1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature
and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature
sensor - 9. Timing phase sensor - 10. Air temperature and pressure sensor - 11. Electro-injector
Disconnect the engine cable from the connectors: (1)

electro-injector wiring; (10) air pressure/temperature sensor;
(3) fuel pressure sensor; (6) EDC7 control unit; (9) camshaft
timing sensor; (7) fuel flow rate sensor; (8) fuel temperature
sensor; (2) engine coolant temperature sensor on
thermostat; (4) engine oil temperature and pressure sensor;
(5) engine speed sensor.
Open the straps holding the engine cable to the engine block
and remove it completely.
Installation
Place the engine cable in position, close the retaining straps
and connect the sensor, control unit and electro-injector
connectors (refer to Figure 8).

REMOVAL AND INSTALLATION LOW- Figure 12

PRESSURE FUEL LINES
Removal
Figure 10 (D)
116237
Position a suitable container to catch any fuel.

To disconnect the low pressure fuel hose from the relevant
connecting joint, you need to keep the clasp (1) pressed, and
release the quick fitting joint (2).
173236
(D) F4AE3481/2
Installation
To connect the low pressure fuel hose to the connection
fitting, insert the quick-fit coupling (2) in the connection
Figure 11 (*) fitting and push it in until the catch (3) engages.
NOTE Check proper fuel hose connection.
166625
(*) F4AE3681
1. Hose from fuel pre-filter to heat exchanger on engine
control unit - 2. Hose from heat exchanger on engine
control unit to fuel pump - 3. Hose from fuel pump to fuel
filter support - 4. Hose from fuel filter support to high
pressure pump intake - 5. Fuel return Hose from common
rail outlet and pressure limiter on cylinder head to filter
support - 6. Fuel return hose from high pressure fuel
pump outlet to filter support - 7. Fuel return hose from
filter support to fuel tank

REMOVAL AND INSTALLATION FUEL Installation

HOSE FROM HIGH PRESSURE PUMP TO Position a new fuel supply hose (2) and tighten its couplings
COMMON RAIL (1) to the high pressure pump and common rail to the
Removal specified torque.
NOTE The high pressure fuel hose must always be

Figure 13 (D) replaced with a new one whenever it is removed.
The hose couplings must be tightened to 20 Nm
torque using spanner 99317915 and torque
wrench 99389829.
173237
(D) F4AE3481/2
Figure 14 (*)
166632
(*) F4AE3681

ENGINE CONTROL UNIT REMOVAL AND FUEL FILTER REMOVAL AND

INSTALLATION INSTALLATION
Removal Removal
Disconnect the engine cable from the engine control unit Position a suitable container to catch any fuel.
electrical connections, as described in the relative section.
Figure 16 (D)
Disconnect the fuel hoses from the engine control unit heat
exchanger, as described in the relative section.
Figure 15
173238
(D) F4AE3481/2
2 Figure 17 (*)
74174
Remove the retaining screws (1) and disconnect the ECU (2)
including the heat exchanger.
Installation
Position the ECU, (2) including the heat exchanger, on the
crankcase and tighten the screws (1) to the specified torque.
166627
NOTE Replacing the elastic support elements is (*) F4AE3681

recommended.
Installation
Fully screw the fuel filter onto the connection on its support
by hand, then further tighten to a torque of 202 Nm.
Connect the fuel hoses to the engine control unit heat
exchanger, as described in the relative procedure.
Connect the engine cable to the engine control unit electrical
connections, as described in the relative procedure.

INJECTION PUMP REMOVAL AND REMOVAL AND INSTALLATION COMMON

INSTALLATION RAIL
Removal Removal
Position a suitable container to catch any fuel. Position a suitable container to catch any fuel.
Disconnect the low pressure fuel hose from the mechanical Disconnect the fuel pressure sensor connector as described
fuel pump and the high-pressure pump as described in the in the procedure regarding the engine cable.
relative procedure. Disconnect the low pressure fuel return hose from the
Remove the fuel hose from the high pressure pump to the common rail, as described in the relative procedure.
common rail as described in the relative procedure. Remove the fuel hose from the high pressure pump to the
common rail as described in the relative procedure.
Figure 18 Figure 19 (D)
166629
Remove the three retaining nuts (1) and remove the high
pressure pump (2) complete with the fuel supply pump (3).
173239
Installation (D) 4-cylinder engine

Position the high pressure pump (2) complete with the fuel
supply pump (3) and tighten the three retaining nuts (1) to
the specified torque. Figure 20 (*)
Install the fuel hose from the high pressure pump to the
Connect the low pressure fuel hose to the mechanical fuel
pump and the high-pressure pump as described in the relative
procedure.
166634

Disconnect the high pressure hose couplings (1) from the
common rail (2) and injector manifolds (3), then remove
them.

Figure 21 (D) Figure 23 (D)
173240 173241
Figure 24 (*)
Figure 22 (*)
166636

166635
Place the new high pressure fuel hoses (1) in position and
(*) 6-cylinder engine tighten the couplings to the electro-injector collectors (3)
and the common rail (2) to the specified torque.
Remove the intake manifold retaining screws (1) and remove
the common rail (2).
Installation NOTE The hoses (1), as they are subject to high pressure,
must be replaced every time they are removed.
Place the common rail (2) in position and tighten the screws The hose couplings must be tightened to a torque
(1) fastening it to the intake manifold to the prescribed of 24 4 Nm, using spanner 99317915 (4) and
torque. torque wrench 99389829 (5).
Install the fuel hose from the high pressure pump to the
Connect the low pressure fuel return hose to the common
rail, as described in the relative procedure.
Connect the fuel pressure sensor connector as described in
the procedure regarding the engine cable.

OIL VAPOUR RECIRCULATION Installation

(BLOW- BY) SYSTEM REMOVAL AND Place the blow-by filter (6) in position and tighten the
INSTALLATION fastening screws.
Removal
Place the pipe (5) in position with new copper washers in
the tappet cover and timing case couplings (4). Then tighten
Figure 25 the couplings (4) to the specified torque.
Place the blow-by pipe (3) into the coupling located on the
timing case and secure it with the elastic strap (2).
Insert the upper coupling of the new blow-by pipe (5), with
a new seal ring, into the tappet cover and tighten the screw
(1).
166631
166631
Undo the screw (1). Loosen the elastic strap (2) and remove
the blow-by pipe (3).
Unscrew the couplings (4) and remove the pipe (5).
Undo the screws and remove the blow-by filter (6).

TAPPET COVER REMOVAL AND Figure 28

INSTALLATION
Removal
Figure 26
166630
Install the tappet cover (7) and tighten the nuts (6) to the
specified torque.
Place the pipe (5) in position with new copper washers in the
166630 tappet cover and timing case couplings (4). Then tighten the
couplings (4) to the specified torque.
Undo the screw (1). Loosen the elastic strap (2) and remove
the blow-by pipe (3). Place the blow-by pipe (3) into the coupling located on the
Remove the nuts (6) and take off the tappet cover (7) a new seal ring, into the tappet cover and tighten the screw
complete with seal. (1).
Installation
Figure 27
74757
Fit a new gasket (2) on the tappet cover (1).

INJECTOR WIRING SUPPORT REMOVAL Figure 31

AND INSTALLATION
Removal
Remove the tappet cover as described in the relative section.
Disconnect the engine cable from the injector wiring
connections, as described in the relative section.
Figure 29
99227
Fit the wiring bracket (2) and tighten the screws (1) to the
specified torque.
NOTE Always check that the threads on the screws and

their holes do not show any signs of wear or traces
of dirt before fitting.
166637
Remove the nuts (1) and disconnect the electrical cables

from the injectors (2). Figure 32
Take out the screws (3) and remove the injector wiring
bracket (4) together with the gasket.
Installation
Figure 30
99228
Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the retaining
nuts (2) to the specified torque.
Connect the engine cable to the injector wiring connections,
74756 as described in the relative procedure.
Check the condition of the electrical cables (5), if they are Install the tappet cover as described in the relative section.
damaged replace them by cutting the straps (2) securing
them to the bracket and removing the screws (4) securing
the connectors to this (3).
Fit a new gasket (1) on the bracket (2).

REMOVAL AND INSTALLATION ROCKER Figure 35

ARM ASSEMBLY
Removal
Remove the injector wiring support as described in the
relative section.
Figure 33
70343
ROCKER ARM ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rocker arms
Figure 36
70132
Loosen the tappet adjuster retaining nuts (1) and unscrew

the adjusters.
Unscrew the screws (2) and remove the rocker arm
assembly (3), composed of: bracket (6), rocker arms (4),
shafts (5).
Remove the bridges (7) from the valves and extract the rods
(8).
Installation 70344
Figure 34 SHAFT-ROCKER MAIN DATA

Check that shaft/rocker arm coupling surfaces are not
excessively worn or damaged.
Figure 37
122587
The control rods of the rocker arms must have no

deformations; the spherical seats for contact with the rocker
arm adjustment screw and with the tappets (arrows) must
show no trace of seizure or wear; if they do, replace them.
The intake and exhaust valve control rods are identical and
are therefore interchangeable.
74765
Fit the rods (2).

Position the bridges (1) on the valves with the marks ()
facing the exhaust manifold.

Figure 38
NOTE In order to perform the rocker arm - valve
clearance adjustment more quickly, proceed as
follows:
4-cylinder engines
- Rotate the crankshaft, balance the valves of
cylinder no. 4 and adjust the valves marked by
the asterisk as shown in the tables below:
cylinder no. 1 2 3 4
intake - - * -
exhaust - * - *
70346
Check that tappet adjusters (1) are loosened to prevent their cylinder no. 1 2 3 4
catching on the rods (2, Figure 37) when refitting the rocker intake - - * -
arm assembly.
exhaust - * - *
Then install the rocker assembly consisting of the bracket (5),
rockers (3) and shafts (4), securing them to the cylinder head
by tightening the retaining screws to 36 5 Nm. 6-cylinder engines
Figure 39
intake * * - * - -
exhaust * - * - * -

intake * * - * - -
exhaust * - * - * -
70520
Install the injector wiring support as described in the relative
Adjust the clearance between the rocker arms and valves section.
using Allen key (1), box wrench (3) and feeler gauge (2).
Install the tappet cover as described in the relative section.
The operating clearance is:
- 0.25 0.05 mm for the intake valves

INJECTOR REMOVAL AND INSTALLATION Figure 42

Removal
Remove the injector wiring support as described in the
relative section.
Remove the rocker arm assembly as described in the relative
section.
Figure 40
70133
Remove the injector fastening screws and use tool 99342101

(1) to remove the injectors (2) from the cylinder head.
Installation
Figure 43
166638
Disconnect the high pressure hose couplings (1) from the

common rail (2) and injector manifolds (3), then remove
them.
70338
Fit a new seal ring (2) lubricated with vaseline and a new
Figure 41
washer (3) on the injector (1).
Figure 44
166630
Unscrew the nuts (1) and remove the fuel manifolds (2). 70339
Place the injectors (1) in position on the cylinder head seats

so that the fuel inlet hole (2) is facing the fuel manifold seat
(3) side.

Figure 45 Figure 47
70342
Gradually and alternately tighten injector fixing screws (1) in

four stages:
70133 - 1st stage, tightening to 3.5 0.35 Nm torque with
dynamometric wrench.
Use tool 99342101 (1) to fit the injector (2) into position.
- 2nd stage, tightening to 25 1 angle;
Screw in the injector fastening screws without tightening
them. - 3rd stage, tightening to 25 1 angle;
- 4th stage, tightening to 25 1 angle.
NOTE Tightening to angle is performed using tool

Figure 46 99395216.
Tighten the fuel manifold (3) retaining nuts (2) to 50 5 Nm.
Figure 48
91572
Fit a new seal ring (3), lubricated with Vaseline, onto a new
fuel manifold (2).
Position the fuel manifold in place on the cylinder head seat
so that the positioning balls (5) coincide with the relevant 166640
housing (4).
tighten the couplings to the electro-injector collectors (3)
NOTE Fuel manifolds (2) must not be reused after and the common rail (2) to the specified torque.
removal but rather replaced with new ones.
NOTE The hoses (1), as they are subject to high pressure,

Screw on the fastening nuts (2, Figure 47) without tightening The hose couplings must be tightened to a torque
them fully. of 20 Nm, using spanner 99317915 (4) and torque
wrench 99389829 (5).
NOTE During this operation, manoeuvre the injector (1)
so that the manifold (2) is properly inserted into
the injector fuel inlet hole (2, Figure 44). Install the rocker arm assemblies as described in the relative
chapter. Install the injector wiring support as described in the
relative section. Install the tappet cover as described in the
relative section.
TURBOCHARGER REMOVAL AND INSTALLATION

Removal
Figure 49 (D) Undo the retaining screws and remove the oil return pipe (1)
from the engine block.
Unscrew the couplings on the heat exchanger/oil filter and
on the turbocharger and remove the oil supply pipe (2) from
the turbocharger.
Undo the nuts (3) and remove the turbocharger (4) from the
exhaust manifold (5).
Installation
Place the turbocharger (4) in position on the exhaust
manifold (5), after fitting a new gasket.
Screw down the retaining nuts (3) and tighten them to the
specified torque.
Place the oil supply pipe (2) in position on the turbocharger,
after fitting a new gasket and tighten the couplings on the
heat exchanger/oil filter bracket and on the turbocharger to
the specified torque.
Place the pipe (1) in position on the engine block, after fitting
a new gasket and tighten the retaining screws (1) to the
176520
specified torque.
(D) F4AE3481/2
Figure 50 (*)
176530
(*) F4AE3681

EXHAUST MANIFOLD REMOVAL AND Installation

INSTALLATION Place the exhaust manifold (2) with new gaskets in position.
Removal Insert the fixing screws (1) and tighten them to the specified
Remove the turbocharger as described in the relative section. torque.
Install the turbocharger as described in the relative section.
Figure 51 (D)
176521
(D) F4AE3481/2
Figure 52 (*)
176531
(*) F4AE3681

INTAKE MANIFOLD REMOVAL AND Installation

INSTALLATION Apply a sufficient layer of LOCTITE 5999 to the contact
Removal surface of the intake manifold (2) complete with the
Remove the common rail as described in the relative section. cold-start heater (if fitted).
Disconnect the cold-start heater electrical connections (if Place the intake manifold (2) in position and tighten the
fitted). retaining screws (1) to the specified torque.
Install the common rail as described in the relative section.
Connect the cold-start heater electrical connections (if
Figure 53 (D) fitted).
176522
(D) F4AE3481/2
Figure 54 (*)
176532
(*) F4AE3681

CYLINDER HEAD REMOVAL AND

INSTALLATION
Removal
Remove the engine cable as described in the relative section.
Remove the thermostat as described in the relative section.
Remove the common rail as described in the relative section.
Remove the rocker arm assembly as described in the relative
section.
Remove the injectors as described in the relative section.
Remove the turbocharger as described in the relative section.
Remove the exhaust manifold as described in the relative
section.
Remove the intake manifold as described in the relative
section.
Figure 55
74779
Undo the retaining screws, hook metal cables onto the

brackets (1) and remove the cylinder head (2) from the
engine block using a hoist.
Remove the head gasket.

Installation Figure 58
Figure 56
75703
NOTE Before re-using retaining screws (1) measure

diameters D1 and D2 as shown in the figure:
- if D1-D2 < 0.1 mm the screw can be reused
- if D1-D2 > 0.1 mm the screw must be
replaced
70335
Clean the cylinder head and engine block contact surfaces.

There are two types of head gasket:
- Type A 1.25 mm thick
- Type B 1.15 mm thick
Check the average projection S of the pistons as indicated on their holes do not show any signs of wear or traces
page 29 of Section 7. of dirt before fitting.
If S > 0.40 mm use gasket type A.
If S 0.40 mm use gasket type B.
Take care not to get the cylinder head gasket dirty. Figure 59
Arrange a new cylinder head gasket (1) on the engine block
with the marking TOP facing the head.
The arrow shows the point where the gasket thickness is
marked.
Figure 57

74766
Insert the cylinder head (1) retaining screws (2) and tighten
them in three stages, following the order and method shown
in the figure below.
NOTE The external screws are the shortest.
74779
Position the cylinder head (2), supported by the brackets (1),

on the seal. NOTE Use tool 99395216 (3) for angle tightening.

Figure 60 (D) ENGINE OIL FILTER REMOVAL AND

INSTALLATION
Removal
Position a suitable container to catch any engine oil.
Figure 62

A
70337
Figure 61 (*)
166649
70476 Installation
Lubricate the seal ring (2) with engine oil and set it on the oil
(*) 6-cylinder engine filter (1).
Diagram of the tightening sequence for the cylinder head Screw the oil filter (1) all the way on to the support
fixing screws: connection (3) by hand and then tighten to 182 Nm.
- 1st pre-tightening stage, with torque wrench: Run the engine for a few minutes and then check the level
Screw 12x1.75x130 ( ) 35 5 Nm using the dipstick: the level must be near the MAX mark on
Screw 12x1.75 x 150 ( ) 55 5 Nm the dipstick.
- 2nd tightening stage to a 90 2 angle If it is much below this level, top up with the necessary
quantity.
- 3rd tightening stage to a 90 2 angle
A = Front side
Install the intake manifold as described in the relative section.
Install the exhaust manifold as described in the relative
section.
Install the turbocharger as described in the relative section.
Install the injectors as described in the relative section.
Install the rocker arm assemblies as described in the relative
chapter.
Install the common rail as described in the relative section.
Install the thermostat as described in the relative section.
Install the engine cable as described in the relative section.

REMOVAL AND INSTALLATION ENGINE Installation

OIL HEAT EXCHANGER
Figure 64
Removal
Remove the auxiliary components drive belt as described in
Remove the alternator as described in the relative section.
Position a suitable container to catch any engine oil.
Remove the engine oil filter as described in the relative
section.
Figure 63
107275
Fit the following on the engine block: a new gasket (1), the
heat exchanger (2) a new gasket (3) and the oil filter bracket
(4).
Tighten the screws (5) to the specified torque.

166651
Unscrew the coupling (1) and remove the turbocharger oil

delivery pipe (2).
Remove the screws (3) and the oil pressure / temperature
sensor (4).
Remove the screws (5) and disassemble the oil filter / heat
exchanger bracket (6), intermediate plate (6) and relative
gaskets.

Figure 65 OIL SUMP REMOVAL AND INSTALLATION

(DEMONSTRATION)
Removal
Place a suitable container under the oil sump drain plug to
catch the oil.
Open the oil filler on the cylinder head and remove the
dipstick to aid the flow of oil.
Unscrew the drain plug and let the oil in the sump drain
completely.
NOTE It is recommended to drain the oil when the engine

is hot.
166652
Place the oil temperature/pressure sensor (2) in position on

the bracket (1) with a new seal ring then screw in the Figure 66
retaining screws (3) and tighten them to the specified torque.
Install the oil delivery pipe (1), screwing on the coupling (2).
Install the engine oil filter as described in the relative section.
Install the alternator as described in the relative section.
relative procedure.
Check the oil level with the dipstick: the level must be near
the MAX mark on the dipstick.
If it is much below this level, top up with the necessary
quantity.
74775
Undo the screws (2) then remove the plate (3) and oil sump
(1), retaining the gasket.

Installation Figure 68
Figure 67
74775
74770
Place the oil sump (1) in position and apply the plate (3) to
it.
Set the gasket (1) on the oil sump (2).
Screw on the drain plug with a new washer and proceed to
NOTE If it does not show any signs of damage the gasket fill with clean oil.
can be reused.
Use only recommended oils or those with the

required characteristics to ensure correct operation
of the engine.
Failure to observer these requirements shall void the
guarantees.
Check the oil level with the dipstick: the level must be near
the MAX mark on the dipstick.
If it is much below this level, top up with the necessary
quantity.


F4AE ENGINES SECTION 7 - GENERAL MECHANICAL OVERHAULING 1
SECTION 7
General mechanical overhauling
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 3
FITTING THE ENGINE TO THE ROTATING

STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL OF MAIN COMPONENTS . . . . . . . 5
BENCH ENGINE BLOCK DISASSEMBLY . . . . . 13
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Controls and measurements . . . . . . . . . . . . . . 15
- Checking head supporting surface on cylinder

unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 16
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Cam lift check and pin alignment check . . . . . 17
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 18
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Fitting tappets camshaft . . . . . . . . . . . . . . . . 19
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Measuring journals and crankpins (4-cylinder) . 20
- Measuring journals and crankpins (6-cylinder) . 22
CONNECTING ROD PISTON ASSEMBLY . . 24
- Connecting rod-piston assembly removal . . . . 24
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 27

2 SECTION 7 - GENERAL MECHANICAL OVERHAULING F4AE ENGINES
Page Page
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVING THE ENGINE FROM THE ROTATING
- Fitting connecting rod-piston assembly . . . . 28 STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
- Connecting rod-piston assembling . . . . . . . 28 COMPLETING ENGINE ASSEMBLY . . . . . . . . . 53
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . 28 CHECKS AND INSPECTIONS . . . . . . . . . . . . . . 55

BENCH ENGINE BLOCK ASSEMBLY . . . . . . . . 29
- Replacing oil pump control gear . . . . . . . . . 29
- Fitting main bearings . . . . . . . . . . . . . . . . . . 29
- Crankshaft installation . . . . . . . . . . . . . . . . . 29
- Checking crankshaft end float . . . . . . . . . . . 30
- Fitting connecting rod half bearings . . . . . . 31
- Fitting connecting rod-piston assembly into

cylinder barrels . . . . . . . . . . . . . . . . . . . . . . 31
- Checking piston protrusion . . . . . . . . . . . . . 32
CYLINDER HEAD DISMANTLING . . . . . . . . . . 33
- Removing the valves . . . . . . . . . . . . . . . . . . 33
- Checking cylinder head wet seal . . . . . . . . . 33
- Checking cylinder head supporting surface . 34
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Removing carbon deposits, checking and grinding

valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Checking clearance between valve stem and

valve guide and valve centering . . . . . . . . . . 35
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . 35
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Regrinding - replacing the valve seats . . . . . 35
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLING CYLINDER HEAD . . . . . . . . . . . . 38
REFITTING MAIN COMPONENTS . . . . . . . . . . 39

INTRODUCTION Figure 2 (*)

The following description covers general mechanical
overhaul starting from the engine which has been removed
from the vehicle.
NOTE Refer to the specific publication for removing the

engine from the vehicle.
Engine removal operations, as with overhauling,
must be carried out by specialised personnel with
specific equipment.
166072
This section contains:
- the operations to perform for mounting the engine on (*) F4AE3681
the rotating stand,
To apply the brackets 99361037 to the engine block for
- the sequence of removal operations for the main com fastening the engine to the overhaul stand, proceed as
ponents, follows, working from the left side of the engine:
- overhaul of the engine block and the cylinder head, - Position a suitable container to catch any fuel.
- the sequence of refitting operations for the main com - Using tool 99360076, remove the fuel filter (1) from its
ponents, support.
- operations required for completing engine assembly - Unplug the fuel temperature sensor and the camshaft
after removal from the rotating stand, timing sensor electrical connections (2).
- final checks and tests. - Disconnect the low-pressure fuel hoses (3) from the
Part of the operations covered in this section can be filter support.
performed directly on the engine still fitted in the vehicle, in - Unscrew the fastening screws and remove the fuel filter
relation to their accessibility in the engine compartment and support (4) complete with the bracket, if fitted, from the
on the vehicle version; these are listed in Section 6 - engine block.
Removal-refitting of main engine components.
- Unscrew the couplings, disconnect the high-pressure
fuel hose (5) from the common rail and high-pressure
pump, open the fastening straps and remove it from the
engine block.
FITTING THE ENGINE TO THE ROTATING
STAND
Figure 1 (D)
173245
(D) F4AE3481/2
- Disconnect the low-pressure fuel hose (6) supplying the Figure 5 (*)
mechanical pump connected to the high pressure pump
via the electronic control unit heat exchanger.
- Remove the oil delivery pipe, if present, unscrewing and
removing the retaining screws. Remove the O-ring from
the pipe.
NOTE Because of the high pressure in the hoses running

from the high pressure pump to the rail and from
this to the injectors, you must absolutely avoid:
- Disconnecting the hoses when the engine is
running
- Reusing hoses after they have been removed
176533
(*) F4AE3681
From the right of the engine, unscrew the retaining screws
Figure 3 and remove the oil outlet pipe (1) from the turbocharger (2)
and the engine block.
Figure 6
116237
To disconnect the low pressure fuel hose from the relevant

connecting joint, you need to keep the clasp (1) pressed, and 2
release the quick fitting joint (2).
74166
Figure 4 (D)
Unscrew the flywheel cover retaining screws (1) and remove
the starter motor (2).
Fit brackets 99361037 to the engine block and use these to
secure the engine to the rotating stand 99322205.
Drain the oil from the engine by removing the plug from the
oil sump.
Remove the fan from the crankshaft pulley.
Dispose of the oil according to applicable laws.
176523
(D) F4AE3481/2

REMOVAL OF MAIN COMPONENTS
Figure 7
107246
1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature
and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature
sensor - 9. Camshaft timing sensor - 10. Air temperature and pressure sensor - 11. Electro-injector.
Disconnect the following engine cable connectors: (1) electro-injector wiring; (10) air pressure/temperature sensor; (3) fuel
pressure sensor; (6) EDC7 control unit; (9) camshaft timing sensor; (7) fuel flow rate regulator; (8) fuel temperature sensor; (2)
engine coolant temperature sensor on thermostat; (4) engine oil temperature and pressure sensor; (5) engine speed sensor.
Open the straps holding the engine cable to the engine block and remove it completely.

Figure 8 (D) Figure 10
173247
Figure 9 (*)
166077
Disconnect the pipe (2) from the fuel return pressure relief
valve (1), as described in Figure 3.
Unscrew the screw (3), loosen the retaining strap (4) and
remove the blow-by pipe (5).
Undo the screws and remove the blow-by filter (8).
Unscrew the nuts (10) and remove the tappet cover (9).
Figure 11
107247

Disconnect the fuel hose (3) from the rail (2) according to
the procedures described in Figure 3. Disconnect the fuel
hose (5) from the rail (2) and from the injector manifolds (4).
Remove the screws (1) and remove the rail (2).
74744
Remove the nuts (7) and disconnect the electrical cables

from the electro-injectors (8).
Undo the screws (1) and remove the injector wiring support
(2), complete with gasket.
Remove the screws (5) and detach the air
temperature/pressure sensor (6).
Undo the nuts (3) and remove the fuel manifolds (4).
NOTE Fuel manifolds (4) must not be reused after

removal but rather replaced with new ones.

Figure 12 Figure 14 (Demonstration)
70132 176526
Loosen the tappet adjuster retaining nuts (1) and unscrew the Operate on the belt tensioner (1) and extract the belt (2)
adjusters. from the alternator pulleys, the coolant pump and the return
pumps.
Remove screws (2), disassemble the rocker unit (3) including
support (6), rocker arms (4),and shafts (5) and remove the Unscrew the fastening screw and remove the belt tensioner
bridges (7) from the valves. (1).
Remove the rods (8). Unscrew the screws fastening the alternator to its bracket
and remove it.
Figure 13
70133
Undo the injector fastening screws and use tool 99342101 (1)
to remove the injectors (2) from the cylinder head.

Figure 15 (D) Figure 17 (D)
176525
(D) F4AE3481/2
176524
(D) F4AE3481/2 Figure 18 (*)
Figure 16 (*)
176535
(*) F4AE3681
From the opposite side, undo the intake manifold (1)
176534 retaining screws and remove it, complete with the cold-start
(*) F4AE3681 heater (if fitted).
Unscrew the couplings on the heat exchanger/oil filter

support and on the turbine, disconnect the oil supply pipe (3) Figure 19
and remove it.
Remove the retaining nuts and disconnect the turbocharger
(1) from the exhaust manifold (2).
Undo the screws and remove the exhaust manifold (2) from
the cylinder head.
74779
Undo and remove the cylinder head retaining screws.

Hook metal cables onto the brackets (1) and remove the
cylinder head (2) from the engine block using a hoist.

Figure 20 Figure 23
1 4 3
2
166083 74176
Undo the screws (1) and remove the alternator bracket (2). Undo the screws (3) and remove the cover (1). Retrieve the
gasket (4), the PTO (2) and the second gasket (4).
Use tool 99360076 to remove the oil filter (3).
Figure 21 Figure 24
70145
166085
Remove nut (1) and detach the timing sensor (2).
Remove the screws (1) and the oil pressure / temperature Remove the nuts (3) and disconnect the high pressure pump
sensor (2). (4) including the fuel supply pump (5).
Undo the screws (3) and remove the oil filter / heat
exchanger support (4), intermediate plate (5) and relative
gaskets. Figure 25
Figure 22
70146
74174
Remove the screws (1) and disconnect the electronic Apply the tool 99360351 (2) to the flywheel housing (1), to
control unit (2) complete with heat exchanger. stop the flywheel (3) from rotating.
Unscrew the screws (4).

Figure 26 Figure 29
108548
Undo the screws (3) and remove the damper (2) and the
pulley (1). 00904t
The flywheel blocking device can help aid removal of the

damper (2) fitted to the pulley (1). Fit the appropriate tie-rod (3) of tool 99363204 onto the
external seal (2) as illustrated in the figure and, using the lever
(4), extract it from the front cover (1).
Figure 27
Figure 30
176536
176537
Undo the screws (1) and remove the coolant pump (2).
Undo the screws (3) and remove the roller (4). Remove screws (1 and 3) and take off the front cover (2).
Undo the screw (5) and remove the engine speed sensor (6).
NOTE Note down the installation positions of the screws

Figure 28 (1) since they are of different lengths.
00900t
Extract the crankshaft front cover seal. Fit the tool 99340055
(4) onto the front shank (2) of the crankshaft. Through the
guide holes in the tool, perforate the internal seal (1) with a
drill bit ( 3.5 mm) to a depth of 5 mm.
Secure the tool to the ring (1) with the 6 screws provided.
Then extract the ring by screwing in the screw (3).

Figure 31 Figure 34
Undo the screws (1) and remove the oil pump (2).
Figure 32 00903t
Extract the flywheel housing seal ring by fitting tool

99340056 (3) on the rear shank (5) of the drive shaft.
Through the guide holes of the tool, perforate the internal
seal ring with a drill bit ( 3.5 mm) to a depth of 5 mm.
Fix tool 99340056 (3) to the ring (1) by means of the 6
screws (4) provided.
Proceed to remove the ring (1) by screwing in the screw (2).
Fit the appropriate tie-rod of tool 99363204 onto the
flywheel housing external seal and extract it using the lever.
70151
Remove the two opposing screws (1) where the extraction

pins will be inserted (2, Figure 33).
Undo the remaining screws fastening the flywheel (3) to the Figure 35
drive shaft (4).
Remove flywheel blocking tool 99360351.
Figure 33
70153
Undo the screws (2) and remove the flywheel housing (1).
70152

Screw two medium-length screws into the holes (4) in order (2) since they are of different sizes.
to sling the flywheel with a hoist.
Remove the flywheel (1) using the hoist, guided by the two
guide pins (2) previously screwed into the holes in the drive
shaft (3).

Figure 36 Figure 38
74775
70156
Turn the engine over.
Remove the screws (2), disassemble the frame (3) and Remove the screws (1) and remove the gear (3) from the
remove the oil sump (1). camshaft (2).
Figure 39
NOTE The size and shape of the sump and suction strainer
vary depending on the engine use.
The illustrations therefore provide a general
outline of the procedure to be performed.
The procedures described are applicable in any
case.
Figure 37
70157
Undo the screws (2) and remove the timing gear case (1).

(2) since they are of different sizes.
86516
Undo the screws (1 and 4) and remove the oil suction

strainer (5).
Undo the screws (2) and remove the stiffening plate (3).
NOTE The stiffening plate (4) has a single part in the

engines.

BENCH ENGINE BLOCK DISASSEMBLY Figure 42
Figure 40
70160
70158
The second-last-main cap (1) and its relevant support have
the half-bearing (2) equipped with shoulder.
Remove and remove the connecting rod cap (2) fixing
screws (1).
Extract the pistons together with the connecting rods from NOTE Write down the upper and lower half-bearing
the top of the crankcase. assembling position, in the event of use, they should
be mounted in the position detected when
NOTE Maintain the half-bearings in their relevant seats disassembling.
because, in the event of use, they should be
mounted in the position detected when
disassembling. Figure 43 (D)
Figure 41
70161
Figure 44 (*)
70159
Remove the screws (1) and remove the main caps (2).
74774

Remove the crankshaft (2) from the block by means of tool
99360500 (1) and hoister.

zs
Figure 45 Figure 47
70164
70162 Carefully withdraw the camshaft (1) from the crankcase.

Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Figure 48
Figure 46
70163
70165
Remove the screws (1) and remove the camshaft (3) check
plate (2)
Withdraw the tappets (1) from crankcase.
NOTE Write down the plate (2) assembling position.

CRANKCASE Figure 51
Controls and measurements
Figure 49 (D)
70167
The measurements must be performed for each individual

cylinder at three different heights from the barrel and on two
perpendicular surfaces: one parallel to the longitudinal engine
axis (A) and the other one perpendicular (B); usually the max
70166
wear is detected on this latter surface and in correspondence
(D) 4-cylinder engine with the first measurement.
If you detect any ovalization, taper or wear, ream and grind
Figure 50 (*) the cylinders. The cylinder barrel regrinding must be
performed in relation to the diameter of the spare pistons
oversized of 0.4 or 0.8 mm in respect of the nominal value
and prescribed assembling clearance.
Figure 52
75386

Carefully clean the crankcase, when performed the engine
disassembly.
Use the proper rings to transfer the crankcase.
Carefully check that the block does not present any cracks.
Check the plug conditions. Replace them if they are rusty or
in case of doubt about their conditions.
Examine the cylinder bore surfaces; they must not present
any seizing, scoring, ovalization, taper, and excessive wearing
traces.
The internal diameter check of the cylinder bore, to verify the
ovalization, taper and wearing entity, is performed by means
of bore meter (1) equipped with dial gange previously set to
zero on the ring gauge (2) of the cylinder barrel diameter.
176515
NOTE If you do not have at your disposal the ring gauge, NOTE In the event of grinding operation, all the cylinders
use a micrometer for the zero setting operation. must result of the same oversize (0.4 or 0.8 mm)

Check the main bearing seats, proceeding as follows: Checking head supporting surface on cylinder
- mount the main caps on the supports without bearings; unit
- tighten the fixing screws to the torque prescribed; When finding the distortion areas, replace the cylinder unit.
- by means of an adequate gauge, verify that the internal Planarity error shall not exceed 0.075 mm.
diameter of the seats correspond to the value pre
Check cylinder unit operating plug conditions, replace them
scribed.
in case of uncertain seal or if rusted.
If you detect a higher value, replace the crankcase.
TIMING SYSTEM
Camshaft
Figure 53
70169
CAMSHAFT MAIN DATA (4 cyl.)

Specified data refer to pin standard diameter
Figure 54
84089
MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders)

Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bush.
if they show any traces of seizing or scoring replace the
Checking cam lift and pin alignment BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge set
Figure 56
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.
Figure 55
70172
Camshaft bush (2) shall be pressed into its housing.

Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
70171 Measurements shall be performed on two perpendicular
axes.
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
Figure 57
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)

* Value to be obtained after driving the bush.
Figure 58
176518
MAIN DATA OF THE BUSH FOR THE CAMSHAFT AND THE RELEVANT SEAT (6-engine cylinders)
*Dimension to be obtained after driving the bushing.
Bush replacement TAPPETS

Figure 59 Figure 60
70174
To replace rear bushing (1), use, for dismounting and 112890
mounting it, beater 99360362 (2) and handgrip 99370006 MAIN DATA CONCERNING THE TAPPETS AND THE
(3). RELEVANT HOUSINGS ON THE ENGINE BLOCK
NOTE Bushing (1), on mounting, must be oriented in such

a way that lubrication holes match the holes
present on block seat.

Fitting tappets camshaft Figure 64

Figure 61
70179
Check camshaft end float (1).

70176
It shall be 0.23 0.13 mm.
Lubricate the tappets (1) and fit them into the relevant Figure 65
housings on the engine block.
Figure 62
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
70164
Lubricate the bushing and other timing system shaft support

seats and mount camshaft (1) taking care that, during the
operation, the bushing or support seats are not being
damaged.
Figure 63
70238
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.

CRANKSHAFT
NOTE It is recommended to insert the found values in the
Measuring journals and crankpins (4-cylinder) proper table. See next Figure.
Figure 66
Undersize classes are:
NOTE Journals and crankpins shall always be ground to

the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB.
70182
Grind journals and crankpins if seizing, scoring or excessive

ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
Figure 67
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value

Figure 68
measured on > 45.5 mm radius

between adjacent journals
70183
OUTPUT SHAFT MAIN TOLERANCES
Figure 69
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

Measuring journals and crankpins (6-cylinder)

NOTE It is recommended to insert the found values in the
proper table. See next Figure.
Figure 70
Undersize classes are: 0.250 0.500 mm
NOTE Journals and crankpins shall always be ground to

the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
70182
Grind journals and crankpins if seizing, scoring or excessive

ovalisation are found. Before grinding the journals (2)
measure them with a micrometer (1) to decide the final
diameter to which the pins are to be ground.
Figure 71
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (6 CYL.)
*Rated value

Figure 72
* Measured on a radius greater than 45.5 mm 70577

** 0.500 between adjacent main journals
MAIN CRANKSHAFT TOLERANCES
Figure 73
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

CONNECTING ROD PISTON ASSEMBLY Figure 75

Connecting rod-piston assembly removal
Figure 74
32613
Remove split rings (1) from piston (2) using pliers 99360183
70191
(3).
CONNECTING ROD PISTON ASSEMBLY
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws Figure 76
- 6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE Pistons are supplied spare with 0.4 or 0.8 mm

oversize.
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
Figure 77
176517
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter

Pistons Gudgeon pins

Measuring piston diameter
Figure 78 Figure 80
32615 18857
Using a micrometer (2), measure the diameter of the piston To measure the piston pin (1) diameter use the micrometer
(1) to determine the assembly clearance. (2).
Conditions for proper pin-piston coupling
Figure 79 Figure 81
70192
32619
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure. Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.

Piston rings Figure 84
Figure 82
16552 41104
Use a micrometer (1) to check split ring (2) thickness. DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
Figure 83 between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
Figure 85
32620
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
70194
Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).

Connecting rods Figure 87

Figure 86
CONNECTING
ROD BODY CAP
CONN. WEIGHT CONN.

ROD Nr. ROD Nr.
CONNECTING ROD CAP

F
YEAR DAY
F = 2003
G = 2004
H = 2005
176516 I = 2006
70196
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
NOTE Every connecting rod is marked as follows:
- On body and cap with a number showing their
* Value for inside diameter to be obtained after driving in coupling and the corresponding cylinder.
connecting rod small end and grinding. In case of replacement it is therefore necessary
to mark the new connecting rod with the same
numbers of the replaced one.
NOTE The surface of connecting rod and rod cap are - On body with a letter showing the weight of
knurled to ensure better coupling. the connecting rod assembled at production:
Therefore, it is recommended not to smooth the
knurls. S V, 1560 to 1600 g (yellow marking);
S W, 1601 to 1640 g (green marking);
S X, 1641 to 1680 g (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.

Fitting connecting rod-piston assembly Figure 90

Connecting rod-piston assembling
Figure 88
FLYWHEEL SIDE
126312
Position the piston on the connecting rod according to the

FAN SIDE diagram shown in the figure, fit the pin and stop it by the split
162243 rings (2).
The piston crown is marked as follows: Fitting split rings
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder Figure 91
barrel, this arrow shall face the front key of the engine
block (fan side);
3. Marking showing 1st slot insert testing;
4. Manufacturing date;
5. Product traceability
Figure 89
126311
Use pliers 99360183 (1) to fit the split rings on the piston (2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
162244
NOTE Split rings are supplied spare with the following
Connect piston (2) to connecting rod (4) with pin (3) so that sizes:
the reference arrow (1) for fitting the piston (2) into the - standard;
cylinder barrel and the numbers (5) marked on the
- 0.4 mm oversize;
connecting rod (5) are read as shown in the figure.
- 0.8 mm oversize.

BENCH ENGINE BLOCK ASSEMBLY Crankshaft installation

Replacing oil pump control gear Figure 94 (D)
Figure 92
70161
70184 Figure 95 (*)

Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).
On mounting the new gear, the gear has to be heated for 10'
at 180 C temperature and keyed on engine shaft by putting
the key in between.
Fitting main bearings

Figure 93
74774

Refit the output shaft (2).
70185
NOTE Refit the main bearings that have not been

replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 0.500 mm

undersize on the internal diameter.
NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the

lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Figure 96 Figure 98
70188
128169
- 2nd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90 2 angle.
- Clean accurately the parts and remove any trace of oil;
- fit caps (1), including the half bearings (2) on the relevant
supports.
Checking crankshaft end float
Figure 99
NOTE Before reusing the fastening screws (1), perform

two diameter measurements as shown in figure,
registering diameters D1 and D2:
if D1-D2 < 0.1 mm the screw may be reused
if D1-D2 > 0.1 mm the screw must be replaced
75703
70190
This check is performed by setting a magnetic-base dial gauge

Figure 97 (2) on the crankshaft (3) as shown in the figure.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft journals and main half bearings.
70187
Tighten the pre-lubricated screws (1) in the following two

successive stages:
- 1st stage, with torque wrench to 80 6 Nm.

Fitting connecting rod half bearings Figure 102
Figure 100
162245
70200 DIAGRAM FOR INSTALLING CONNECTING ROD

PISTON ASSEMBLY INTO CYLINDER
(viewed from front)
Fit half bearings (1) on connecting rod and cap.
- split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
NOTE Refit the main bearings that have not been weight;
replaced, in the same position found at removal.
- the arrow marked on the piston crown shall be facing the
Do not try to adapt the half bearings.
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 103
Figure 101
70201
128170
Lubricate accurately the pistons, including the split rings and - Clean the parts accurately and remove any trace of oil;
the cylinder barrel inside. - install the big end caps (1) with the relative half-bearings
Use band 99360605 (2) to fit the connecting rod-piston (2).
assembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to
the cap coupling number.

Figure 104 Checking piston protrusion

Figure 107
70204
166655
- lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench Once connecting rod-piston assemblies refitting is over, use
(2). dial gauge 99395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block, carrying out the following operations:
Figure 105
- measure the protrusions S1 and S2 of piston no. 1 from
the top surface of the engine block at a distance of 45
mm from the centre of the piston and then calculate the
average protrusion:

S cil1 = S1 + S2
2
- For 4-cylinder versions:

repeat the operation to calculate the average protrusion
of pistons 2, 3 and 4, then calculate the average value of
the protrusions:
70205 S + S cil2 + S cil3 + S cil4
S = cil1
- apply tool 99395216 (1) to the socket wrench and 4
tighten screws (2) of 60 2.
- For 6-cylinder versions:
Figure 106 repeat the operation to calculate the average protrusion
of pistons 2, 3, 4, 5 and 6, then calculate the average value
of the protrusions:
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6

S=
6
70207
Check manually that the connecting rods (1) are sliding

axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 0.33 mm.

CYLINDER HEAD DISMANTLING Figure 110

Removing the valves
Figure 108
70322
Remove the sealing rings (1 and 2) from the relevant valve

70319 guides.
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch () of the exhaust valve (2) head NOTE Sealing rings (1) for intake valves are yellow.
distinguishes it from the intake valve. Sealing rings (2) for exhaust valves are green.
NOTE Should valves be not replaced, number them

before removing in order to refit them in the same
position. Checking cylinder head wet seal
A = intake side S = exhaust side
Figure 111
Figure 109
70323
This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90 C and 2
to 3 bar pressure.
70321
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
Valve removal shall be performed using tool 99360268 (1)
and pressing the cap (3) so that when compressing the springs
(4) the cotters (2) can be removed. Then remove the cap (3)
and the springs (4).
Repeat this operation for all the valves. NOTE Before refitting, smear the plug surfaces with
water-repellent sealant.
Overturn the cylinder head and withdraw the valves (5).
Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface VALVES
Distortion found along the whole cylinder head shall not Figure 113
exceed 0.20 mm.
EXHAUST INTAKE
If higher values are found grind the cylinder head according to VALVE VALVE
values and indications shown in the following figure.
Figure 112
162247
INTAKE AND EXHAUST VALVE MAIN DATA
70325
The rated thickness A for the cylinder head is 105 0.25 mm, Removing carbon deposits, checking and
max. metal removal shall not exceed thickness B by 0.13 mm. grinding valves
Figure 114
NOTE After grinding, check valve sinking. Regrind the valve
seats, if required, to obtain the specified value.
18625
Remove carbon deposits from valves using the proper metal

brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, removing as less material
as possible.

Figure 115 VALVE GUIDES

Figure 117
18882
Check the valve stem (1) using a micrometer (2), it shall be

6.990 7.010 mm.
Checking clearance between valve stem and INTAKE EXHAUST

valve guide and valve centering 79457
Figure 116
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value shown
in the figure.
VALVE SEATS
Regrinding replacing the valve seats
Figure 118
70327
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.032 0.072 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
70330
Check the valve seats (2). If slight scoring or burnout is found,

regrind seats using tool (1) according to the angle values
shown in Figure 119.

Figure 119
EXHAUST INTAKE
107281
MAIN DATA OF ENGINE VALVE SEATS
The valve seats are cast in the cylinder head and machined.
Figure 120
EXHAUST INTAKE
107282
If the valve seats cannot be restored by only regrinding, it is To mount the valve seats in the cylinder head it is necessary
possible to mount the inserts supplied as spares. to heat the cylinder head to 80 - 100 C and, using a suitable
drift, mount the new valve seats (2) in them after they have
In this case, it is necessary to make the seats on the cylinder
been cooled.
head with the dimensions shown in the figure and to mount
the valve seats. Then use the specific tool to grind the valve seats to the values
given in Figure 121.

Figure 121
EXHAUST INTAKE 162248
MAIN VALVE SEAT DATA
Figure 122 VALVE SPRINGS

Figure 123
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

70333 VALVE SPRINGS
After regrinding, check with the base 99370415 (2) and the Prior to assembly, check valve spring flexibility using a suitable
dial gauge 99395603 (1) that the valve recessing (3) is as tool. Compare the elastic deformation and load data with
prescribed. those for new springs given in the following table.
Height Under a load of

mm N
H 35.33 Free
H1 35.33 P1 339.8 9
H2 25.2 P2 741 39

ASSEMBLING CYLINDER HEAD
Figure 124
70334
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
Figure 125
770321
Position on the cylinder head: the spring (4) and upper plate
(3): using tool 99360268 (1), compress the spring (4) and
fasten the plate (3) to the valve (5) with the cotters (2).

REFITTING MAIN COMPONENTS Figure 127
Figure 126
70210
70209
LOCTITE 5205 SEALANT APPLICATION AREAS

DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR
Clean accurately the timing gear case (1) and the engine block. CASE FASTENING SCREWS
Refit the case (1) to the engine block.
Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in the
sequence shown in the figure:
Screws M12 65 to 89 Nm
NOTE Perfect seal is only obtained by cleaning accurately Screws M8 20 to 28 Nm
the surface to seal. Screws M10 42 to 52 Nm
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
NOTE Before any assembly operation always verify that the
It shall be uniform (no clots), without air bubbles,
hole and screw threads have no evidence of wear
thin areas or discontinuities.
or dirt.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint. Figure 128
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
70211
With a felt-tip pen, highlight the conducting gear tooth (1)

mounted on the engine shaft (2) upon the side surface of
which a groove has been created for the ignition timing.
NOTE Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.

Figure 129
NOTE Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
114791
Turn the engine shaft (3) and the distribution shaft (4) so that
by mounting the bevel gear on the latter (1) the stencilled
mark on the gear (1) coincides with the groove on the gear Figure 132
tooth (2).
Figure 130
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL

70213 HOUSING FASTENING SCREWS
Tighten the screws (1) fastening gear (2) to camshaft (3) to the
Refit the housing (1) to the engine block and screw the
specified torque.
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
Figure 131 shown in the figure:
NOTE Before any assembly operation always verify that the

hole and screw threads have no evidence of wear
or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS

Figure 133 Figure 135
70152
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
0901t hoister.
Apply tool 99346252 part (6) to the rear output shaft tang Figure 136
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
Figure 134
Apply tool 99360339 (2) to the flywheel housing to stop

engine flywheel (3) rotation. Tighten the screws (1) fastening
the engine flywheel (3) to the output shaft.
Figure 137
70217
Check the supporting surface (1) of the clutch plate and if it

is scratched, it is necessary to carry out turning.
Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel (1, 70219
Figure 133) using a suitable hammer and fit the new one, Tighten engine flywheel (2) fastening screws (1) in two
previously heated to 150 C for 15 to 20 minutes. stages:
Chamfering on ring gear inside diameter shall be facing the - 1st stage, tightening to 50 5 Nm torque with
engine flywheel. dynamometric wrench;
- 2nd stage, tightening to 60 2 angle.

99395216.
Before any assembly operation always verify that
the hole and screw threads have no evidence of
wear or dirt.

106549
70220
Remove the sealing ring (2) from the front cover (1), clean
Fit the oil pump (1).
accurately the coupling surfaces and smear them with
Tighten the fastening screws (2) to the specified torque. LOCTITE 5205.
Figure 142
Figure 139
106550
Clean accurately the front cover (2) surface and refit it.
70221
Apply a new sealing ring (2) to the water pump (1).
Figure 143
Figure 140
00902t
70222
Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Fit the water pump (1). Position part (2) on part (4), screw nut (3) until completing
Tighten the screws (2) to the specified torque. sealing ring (7) fitting into front cover (1).

74775
108553 Place the oil sump (1) in position and apply the plate (3) to
it.
Fit the plate (1), the oil pick up tube (2) and tighten the Tighten the screws (2) to the specified torque.
fastening screws (3) to the specified torque.
Figure 145
of dirt before fitting
Figure 147
74770
Set the gasket (1) on the oil sump (2).
NOTE If it does not show any signs of damage the gasket

can be reused.
108548
Fit the pulley (1) and the damper flywheel (2) onto the
crankshaft.
Tighten the fastening screws (3) to 68 7 Nm torque.

116245
108578
Fit a new seal ring on the speed sensor (3).
Fit the speed sensor (3) on the front cover (1) and tighten
the retaining screw (2) to the specified torque. Lubricate the seal ring (2) with engine oil and place it on the
oil filter (3).
Figure 149 Screw the oil filter (3) all the way on to the bracket
connection (1) by hand and then tighten the oil filter (3) to
18 2 Nm.
Apply a new seal ring to the oil temperature/pressure sensor
(4) and fit it on the support (1).
Fit a new seal ring (6) in the engine block seat.
108576
Fit the following on the engine block: a new gasket (1), the
heat exchanger (2) a new gasket (3) and the oil filter bracket
(4).


176538
70234
Refit the automatic belt tensioner (2).
Position the alternator support (1) so that pins (3 and 4) are Tighten the screw (3) to the specified torque using a wrench,
set against the engine block. turn the automatic belt tensioner (2) to fit the belt (1) on
Tighten the screws (2) to the specified torque. pulleys and guide rollers.
Figure 154
NOTE Before any assembly operation always verify that

wear or dirt.
Figure 152
70145
Refit the high pressure pump (6) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
support (4) with a new sealing ring, the timing sensor (2) with
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.
Figure 155
176539 1 4 3
Refit the alternator (1).

Tighten the screw (2) to the specified torque.
2
74176
Insert the power take-off (2) equipped with the gasket (4),
the cover (I) and its gasket (4).
Tighten the screws (3) to the prescribed matching couple.

74174
Assemble the electronic gearbox (2) equipped with the 74779
exchanger to the engine, fixing it with the screws (1). Direct the output shaft (4) and the camshaft (2) so that when
In case the rubber buffers are cracked or excessively fitting the driven gear (1) on the camshaft the marks on the
deformed, provide replacing them. gears (1 and 3) are coinciding.
NOTE Before reusing the fastening screws (1), perform

two diameter measurements as shown in figure,
registering diameters D1 and D2:
Figure 157 if D1-D2 < 0.1 mm the screw may be reused
if D1-D2 > 0.1 mm the screw must be replaced
D2 D1
75703
Figure 159
70335
Check cleanness of cylinder head and engine block coupling

surface.
There are two types of head gasket:
- Type A - 1.25 mm thick
- Type B - 1.15 mm thick
Check the average protrusion S of the pistons as indicated
70336
on page 29.
Assemble cylinder head (1), tighten the screws (2) in three
If S > 0.40 mm use gasket type A.
following steps, following order and mode shown in the
If S 0.40 mm use gasket type B. figure below.
Do not get the cylinder head gasket dirty.
Place the gasket (1) in position with the marking TOP (1) NOTE The angle tightening is carried out through tool
facing the head. 99395216 (3).
The arrow shows the point where the gasket thickness is
given.
NOTE Before any assembly operation always verify that

wear or dirt.

Figure 160 (D) Figure 163

A
70337
Figure 161 (*)

70339
Fit injectors (1) on the cylinder head seats, directed so that

the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
A Figure 164

70476
Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with dynamometric wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75 x 150 ( ) 55 5 Nm
- 2nd step tightening with a 90 2 angle
- 3rd step tightening with a 90 2 angle
A = Front side
70133
Figure 162 Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).

Figure 165
99395216.
Tighten the fuel manifold (3) fastening nuts (2) to 50 5 Nm

torque.
Carry out the assembly of the equalisers' unit , after previous
check of the components.
Figure 167 (D)
91572
Fit a new sealing ring (3) lubricated with petroleum jelly on

the fuel manifold (2) and fit it into the cylinder head seat so
that the positioning ball (5) is coinciding with the relevant
housing (4).
176525
NOTE Disassembled fuel manifolds (2) must not be used
again. Replace with new items. (D) F4AE3481/2
The fuel manifolds (2) for engines have 2
positioning spheres.
Figure 168 (*)
Screw the fastening nuts (2, Figure 166) without locking

them.
NOTE During this operation, the injector (1) shall be

moved so that the manifold (2, Figure 163) is
properly inserted into the fuel inlet hole (2,
Figure 165).
Figure 166
176535
(*) F4AE3681
Apply to the coupling surface of the intake manifold (1) with

the cylinder head, a sufficient coat of LOCTITE 5999.
Place the intake manifold (1), complete with the cold-start
heater (if fitted), in position and tighten the retaining screws
to the specified torque.
70342
Tighten gradually and alternately the injector fastening

screws (1) in four stages:
- 1st stage, tightening to 3.5 0.35 Nm torque with
dynamometric wrench.
- 2nd stage, tightening to 25 1 angle;
- 3rd stage, tightening to 25 1 angle;
- 4th stage, tightening to 25 1 angle.

Figure 169 (D) Place the exhaust manifold (2) in position with new gaskets
and tighten the retaining screws to the specified torque.
Sling the turbocharger (1) and position it above the exhaust
manifold after fitting it with a new gasket, tighten the fastening
nuts to the specified torque.
Place the the oil supply pipe (3) in position on the
turbocharger and tighten the couplings on the turbocharger
and on the heat exchanger/oil filter bracket to the specified
torque.
Figure 171
176524
(D) F4AE3481/2
Figure 170 (*)
70343
ROCKER ASSEMBLY COMPONENTS:

176534
1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
(*) F4AE3681

SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.
70346
Figure 173 Check that tappet adjusters (1) are loose to prevent their
balking on the rods (2, Figure 174) when refitting the rocker
assembly.
Then refit the rocker assembly consisting of: bracket (5),
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 5 Nm torque.
122587 Figure 176

Rocker control rods shall not be distorted; the ball seats in
touch with the rocker adjusting screw and with tappets
(arrows) shall not show seizing or wear; otherwise replace
them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.
Figure 174
70520
Adjust clearance between rockers and valves using setscrew

wrench (1), box wrench (3) and feeler gauge (2).
Clearance shall be as follows:
- intake valves 0.25 0.05 mm
70345
Fit the rods (2).

Position jumpers (1) on valves with marks () facing the
exhaust manifold.

Figure 177 (D) Figure 180 (*)
173250
Figure 178 (*) 166640

tighten the couplings to the electro-injector collectors (3)
and the common rail (2) to the specified torque.
NOTE The hoses (1), as they are subject to high pressure,

The hose couplings must be tightened to a torque
of 24 4 Nm, using spanner 99317915 (5) and
torque wrench 99389829.
107286

Figure 181
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut to the specified torque.
Figure 179 (D)
70352
Check the condition of the electrical cables (5), if they are

damaged replace them by cutting the straps (2) securing
them to the bracket and removing the screws (4) securing
the connectors to this (3).
Fit a new gasket (1) on the bracket (2).
173251

108570
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
166077
NOTE Before any assembly operation always verify that Fit the tappet cover (9) and tighten the nuts (10) to the
the hole and screw threads have no evidence of specified torque.
wear or dirt. Place the blow-by filter (8) in position and tighten the
fastening screws.
Place the pipe (6) in position with new copper washers in the
Figure 183 tappet cover and timing case couplings (7). Then tighten the
couplings (7) to the specified torque.
Place the blow-by pipe (5) into the coupling located on the
a new seal ring, into the tappet cover and tighten the screw
(3).
Connect the fuel return pipe (2) to the pressure limiter (1)
and common rail as shown in following figure.
Figure 186
108571
Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the fastening
nuts (2) to the specified torque.
Figure 184
116237
To connect the low pressure fuel hose to the connection

fitting, insert the quick-fit coupling (2) in the connection
fitting and push it in until the catch (3) engages.
NOTE Check proper fuel hose connection.
70355 Place the engine cable in position, close the retaining straps
and connect the sensor, control unit and electro-injector
Fit a new gasket (2) on the tappet cover (1).
connectors (refer to Figure 8 on page 5).

REMOVING THE ENGINE FROM THE Figure 187 (*)

ROTATING STAND
Support the engine appropriately with a hoist, disconnect it
from the rotating stand, remove brackets 99341009 and
place it on a suitable support to complete engine assembly.
COMPLETING ENGINE ASSEMBLY

Refit the fan to the crankshaft pulley.
Figure 189
176533
(*) F4AE3681
From the right-hand side of the engine, place the oil drain pipe
(1) in position and tighten the screws fastening it to the
2 turbocharger and engine block to the specified torque.
74166
Position the starter motor (2) on the internal part of the

flywheel cover (1).
Screw down the retaining screws and tighten them to the
specified torque.
Figure 188 (D)
176523
(D) F4AE3481/2

Figure 190 (D) Perform the following operations from the left-hand side of
the engine:
- Place the oil delivery tube in position, if present, with a
new o-ring, and tighten the retaining screws.
- Connect the low-pressure fuel hose (6) supplying the
mechanical pump connected to the high pressure pump
via the electronic control unit exchanger.
- Connect a new high-pressure fuel hose (5) between the
high-pressure pump and the common rail, tighten the
couplings to the specified torque and fasten it to the
engine block with the respective clamps
NOTE Due the high pressures in the hoses running from

the high pressure pump to the rail and from this to
the injectors, reuse of these hoses after removal
must absolutely be avoided.
173245
(D) F4AE3481/2
- Place the fuel filter support (4) in position together with
the bracket, if present, and tighten the retaining screws
Figure 191 (*) to the specified torque.
- Connect the low-pressure fuel hoses (3) to the filter
support.
- Connect the fuel temperature sensor and camshaft
timing sensor electrical connections (2).
- Fully screw the fuel filter onto the connection on its
support by hand, then further tighten to a torque of 20
2 Nm.
166072
(*) F4AE3681

CHECKS AND INSPECTIONS
NOTE The following checking inspections must be carried

out after the engine assembly on the vehicle .
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
- that there are no water leaks from the connecting

sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low
pressure fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.


F4AE ENGINES SECTION 8 - TECHNICAL SPECIFICATIONS 1
SECTION 8
Technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 10

2 SECTION 8 - TECHNICAL SPECIFICATIONS F4AE ENGINES

GENERAL SPECIFICATIONS
Type 4 CYLINDERS 6 CYLINDERS
Cycle Four-stroke diesel engine

Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6

Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 3920 5880
TIMING
start before T.D.C. A 8 30'

end after B.D.C. B 8 30'
start before B.D.C. D 51 00'

end after T.D.C. C 12 30'
Checking timing
mm
X X 0.2 to 0.30
mm
0.46 to 0.56
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 UC31
Injector CRIN2
Nozzle type DSLA
Injection sequence 1-3-4-2 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

1
Cylinder barrels 1 102.01 to 102.03
X
1 0.4 - 0.8
Spare pistons type:

1
Size X 12 / 60.5*
X
Outside diameter 1 101.58 to 101.73 / 101.781 to 101.799*
Pin housing 2 40.010 to 40.016 / 40.008 to 40.014*
2
Piston diameter 1 0.4 - 0.8
Piston - cylinder liners 0.28 to 0.45 / 0.211 to 0.249*
X
Piston protrusion X 0.28 to 0.52
3 Piston pin 3 39.994 to 40.000
Piston pin pin housing 0.010 to 0.022 / 0.0078 to 0.0202*
(*) F4AE3482E*U101

X1 X1* 2.705 to 2.735

Split ring slots X2 2.430 to 2.450 / 2.420 to 2.440*
X2
X3 4.040 to 4.060 / 4.020 to 4.040*
X3
* measured on 101 mm
S 1 2.560 to 2.605
S 1*
S 2 2.350 to 2.380
Split rings S2
S 3 3.975 to 4.000
S3
1 0.100 to 0.175
Split rings - slots 2 0.040 to 0.090
3 0.040 to 0.085 / 0.040 to 0.065*
1 0.4 - 0.8
Split rings 2 0.4 - 0.8
3 0.4 - 0.8
X1
Split ring end opening
X2 X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.25 to 0.55
1
Small end bush
housing 1 42.987 to 43.013
Big end bearing
2 housing 2 72.987 to 73.013
3 Small end bush diameter
S Inside 3 40.019 to 40.033

Big end half
bearings S 1.955 to 1.968
Piston pin bush 0.025 to 0.033
Big end half bearings 0.250 - 0.500
(*) F4AE3482E*U101


X
Size X -
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.990 to 83.010 / 82.993 to 83.013*
Crankpins 2 68.987 to 69.013
Main half bearings S1 2.456 to 2.464

S 1 S 2 Big end half bearings S2 1.955 to 1.968
Main bearings
3 No. 1 - 7 3 87.982 to 88.008
No. 2 - 3 - 4 - 5 - 6 3 87.977 to 88.013
Half bearings Journals

No. 1 - 7 0.044 to 0.106
No. 2 - 3 - 4 - 5 - 6 0.039 to 0.111
Half bearings - Crankpins 0.033 to 0.041 / 0.039 to 0.116*
Main half bearings
0.250 - 0.500
Big end half bearings
Shoulder journal X1 37.475 to 37.545
X 1
Shoulder main bearing X2 32.180 to 32.280
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.265
(*) F4AE3482E*U101

CYLINDER HEAD TIMING SYSTEM mm

1
Valve guide seats on

cylinder head 1 7.042 to 7.062
4 Valves:
4 6.990 to 7.010
60o 0.25o
4 6.990 to 7.010
45o 0.25o
Valve stem and guide 0.032 to 0.072
Housing on head for
valve seat:
1 34.837 to 34.863
1 1 34.837 to 34.863
Valve seat outside diameter;

2 valve seat angle on cylinder
head:
2 34.917 to 34.931
60o
2 34.917 to 34.931
45o

X 0.59 to 1.11
X Sinking X 0.96 to 1.48
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -
(*) F4AE3482E*U101


Valve spring height:
free spring H 47.75

H H1
H 2 under a load equal to:
339.8 9 N H1 35.33
741 39 N H2 25.2
Injector protrusion X -
X
Camshaft bush housings

No. 1 (flywheel side) 59.222 to 59.248
Camshaft pin seats
No. 2-3-4-5-6-7 54.083 to 54.147
1 23 4 5
2
Camshaft journals:
17 53.995 to 54.045
1 3
Bush inside
diameter 54.083 to 54.147
Bushes and journals 0.038 to 0.152

Cam lift:
H H 6.045
H 7.582
(*) F4AE3482E*U101


1
Tappet cap housing
on block 1 16.000 to 16.030
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.960 to 15.975
2
Between tappets and housings 0.025 to 0.070
Tappets -
1
Rocker shaft 1 21.965 to 21.977
Rockers 2 22.001 to 22.027
2
Between rockers and shaft 0.024 to 0.062

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
M12x1.75 screw fastening rear gear case 77 12 7.7 1.2
1st stage 81 0.8 0.1
M8x1.25 screw fastening oil pump 2nd stage 24 4 2.4 0.4
M8x1.25 screw fastening front cover 24 4 2.4 0.4
M8x1.25 screw fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
M8x1.25 screw fastening camshaft gear 36 2 3.6 0.2
M10x1.50 screw fastening crankcase plate 43 5 4.3 0.4
M18x1.50 nut fastening high pressure pump gear 105 5 10.5 0.5
M8x1.25 nuts fastening fuel pump 24 4 2.4 0.4
inch plug on cylinder head 24 4 2.4 0.4
1st stage 3.5 0.35 0.35 0.035
M6x1 screw fastening injectors
2nd stage 25 1
3rd stage 25 1
4th stage 25 1
M22x1.5 fastening nut injector feed connector 50 5 5 0.5
M8x1.25 screw fastening intake manifold 24 4 2.4 0.4
M12x1.75 screw fastening rear brackets for engine lifting 77 12 7.7 1.2
M8x1.25 screws fastening Common Rail 36 5 3.6 0.5
M12x1.75x130 screw fastening cylinder head 35 5 3.5 0.5
M12x1.75x150 screw fastening cylinder head
}1 st stage
55 5 5.5 0.5
2nd stage 90 2
3rd stage 90 2
M8x1.25 screw fastening rocker bracket 36 5 3.6 0.5
Valve clearance adjusting nuts M8x1.25 24 4 2.4 0.4
M14x1.5 nuts fastening fuel pipes from high pressure pump to Common Rail 24 4 2.4 0.4
M8 screw fastening high pressure pipe connector 24 4 2.4 0.4
M6 screw fastening wiring bulkhead 10 2 1 0.2
M8 screw fastening electric wiring support for injector feed 24 4 2.4 0.4
Nuts M4 fastening wiring on each injector 1.5 0.25 0.15 0.025
M12x1.75 screw fastening fuel filter bracket (industrial) 80 8 8 0.8
Fuel filter 20 2 2 0.2
M22 screw fastening oil pressure relief valve on oil filter support 80 8 8 0.8
M27x2 coupling fastening oil filter 20 2 2 0.2
11/8 inch connection on filter support for turbine lubrication 24 4 2.4 0.4
M12 nut fastening turbine lubrication pipe 10 2 1 0.2
M10 screw fastening engine coolant inlet connection 43 6 4.3 0.6

TORQUE
COMPONENT
Nm kgm
M10x1.5 screw fastening exhaust manifold on cylinder head 53 5 5.3 0.5
M12 screw fastening damper adapter 1st stage 50 5 5 0.5
and damper on output shaft 2nd stage 90 5
M10x1,25 screw fastening pulley on output shaft 68 7 6.8 0.7
M8x1.25 screw fastening water pump 24 4 2.4 0.4
M10x1.50 screw fastening auxiliary component control belt tensioners 43 6 4.3 0.6
M10x1.50 screw fastening fixed pulleys for auxiliary component control belt 43 6 4.3 0.6
M12x1,75 screw fastening flywheel housing 85 10 8.5 1
M10x1.50 screw fastening flywheel housing 49 5 4.9 0.5
Nut M8x1.25 fastening valve cover 24 4 2.4 0.4
M6x1 screw fastening camshaft sensor 10 2 1 0.2
M6x1 screw fastening crankshaft sensor 10 2 1 0.2
M14x1.5 screw fastening coolant temperature sensor 24 4 2.4 0.4
M6x1 screw fastening oil pressure/temperature sensor 10 2 1 0.2
Screw fastening fuel pressure sensor 35 5 3.5 0.5
M14 screw fastening fuel temperature sensor 25 2 2.5 0.2
M6x1 screw fastening air temperature/pressure sensor on intake manifold 10 2 1 0.2
M12x1.5 screw fastening engine oil level sensor 10 2 1 0.2
pins M10 71 0.7 0.1
Turbine fixing to exhaust manifold 6-cyl. { nuts M10x1.5 43 6 4.3 0.6
M16 couplings fastening oil delivery pipe to turbocharger 36 5 3.6 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 5 3.5 0.5
Oil pipe fixing on adapter M10 for turbine lubrication to block 43 6 4.3 0.6
M8x1.25 screws fastening oil drain pipe to turbine 24 4 2.4 0.4
Screw M12x1.25 screws fastening engine flywheel 1st stage 50 5 5 0.5
2nd stage 60 2
M8x1.25 screws fastening front bracket for engine lifting 36 5 3.6 0.5
M8x1.25 screws fastening engine oil sump 24 4 2.4 0.4
M8 screws fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
M12 screws fastening crankshaft caps 1st stage 80 6 8 0.6
2nd stage 90 2
M10x1.25 screw fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 2
Alternator
M10x1.5 screw bracket fixing on water feed pipefitting 43 6 4.3 0.6
M10x1.5 screw alternator locking 43 6 4.3 0.6
Starter
M10x1.5 nut fastening starter motor 43 6 4.3 0.6

TORQUE
COMPONENT
Nm kgm
M8x1.25 screws fastening heat exchanger and oil filter support 26 4 2.6 0.4
M8x1.25 screws fastening housing 24 4 2.4 0.4
M8x1.25 screws fastening suction strainer 24 4 2.4 0.4
M10x1.5 screws fastening suction strainer bracket 43 5 4.3 0.5
M18x1.5 heat exchanger valve cap 60 9 6.0 0.9
M18x1.5 nut (left-handed) fastening compressor drive gear 165 10 16.5 1.0
M12x1.75 nuts fastening compressor 77 12 7.7 1.2
M8x1.25 screws fastening compressor support bracket 24 4 2.4 0.4
M6x1 screws fastening thermostat cover 10 2 1.0 0.2
M18x1.5 caps to engine block 24 4 2.4 0.4
M10x1.5 screws fastening rail tube bracket 40 5 4.0 0.2
M18x1.5 couplings 24 4 2.4 0.4
M6x1 screws fastening plate 24 4 2.4 0.4
M10x1.5 screws fastening power steering pump 43 6 4.3 0.6
3/4 coupling 36 4 3.6 0.4
M6x1 screws fastening breather plate 10 2 1.0 0.2
M6x1 screw fastening breather plate to tappet cover 10 2 1.0 0.2
M12x1.5 breather fastening couplings 20 4 2.0 0.4
M8x1.25 screws fastening dipstick 24 4 2.4 0.4
M6x1 screws fastening dipstick clamp 10 2 1.0 0.2
M12x1.5 coupling on cylinder head 22 2 2.2 0.2
Fuel filter adapter 30 2 3.0 0.2
Oil filter adapter 80 8 8.0 0.8
M7x1 screws fastening intake elbow 13 2 1.3 0.2
M8x1.25 screws fastening intake elbow bracket 24 4 2.4 0.4
M8x1.25 screws fastening control unit 24 4 2.4 0.4
M10x1 cap 24 4 2.4 0.4
M6x1 screws fastening control unit to bracket 10 2 1.0 0.2
M12x1.5 coupling on control unit bracket 12 2 1.2 0.2
M8x1.25 nuts fastening heater 13 3 1.3 0.2

F4AE ENGINES SECTION 9 - TOOLS 1
SECTION 9
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 9 - TOOLS F4AE ENGINES

TOOLS
TOOL NO. DESCRIPTION
99317915 Set of 5 9x12 pin wrenches (14 15 - 17 18 - 19 mm)
Revolving stand for overhauling units (700 daN/m capacity,

99322205 120daN/m torque)
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
99341001 Double actingpuller
99341009 Pair of brackets

99341015 Press
99342101 Tool to removeinjectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool to remove oil filter (engine)
99360183 Pliers for removing/refitting piston rings (65 - 110 mm)

99360221 Engine flywheel rotation tool (use with 99360222)
99360222 Pinion (use with 99360221)
99360268 Tool for removing/refitting engine valves
99360330 Flywheelcrankhandle
99360351 Equipment for flywheel holding
Beater for removing/refitting camshaft bushes (to be used with

99360362 993700069)

99360500 Tool for lifting the output shaft
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 - 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to removegaskets
99367121 Manual pump for pressure and vacuum measurements

99370006 Handgrip for interchangeablebeaters
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)
Torque screwdriver for injector solenoid valve connector stop

99389834 nutsetting
99395216 Pair of gauges with and square head for angle tightening
99395603 Dialgauge (0 - 5 mm)

Device for checking the diesel supply circuit and common-rail

99305453 injectionsystem

F4AE ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F4AE ENGINES

F4AE ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

4 APPENDIX F4AE ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

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

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SERIES NEF

Technical and Repair manual

This publication has been drawn up for qualified and

Before performing any operation check that the part relevant

Operations are to be performed by following the indications

Each repair must aim to restore operating efficiency and safety

FPT cannot be held liable for modifications, alterations or other

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the

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

If issues on this publication differ from what is actually noticed

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

- Bonding and screening . . . . . . . . . . . . . . . . . . . 8

OPTIONAL ELECTRICAL AND MECHANICAL

CONVERSIONS BETWEEN THE MAIN UNITS

KEY OF LECTURE OF THE HEADINGS

Print P2D32N020 E Base - May 2012

Base - May 2012 Print P2D32N020 E

Danger for persons

Danger of serious damage for the assembly

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

1 1 = Seat of small end bush

Print P2D32N020 E Base - May 2012

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Air bleeding Preload

Base - May 2012 Print P2D32N020 E

Print P2D32N020 E Base - May 2012

Base - May 2012 Print P2D32N020 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32N020 E Base - May 2012

Bonding and screening

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

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

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

Base - May 2012 Print P2D32N020 E

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Print P2D32N020 E Base - May 2012

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Basic edition referred to When month - year update

Base - May 2012 Print P2D32N020 E

Removal - refitting of main components 6

General mechanical overhauling 7

Safety prescriptions Appendix

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Base - May 2012 Print P2D32N020 E

Section Description Page Date of revision

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CORRESPONDENCE BETWEEN TECHNICAL CODE

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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Technical Code Commercial Code

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LEFT-HAND SIDE VIEW

RIGHT-HAND SIDE VIEW

Base - May 2012 Print P2D32N020 E

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LEFT-HAND SIDE VIEW