DD4-1 Dignostico Motor DW63239101 - DD4 - 1

Trainer document/guide:
Diagnostic methodology: Engine, DD4/1

©201628 DAF Trucks N.V., Eindhoven,
The Netherlands.
In the interest of continuing product development,
DAF reserves the right to change specifications
or products at any time without prior notice.
No part of this publication may be reproduced
and/or published by printing, by photocopying, on
microfilm or in any way whatsoever without the
prior consent in writing of DAF Trucks N.V.
The content of this training material is solely
meant for training purposes and can therefore not
be used for actual “life” situations. The
information in this document is subject to
changes. For the correct chassis specific
technical data it is imperative to consult the
service documentation via Service Rapido.
©
201628 DW63239101
STRUCTURE
TRAINING SUPPORT INFORMATION

Structure
©
201628
Table of contents
TABLE OF CONTENTS
Training support information
Page Date 0
1. HOW TO USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 201628
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 201628
1.2 Icon definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 201628
2. TRAINING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 201628

2.1 Learning objectives DD4/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 201628
2.2 Brief description DD4/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 201628
3. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 201628

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 201628
4. DIAGNOSTIC VEHICLE INFORMATION FILE. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 201628

4.1 Diagnostic vehicle information file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 201628
5. FAULT FINDING CASES/PREPARATION INFORMATION PCI & EAS-3 . . . . 5-1 . . . . . 201628

5.1 Fault finding case: Common rail pump unit . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 201628
5.2 Fault finding case: Irregular running engine . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 201628
5.3 Fault finding case: Irregular running engine (2) . . . . . . . . . . . . . . . . . . . . . 5-4 . . . . . 201628
5.4 Fault finding case: AdBlue module unable to prime . . . . . . . . . . . . . . . . . 5-5 . . . . . 201628
5.5 Fault finding case: Blocked AdBlue doser . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 . . . . . 201628
5.6 Fault finding case: Blocked EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 . . . . . 201628
6. FAULT FINDING CASES/PREPARATION INFORMATION MX-11 ENGINE . . 6-1 . . . . . 201628

6.1 Fault finding case: Fuel pressure control valve . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 201628
6.2 Fault finding case: Fuel filtration module . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 . . . . . 201628
6.3 Fault-finding case: VTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 . . . . 201628
7. FAULT FINDING CASES/PREPARATION INFORMATION MX-13 ENGINE . . 7-1 . . . . . 201628

7.1 Fault finding case: Fuel pressure control valve . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 201628
7.2 Fault finding case: Fuel filtration module . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 . . . . . 201628
7.3 Fault-finding case: VTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 . . . . . 201628
8. FAULT FINDING CASES/PREPARATION INFORMATION ECS-DC6 . . . . . . . 8-1 . . . . . 201628

8.1 Fault finding case: EGR cooler blocked . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 201628
8.2 Fault finding case: Irregular running engine . . . . . . . . . . . . . . . . . . . . . . . 8-5 . . . . . 201628
8.3 Fault finding case: NOx sensor drifted high. . . . . . . . . . . . . . . . . . . . . . . . 8-12 . . . . 201628
8.4 Fault finding case: Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . 8-16 . . . . 201628
8.5 Fault finding case: Faulty injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 . . . . 201628
8.6 Fault finding case: Inlet air pressure in inlet manifold . . . . . . . . . . . . . . . . 8-23 . . . . 201628
8.7 Fault finding case: Exhaust gas pressure before turbine . . . . . . . . . . . . . 8-26 . . . . 201628
8.8 Fault finding case: AdBlue module unable to prime . . . . . . . . . . . . . . . . . 8-29 . . . . 201628
8.9 Fault finding case: Blocked AdBlue doser . . . . . . . . . . . . . . . . . . . . . . . . . 8-32 . . . . 201628
9. FAULT FINDING CASES/PREPARATION INFORMATION PX-5 ENGINE. . . . 9-1 . . . . . 201628

9.1 Fault-finding case: Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 201628
9.2 Fault finding case: EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 . . . . . 201628
9.3 Fault finding case: Exhaust Gas Recirculation . . . . . . . . . . . . . . . . . . . . . 9-7 . . . . . 201628
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Table of contents
Page Date
0 10. FAULT FINDING CASES/PREPARATION INFORMATION PX-7 ENGINE. . . . 10-1 . . . . 201628
10.1 Fault finding case: Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . . 201628
10.2 Fault finding case: EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 . . . . 201628
10.3 Fault finding case: Exhaust Gas Recirculation . . . . . . . . . . . . . . . . . . . . . 10-7 . . . . 201628
11. REQUIRED MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . . 201628

11.1 Room arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . . 201628
11.2 Required material for the trainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 . . . . 201628
11.3 Required material for the participants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 . . . . 201628
11.4 Required training material to support the training . . . . . . . . . . . . . . . . . . . 11-4 . . . . 201628
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How to use
1. HOW TO USE
1.1 INTRODUCTION 0
This document contains practical cases, which
can be used to support an in-depth practical
diagnosis training.
The practical cases must be carried out and
solved according to the DAF Diagnostic
Methodology (GE2/3).
Because the in-class training only consists of
solving fault finding cases, a trainee document is
not applicable and for this reason not available.
NOTE: Always consult Service Rapido
for the correct technical data,
diagnostic procedures and repair
instructions!
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How to use
1.2 ICON DEFINITION

0 The icons included in this document have the
following meaning:
Animation on e-Campus trainer site
On the e-campus trainer site, an E-presentation is available on the subject.
Question/assignment
This is a question/assignment for the student. This question/assignment is also in-
cluded in the trainee document.
Practical assignment
Practical assignment for the trainee.
Teaching method
Recommendation for the teaching method.
Practical explanation/demonstration for the entire group.
Notes
Space for writing notes.
©
1-2 201628
Training characteristics
2. TRAINING CHARACTERISTICS
2.1 LEARNING OBJECTIVES DD4/1 0
On completion of this training module, the
following learning objectives are achieved.
The student is able to:
Knowledge
- state the purpose and significance of the
DAF diagnostic methodology flow chart.
Understanding
- understand the importance of a correct use
of complaint handling for the customer.
Application
- apply the DAF diagnostic methodology in the
correct sequence.
- apply the DAF diagnostic methodology to
solve the customer complaint.
Analysis/diagnostics
- collect and investigate the information
needed for each step in the DAF diagnostic
methodology.
- analyse the data information and
measurement results.
- locate and resolve the fault which caused the
customer complaint.
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Training characteristics
2.2 BRIEF DESCRIPTION DD4/1

0 This training module contains the following
topics:
- fault finding on engine, engine management
system and Emission Aftertreatment
Systems according to the DAF diagnostic
methodology.
Training method
- Classroom and practical based
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2-2 201628
Introduction
3. INTRODUCTION
3.1 INTRODUCTION 0
Purpose
The DAF Diagnostic Methodology is the method
for a structured and logical way to solve customer
complaints.
The DAF Diagnostic Methodology results in
efficient process steps, effective fault-finding and
repair of electrical, electronic and mechanical
systems.
NOTE: The term 'service advisor'
discussed in these chapters can be
anyone who meets the specific role in
the process.
By applying the DAF Diagnostic Methodology,

the service advisor is able to perform the
diagnosis and document it.
Structured documentation makes sure that the
diagnosis, carried out by the organisation, is the
same in each workshop which ensures
consistency and is clear and understandable to
the customer.
The DAF Diagnostic Methodology prevents
unnecessary work, emerged from wrong
thoughts, it is always possible to return to the
point where the work made progress.
A properly executed diagnosis has a positive
influence on:
- The processes in the workshop
The work can be taken over from another
colleagues, it is clear what all the colleagues
had done in the process.
You can always see what the colleagues did
in what step, so if there rises a question, you
can directly contact the right person.
- first-time right
A proper executed diagnose helps
increasing first-time right repairs and bring
down the down-time.
- clear explanation of the work done
Once the DAF Diagnostic Methodology is
finished, every step in the process is
documented en therefore easy to process in
the invoice administration.
- customer satisfaction
The quality of the customer feedback
improves and gives better information
regarding the solution of the concern, or
extra information not related to the concern.
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Introduction
0 Vehicle ID Card
does not match
c 1. Identify vehicle
o VCD update required
n Contact Service Helpdesk Vehicle ID Card matches
c
e
r Non-reproducable concern
n 2. Understand & Verify customer’s concern
Reproducable concern
Operates as designed
3. Customer expectation mismatch
Does not operate as designed
Abnormality identified
Contact Service Helpdesk

4. Perform visual and operational primary checks
No abnormality identified
c
a
u
s 5. Perform diagnostic quick check
e
Publication identified
6. Check for relevant bulletins
No publication identified
7.1 Identify cause

-Rationality type 7.2 Identify cause
DTC -Communication 7.3 Identify cause 7.4 Identify cause
concern or DTC -Plausibility type 7.5 Identify cause
DTC -Symptom no
DTC -No published
diagnostics
c
o
r
r 8. Repair & Validate remedy
9. Re-examine customer’s
e concern
c
t Concern solved Concern not solved
i
o
n 10. Provide feedback to customer of findings
G005010-5
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Introduction
Sequence of the steps

The sequence of the DAF Diagnostic
Methodology is based on:
0
- Processes in the workshop
The steps are based on the normal
workshop processes
- Easy steps first
To prevent that simple concern are
overlooked.
The DAF Diagnostic Methodology is divided in
three phases: c
Vehicle ID Card
does not match
1. Identify vehicle
- 'Concern' represented in yellow. This phase o
n
VCD update required
Contact Service Helpdesk Vehicle ID Card matches
gives an overview: c
e
To make sure that the diagnostic information

r Non-reproducable concern
n 2. Understand & Verify customer’s concern
is relevant and specific for this vehicle. Reproducable concern
To understand the customers concern and Operates as designed

3. Customer expectation mismatch
can it reproduced Does not operate as designed
- 'Cause' represented in blue. This step gives

an overview:
Abnormality identified
Contact Service Helpdesk

4. Perform visual and operational primary checks
To make sure that the vehicle operates as c

a
No abnormality identified
designed or not u
s 5. Perform diagnostic quick check
To identify if there are abnormalities, or not e
To check if there is publication available for Publication identified

this specific problem, yes or no 6. Check for relevant bulletins
Of the DTC's No publication identified
- 'Correction' represented in green. This step 7.1 Identify cause

-Rationality type 7.2 Identify cause
gives an overview of: DTC -Communication 7.3 Identify cause
concern or DTC -Plausibility type 7.4 Identify cause
-Symptom no 7.5 Identify cause
The concern that is solved or not

DTC -No published
DTC
diagnostics
Feedback provided to the customer c

o
r
r 8. Repair & Validate remedy
9. Re-examine customer’s
e concern
c
t Concern solved Concern not solved
i
o
n 10. Provide feedback to customer of findings
G005148-3
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Introduction
flow chart (without text)

0
1.
2.
3.
4.
5.
6.
7.1
7.2
7.3
7.4
7.5
8. 9.
10.
G005184
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Introduction
The image above represents the DAF

Diagnostic Methodology flow chart (no
text). Write down in your own words the 0
meaning of every step.
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Introduction
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Diagnostic Vehicle Information File
4. DIAGNOSTIC VEHICLE INFORMATION FILE

4.1 DIAGNOSTIC VEHICLE INFORMATION FILE 0
To support the process of the diagnostic
methodology, a 'Diagnostic vehicle information
file' must be filled in.
Step 1: Identify vehicle
Name: ………..................................................................................
To make sure that the diagnostic information is relevant and specific for this vehicle.
Customer name:
Chassis number:
Mileage:
Date:
Complaint description:
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Step 2: Understand & verify customer’s concern
Name: ……….................................................................................. (same as step1) □

To enable validation of the remedy at the final step of the diagnostic method.
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0 Step 3: Customer expectation mismatch
Name: ……….................................................................................. (same as step1) □

To verify if the vehicle operates as designed or not and therefore if the concern is valid or not.
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Step 4: Perform visual and operational primary checks
Name: ……….................................................................................. (same as step1) □

To identify if something “obvious” is causing the previously validated concern.
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Step 5: Perform diagnostic quick check
Name: ……….................................................................................. (same as step1) □

To investigate commonalities in the faults and warning messages and set priorities to identify the cause
of them.
DTC: System: Description:
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4-2 201628
Step 6: Check for relevant Bulletins
Name: ……….................................................................................. (same as step1) □

0
To identify whether this is a “known concern” for which a bulletin with solution is available.
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Step 7.1: Identify cause - Rationality type DTC
Name: ……….................................................................................. (same as step1) □

A Diagnostic Trouble Code related directly to a component of which one or more parameters is found to
be incorrect.
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Step 7.2. Identify cause - Communication concern or DTC
Name: ……….................................................................................. (same as step1) □

Communication concerns or DTCs provide a communication disorder in the vehicle communication net-
work.
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0 Step 7.3. Identify cause - Plausibility type DTC
Name: ……….................................................................................. (same as step1) □

The plausibility type DTC is used for failures where the ECU compares two or more input parameters for
plausibility.
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Step 7.4. Identify cause - Symptom - no DTC
Name: ……….................................................................................. (same as step1) □

With this type of concern the technician must come to a list of suspected components or systems.
After analysing the information obtained and the diagnosis-related information in Service Rapido the
symptom must be reproduced by taking tests and measurements.
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Step 7.5. Identify cause - no published diagnostics
Name: ……….................................................................................. (same as step1) □

The cause must be identified with the information provided from the customer and by tests and
measurements.
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Step 8: Repair and validate remedy
Name:
Step 9: Re-examine customer' s concern
Name:
0
………....................................... (same as step1) □ ................................................ (same as step1) □
Step 10: Provide feedback to customer of findings
Name: ……….................................................................................. (same as step1) □
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Step 11: Customer recommendations
Name: ……….................................................................................. (same as step1) □
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0 Component tests Measured value Checking data value Service Rapido
©
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Fault finding cases/preparation information PCI & EAS-3
5. FAULT FINDING CASES/PREPARATION INFORMATION PCI &

EAS-3 0
5.1 FAULT FINDING CASE: COMMON RAIL PUMP UNIT
Fault finding case No. 2.1 Training module Date

DD4/1-1 Diagnostic methodology: Engine DD4/1 08/09/2014
Training material/support used for the test case

Vehicle series and type XF_E6, FT
Chassis number 0E986120
Component Common rail pump unit L092
System PCI
Description of the complaint or the

instruction related to the test case
The engine is running normal on light loads.
When the engine must perform on high loads, the
engine sets a DTC.
First the failure is recognised by a yellow engine
warning on DIP-5, also the MIL lamp is on. If the
high engine load continuous, the red engine
warning appears on DIP-5.
Use the user-defined monitor set
in DAVIE4.
- Engine speed
- Common rail operating state
- Common rail pump delivery
(actual)
- Common rail pump delivery
(correction)
- Actual fuel quantity
- Fuel pressure
- rail pressure actual (absolute)
- rail pressure (requested by the
ECU)
- Coolant temperature
Perform a test drive and then study the
log file with the correct fault analysis.
Check with DAVIE the DTC and consult
Service Rapido for the procedure.
Failure description
The common rail pump unit sets a DTC 'P228D
Engine rail pressure control - Incorrect' .
Preparation of the failure
Replace one of the two common rail pump units
for a defect or modified common rail pump unit.
Necessary tools
- DAVIE4 diagnostic tool
©
201628 5-1
Additional information
0 The participant must find the problem caused by
the common rail pump unit. For the diagnostics
the participant can use DAVIE or the Fluke123.
He must compare the values and descriptions of
the DTC's in Service Rapido. The participant
must make a 'step by step' plan how to solve the
problem.
NOTE:
©
5-2 201628
5.2 FAULT FINDING CASE: IRREGULAR RUNNING ENGINE

0

Component Injector cylinder 1
System PCI

The engine is running on five cylinders, the
engine sets a DTC.
Use DAVIE4 to perform all the relevant
diagnostics tests.
Failure description
DTC P0301, cylinder 1 - Contribution too low or
misfire is set by PCI. This diagnostic runs
according to the description 'Repair validation' in
Service Rapido.
This DTC changes to inactive when the fault is no
longer detected.
Prepare the case by mounting an extra injector
coil parallel over the first injector.
Necessary tools
- Basic toolkit
The participant must find the problem caused by
the injector. For the diagnostics the participant
can use DAVIE4. He must compare the values
and descriptions of the DTC's in Service Rapido.
The participant must make a 'step by step' plan
how to solve the problem. The focus must be
'Diagnose the crank speed and Injection test' in
DAVIE4.
NOTE:
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201628 5-3
5.3 FAULT FINDING CASE: IRREGULAR RUNNING ENGINE (2)

0

Component
System PCI

engine sets a DTC.
Use DAVIE4 to perform the Crank
Speed Injection Diagnostics test
Failure description
The P0306 is set by PCI, This diagnostic runs
when the engine is running at a steady speed and
load, and the vehicle speed is steady.
longer detected.
Adjust the exhaust valve from cylinder 6 to a
negative valve clearance that leave the valve
open wile the engine is running.
WARNING! When the opening gap
from the valve is to much there will
be permanent valve damage.
Necessary tools
- Basic toolkit
The participant has to find the problem caused by
the valve leak. For the diagnostics the participant
can use DAVIE4. He has to compare the values
and discriptions of the DTC's in Service Rapido.
The participant must make a "step by step" plan
how to solve the problem.
NOTE:
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5.4 FAULT FINDING CASE: ADBLUE MODULE UNABLE TO PRIME

0

Component AdBlue pump module
System EAS-3

The truck has a problem with the AdBlue system.
The truck is coming from another dealer where
they replaced the AdBlue pump module to solve
the problem.
The EAS-3 system cannot prime the system. The
driver gets a warning on DIP-5 and PCI sets a
DTC.
Use DAVIE4 to monitor the AdBlue
pressure and perform the AdBlue prime
test.
Failure description
The P3912 is set by PCI.
longer detected.
Swap the AdBlue lines on the pump module.
Necessary tools
- Basic toolkit
the swapped lines on the pump module. For the
diagnostics the participant can use DAVIE4. He
must compare the values and descriptions of the
DTC's in Service Rapido. The participant must
make a 'step by step' plan how to solve the
problem.
NOTE:
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5.5 FAULT FINDING CASE: BLOCKED ADBLUE DOSER

0

Component AdBlue doser
System EAS-3

The truck is in the workshop with an active engine
torque derate. The truck comes from another
dealer where they reset the DTC's to solve the
problem.
The driver gets the warning 'engine torque derate
active' on DIP-5, when the truck comes to a
standstill.
pressure and perform the AdBlue
dosing test.
Failure description
PCI sets DTC:
- P1518 Emission Aftertreatment System -
engine torque derate active
- P3859 EAS-3 - AdBlue dosing valve - Not
responding or out of adjustment
Block the supply pipe (1) from the AdBlue doser.
1 AdBlue connection 2
2 Coolant connection
1
I402241
©
5-6 201628
Necessary tools
-
-
DAVIE4 diagnostic tool
Basic toolkit
0
the blocked AdBlue doser. For the diagnostics
the participant can use DAVIE4. He must
compare the values and descriptions of the
problem.
NOTE:
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201628 5-7
5.6 FAULT FINDING CASE: BLOCKED EGR

0

Component EGR pressure difference sensor
System EAS-3

problem.
standstill.
dosing test.
Failure description
PCI sets DTC:
- P127A, EGR pressure difference - Data valid
but too low
- P1719, EGR mass flow - Data valid but too
low
- P1496, EGR - Shut-off
Block the inlet pipe after the venturi with an
appropriate plate.
Necessary tools
- Basic toolkit
the blocked EGR. For the diagnostics the
participant can use DAVIE4. He must compare
the values and descriptions of the DTC's in
Service Rapido. The participant must make a
'step by step' plan how to solve the problem.
NOTE:
©
5-8 201628
Fault finding cases/preparation information MX-11 engine
6. FAULT FINDING CASES/PREPARATION INFORMATION MX-11

ENGINE 0
6.1 FAULT FINDING CASE: FUEL PRESSURE CONTROL VALVE


Vehicle series and type CF_MX-11_E6, FT
Chassis number
Component Fuel pressure control valve
System Fuel system

When an active or stationary regeneration starts,
the fault code P0087 is set. This fault code can
also be set during driving.
The fault has to be located with the
help of the tools included in this
description.
Failure description
Failure in fuel pressure control valve.
Order component with DAF number 1875053.
Prepare the pressure control valve so that the
spring inside the fuel pressure control valve is
weaker.
©
201628 6-1
18
16 10
21
25 20
15 19
24
23 8
1
3 4
13
22
11
9
2 12
6
14 3
17
5 14
3
i403019
©
6-2 201628
i402571
Remove the spring from the fuel pressure control

valve and cut about two coils of the spring.
The length after preparation must be
approximately 28.4 mm. i402572
Mount the fuel pressure control valve after
preparation.
Mount the prepared fuel pressure control valve in
the MX-11 engine.
Necessary tools
- Tool box 1903030
- Adapter set for fuel pressure in combination
with tool box 1453163
- DAVIE diagnostic tool
the fuel pressure control valve. The participant
has to measure the fuel pressure at more places.
For some measurements he can use the toolbox
with adapter set. For some values he can use
DAVIE. He has to compare the values with the
values in Service Rapido. After this he has to
decide in which part of the fuel system the
pressure is too low or too high. The mechanic
must plan how to solve the problem.
©
201628 6-3
0
E
b
5
a a a a a a
P
b 4
U
T
U
e
M M
b b c
D
k l g C
s P c n
7 U
d h c
e
a b
i
h b f r
g a
d o
f M
P
U b
8 B
2
a
9 1 q p
b A c
R
d
U
e
a
6
i402516-2
A Fuel pressure before primer pump
B Fuel pressure after primer pump
C Fuel pressure after lift pump
D Fuel pressure gallery
E Fuel injector leak pressure
Use the information in Service Rapido for the

technical data. Job code: H 1410 000000 010 201
The fuel pressure after lift pump and in gallery
(gauge D and gauge C) is too low.
Pressure in gallery could be read out with DAVIE.
©
6-4 201628
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
201628 6-5
6.2 FAULT FINDING CASE: FUEL FILTRATION MODULE

0

Chassis number
Component Strainer in primer pump
System Fuel system

When an active or stationary regeneration starts,
the fault code P0087 is set. This fault code can
also be set during driving.
description.
Failure description
Failure in strainer in primer pump.
©
6-6 201628
0
12
0
13
14
1
9
11
15 8
10
7 3
6
17
4 16
i403020
Prepare the strainer inside the primer pump.

Place a shrink sleeve around the core of the
strainer with about four small holes (1 mm).
i402569
©
201628 6-7
Mount the prepared strainer in the primer pump.

0 Bleed the fuel system.
i402568
Necessary tools
- Tool box 1903030
with tool box 1453163
- DAVIE4
the strainer inside the primer pump. The
participant has to measure the fuel pressure at
several locations. For some measurements he
can use the toolbox with adapter set. For some
values he can use DAVIE. He has to compare the
values with the values in Service Rapido. After
this he has to decide in which part the pressure is
too low or too high. The mechanic must plan how
to solve the problem
©
6-8 201628
0
E
b
5
a a a a a a
P
b 4
U
T
U
e
M M
b b c
D
k l g C
s P c n
7 U
d h c
e
a b
i
h b f r
g a
d o
f M
P
U b
8 B
2
a
9 1 q p
b A c
R
d
U
e
a
6
i402516-2
A Fuel pressure before primer pump
B Fuel pressure after primer pump
E Fuel Injector leak pressure

The fuel pressure before primer pump (gauge A)
is too low.
©
201628 6-9
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
6-10 201628
6.3 FAULT-FINDING CASE: VTG

0

Chassis number
Component Separate VTG
System VTG turbo charger

The MX-13 engine issues a VTG-related fault
code. DTC P0046 is set
The VTG actuator must be checked.
The fault has to be located with the help
of the tools included in this description.
Failure description
Failure in the VTG actuator.
Prepare the turbocharger with VTG. Demount the
turbine housing and drill a hole in the internal
vane housing and screw a screw in the hole.
Mount the turbine housing and connect the
prepared turbine to the VTG connector. Switch
the ignition on and off. Make a break out cable to
connect the prepared turbocharger to the VTG
with the vehicle connector.
Make a cable to connect the other turbine to the
VTG
i402592
©
201628 6-11
Disassemble the turbine with VTG and drill a hole

0 in the internal housing.
i402593
Screw a screw in the hole.

Assemble the turbine with VTG
i402594
Necessary tools
- Adapter cable (shop made)
- DAVIE4
- Service Rapido
- Separate VTG turbocharger
©
6-12 201628
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
201628 6-13
©
6-14 201628
7. FAULT FINDING CASES/PREPARATION INFORMATION MX-13

ENGINE 0
7.1 FAULT FINDING CASE: FUEL PRESSURE CONTROL VALVE


Vehicle series and type XF_E6
Component Fuel pressure control valve
System Fuel system

The driver complains that the truck does not have
enough power during acceleration and a red
warning is set during acceleration and DTC
P0087 is set. DTC P0087 is also set when an
active or stationary regeneration starts.
Locate the fault with the help of the
tools included in this description.
Failure description
Failure in fuel pressure control valve.
Prepare the pressure control valve so that the
spring inside the fuel pressure control valve is
weaker.
©
201628 7-1
©
7-2 201628
i402571
Remove the spring from the fuel pressure control

valve and cut about two coils of the spring.
The length after preparation must be
approximately 25 mm i402572
Mount the fuel pressure control valve after
preparation
Mount the prepared fuel pressure control valve in
the MX-13 engine
Necessary tools
- Toolbox 1903030
with toolbox 1453163
the fuel pressure control valve. The participant
must measure the fuel pressure at more places.
For some measurements he can use the toolbox
with adapter set. For some values he can use
DAVIE. He must compare the values with the
values in Service Rapido. After this he must
decide where the pressure is too low or too high.
The technician must plan how to solve the
problem
©
201628 7-3
0 5
E
a a a a a a
P
U b D 4
T P
U U
d c
e
M M
b b
3
a
l m C
g
k c
7
j n
e d h c
b
a i
f r
o a
h b M
g b
f e P
B 2
U
8 a
1 q p
b A c
9
R d
U
e
a
6
i401926-4
A fuel pressure before hand priming pump
B fuel pressure after hand priming pump
C fuel pressure after lift pump
D fuel pressure gallery
E fuel leak pressure

The fuel pressure after lift pump and in gallery
(gauge D and gauge C) is too low.
Pressure in gallery can be read out with DAVIE.
©
7-4 201628
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
201628 7-5
7.2 FAULT FINDING CASE: FUEL FILTRATION MODULE

0

Vehicle series and type XF_E6
Component Strainer in hand priming pump
System Fuel system

enough power during acceleration. A red warning
and fault code P0087 are set during acceleration.
Fault code P0087 is also set when an active or
stationary regeneration starts.
The fault must be located with the help
Failure description
Failure in strainer in hand priming pump.
Prepare the strainer inside the hand priming

pump. Place a shrink sleeve around the core of
the strainer with about six small holes (1 mm).
i402569
Mount the prepared strainer in the hand priming

pump.
Bleed the fuel system.
i402568
Necessary tools
- Toolbox 1903030
with toolbox 1453163
©
7-6 201628
the strainer inside the hand priming pump. The
0
participant has to measure the fuel pressure at
more places. For some measurements he can
use the toolbox with adapter set. For some values
he can use DAVIE. He has to compare the values
with the values in Service Rapido. After this he
has to decide in which part the pressure is too low
or too high. The technician must plan how to
solve the problem
E
a a a a a a
P
U b D 4
T P
U U
d c
e
M M
b b
3
a
l m C
g
k c
7
j n
e d h c
b
a i
f r
o a
h b M
g b
f e P
B 2
U
8 a
1 q p
b A c
9
R d
U
e
a
6
i401926-4
A Fuel pressure before hand priming pump
B Fuel pressure after hand priming pump
E Fuel leak pressure

The fuel pressure before hand priming pump
(gauge A ) is too low.
©
201628 7-7
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
7-8 201628
7.3 FAULT-FINDING CASE: VTG

0

Component Separate VTG
System VTG turbocharger

The MX-13 engine issues a VTG-related fault
code. DTC P0046 is set
The VTG actuator must be checked.
The fault has to be located with the help
Failure description
Failure in the VTG actuator.
Prepare the turbocharger with VTG. Demount the
turbine house and drill a hole in the internal vane
housing and screw a screw in the hole. Mount the
turbine housing and connect a prepared turbine
to the VTG connector. Switch the ignition on and
off. Make a break out cable to connect the
prepared turbocharger to the VTG with the
vehicle connector.
Make a cable to connect the other turbine to the
VTG
i402592
©
201628 7-9
Disassemble the turbine with VTG and drill a hole

0 in the internal housing.
i402593
Screw a screw in the hole.

Assemble the turbine with VTG
i402594
Necessary tools
- Adapter cable (shop made)
- DAVIE
- Service Rapido
- Separate VTG turbocharger
©
7-10 201628
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
201628 7-11
©
7-12 201628
Fault finding cases/preparation information ECS-DC6
8. FAULT FINDING CASES/PREPARATION INFORMATION ECS-DC6

8.1 FAULT FINDING CASE: EGR COOLER BLOCKED 0
DD4/1-1 Diagnostic methodology: Engine DD4/1-1 26/03/2015

Vehicle series and type LF_8-12t_E6, LF_14-16t_E6, LF_18-19t_E6, CF_PX-7_E6
Chassis number
Component EGR cooler blocked
System ECS-DC6

A fleet owner has a couple of identical vehicles.
One of the vehicles has a to high AdBlue
consumption compared too the other vehicles. All
vehicles drive on the same route.
Perform a test drive with a vehicle
without faults and a test drive with a
vehicle prepared with the fault. Make a
monitor recording of both test drives.
Compare both monitor recordings and
then study the monitor recordings with
the correct fault analysis.
Check with DAVIE for DTC's and
consult Service Rapido for the
procedure.
Use the user-defined monitor set in
DAVIE4 and select the following
signals:
- Engine load
- AdBlue dosing rate (actual)
- NOX concentration before catalyst
- NOX concentration after catalyst
- EGR valve position
- EGR pressure difference
- AdBlue dosing valve
Failure description
The EGR system is partially blocked.
©
201628 8-1

0 A 8 mm drilled hole
Prepare a blockage from a piece of metal.

Remove the gasket from the EGR cooler/
crossover tube. Replace the gasket with the
prepared blockage.
A
i405051
Necessary tools
The participant must find the problem of the
blocked EGR cooler. For the diagnostics the
participant can use DAVIE4 and the DAVIE4
monitor recordings. The participant must
compare the values from the monitor recordings
to find the problem. The participant must make a
'step by step' plan on how to solve the problem.
©
8-2 201628
Explanation DAVIE4 monitor with a fault case

and a good case
0
Recording with fault
4.4.1 | 15.05.2 | VCD: 31-03-2015 14:56:28
Monitoring
ECS-DC6 all signals
Signals
100
0 sec
0.0 48.0 96.0 144.0 192.0 240.1 288.1 336.1 384.1 432.1 480.1 528.1 576.1 624.2 672.2
1 ECS-DC6 Engine load (Actual) 43.36 5 ECS-DC6 EGR valve position 101.50
2 ECS-DC6 AdBlue dosing rate (Actual) 1213.95 g/h 6 ECS-DC6 EGR differential pressure 7.03 mBar
3 ECS-DC6 NOx concentration before cat... 734.50 PPM
4 ECS-DC6 NOx concentration after catalyst 17.78 PPM
7:52 12:00
User name Chassis number
M205002-2
1 Engine load (Actual)

2 AdBlue dosing rate (Actual)
3 NOx concentration before catalyst
4 NOx concentration after catalyst
5 EGR valve position
6 EGR differential pressure
©
201628 8-3
0 Recording without fault
4.4.1 | 15.05.2 | VCD: 31-03-2015 14:56:28
Monitoring
ECS-DC6 all signals
Signals
100
0 sec
0.0 48.1 96.2 144.4 192.5 240.6 288.7 336.9 385.0 433.1 481.2 529.3 577.5 625.6 673.7
2 ECS-DC6 AdBlue dosing rate (Actual) 560.16 g/h 6 ECS-DC6 EGR differential pressure 35.00 mBar
4 ECS-DC6 NOx concentration after catalyst -1.13 PPM
7:49 12:01
i405016-2

6 EGR differential pressure
In both cases, the vehicle drives the same route

and cruise control is activated. Therefore, the
engine load and the NOx out of the engine should
be the same for both cases, but it isn't. The faulty
engine has a higher NOx out concentration
before the catalyst. If there is no fault in the NOx
sensor then the problem must be before the
Emission Aftertreatment System. The NOx out is
being monitored by the ECS-DC6 system and
controlled by the EGR system. The use of EGR
can reduce the NOx, but it can increase the
production of soot. ECS-DC6 calculates the right
amount of EGR gases for each operating
condition of the engine. The EGR system is a
closed loop controlled system. The ECS-DC6
system controls the EGR mass flow based on
with the signals from the EGR valve position,
EGR low temperature and EGR pressure
difference sensor. Depending on the measured
NOx concentration in the exhaust gases this EGR
mass flow is adjusted.
©
8-4 201628
If the EGR cooler is partially blocked, the EGR

valve needs to be opened further to achieve the
same required EGR mass flow. When this EGR 0
valve is already 100% opened, the EGR mass
flow may not be sufficient. As a result, the NOx
levels will be too high. The ECS-DC6 control
system tries to compensate for this by adding
more AdBlue to the SCR (which is the complaint
of the driver).
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
201628 8-5
8.2 FAULT FINDING CASE: IRREGULAR RUNNING ENGINE

0

Chassis number
Component Wiring common rail pressure sensor
System ECS-DC6

Sometimes when the engine is running irregular,
the engine sets no DTC is set.
4.4.1 | 15.05.2 | VCD: 01-04-2015 11:19:03
Monitoring
ECS-DC6 All signals
Signals
15
A B
0 sec
0.0 81.1 162.3 243.4 324.5 405.6 486.8 567.9 649.0 730.1 811.3 892.4 973.5 1054.7 1135.8
1 ECS-DC6 Aftertreatment operation status SCR warmi... 5 ECS-DC6 Common rail fuel pressure (C... 778.55 bar
2 ECS-DC6 Engine torque mode Engine Sp...
3 ECS-DC6 Engine speed 1266.38 rpm
4 ECS-DC6 Common rail fuel pressure (A... 735.25 bar
5:51 20:16
i405017-2
DAVIE4 monitor recording

A+B Engine torque mode; Engine Speed
Control
1 Aftertreatment operation status

2 Engine torque mode
3 Engine speed
4 Common rail fuel pressure (Actual)
5 Common rail fuel pressure (Commanded)
©
8-6 201628

prepared with the failure. Make a
DAVIE4 monitor recording of the test 0
drive. Make sure that the vehicle runs in
a stable condition, for example with
ESC (A+B), whilst the engine is
switching from one Aftertreatment
operating status (1) to an other
aftertreatment operating status (1).
Then study the monitor recording with
the correct fault analysis. Use DAVIE4
to perform all the relevant diagnostics
tests.
procedure.
Failure description
The common rail pressure sensor signal is
pulled-up with 200 bar. This means that the
actual pressure inside the rail is 200 bars less
then the sensor signal output.
D431 ECS-DC6 ECU
F854 common rail pressure sensor
D431
D58 D59 D82
1 2 3
U
P
F854
I402875-4
D431 F854 Function

D58 3 Earth
D59 2 Signal, rail pressure
D82 1 Power supply
©
201628 8-7
A 0,5K Ohm resistance

0
A
i405046
A 0,5K Ohm resistance

B Signal wire contact from rail pressure
sensor connector
Prepare the faulty installing a wire (A) with a

resistance of 0,5K Ohm between the connector of
the rail pressure sensor and the signal wire
contact (B). Use the correct special tool to
remove the wire out of the rail pressure sensor
connector. The wire should be fitted between the
signal wire (D59) of the rail pressure sensor and
the connector of the rail pressure sensor (which is
connected to the harness).
A B
i405045
Necessary tools
- Basic toolkit
the resistance in the wire. For the diagnostics the
participant can use DAVIE4. The participant must
compare the values and descriptions in Service
Rapido. The participant must make a 'step by
step' plan on how to solve the problem. The focus
must be the 'aftertreatment operating status' and
'common rail fuel pressure' in DAVIE4.
Each aftertreatment operating status has it's own
fuel control strategy, EGR control strategy and
VTG control strategy (see table below). If the
actual fuel pressure inside the rail drops with 200
bars the problem will be more noticeable in an
aftertreatment operating status where the
commanded common rail pressure is already
low. For example in the operating status 'SCR
'warming up'. In this state the commanded
common rail fuel pressure at 1200 RPM with no
load is only 325 bars.
©
8-8 201628
Aftertreatment operation status in relation to 'common rail fuel pressure', 'EGR valve position'
and 'VTG actuator position' measured with an engine speed of 1200 RPM (ESC) 0
Aftertreatment operation status Common rail fuel EGR valve VTG actuator
pressure position position
1. Normal 940 bar 10% 15%
5. Protection 940 bar 0% 96%
7. HC desorption 825 bar 0% 3%
8. Stationary regeneration 800 bar 0% 3%
9. SCR warming up 325 bar 0% 10%
11. SCR warming up slowly 325 bar 0% 96%
DAVIE4 Fault case 'Normal' versus 'SCR

warming up slowly'
4.4.1 | 15.05.2 | VCD: 01-04-2015 11:19:03
Monitoring
ECS-DC6 All signals
Signals
15
B C
A
0 sec
791.5 812.3 833.0 853.7 874.4 895.1 915.8 936.5 957.3 578.0 998.7 1019.4 1040.1 1060.8 1081.5
1 ECS-DC6 Aftertreatment operation status Normal 5 ECS-DC6 Common rail fuel pressure (C... 969.63 bar
4 ECS-DC6 Common rail fuel pressure (A... 966.88 bar
14:25 20:16
i405019-2
A Engine torque mode; Engine Speed
Control
B Aftertreatment operation status; Normal
C Aftertreatment operation status; SCR
warming up slowly

3 Engine speed
Each aftertreatment operating status has it's own

fuel control strategy. In the 'Normal' operating
status (B) the commanded common rail fuel
pressure at 1200 RPM (ESC (A)) with no load is
approximately 940 bars (according to the table).
The fault pulls up the signal with 200 bars. This
©
201628 8-9
means that the actual fuel pressure inside the rail

0 is 940 bars- 200 bars= 740 bars. In the 'Normal'
operating status (B) the actual fuel quantity
injected is 22% less then without fault. This is not
noticeable for the driver
In the 'SCR warming up slowly' operating status
(C) the commanded common rail fuel pressure at
1200 RPM (ESC (A)) with no load is
is only 325 bars- 200 bars= 125 bars. In the 'SCR
warming up slowly' status the actual fuel quantity
injected is 62% less then without fault. This is
much more noticeable for the driver then when
the vehicle runs in 'Normal' operating status (B).
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
8-10 201628
DAVIE4 Fault case 'SCR warming up' versus

'SCR warming up slowly'
0
4.4.1 | 15.05.2 | VCD: 01-04-2015 11:19:03
Monitoring
ECS-DC6 All signals
Signals
15
B C
A
0 sec
62.9 105.5 148.2 190.9 233.5 276.2 318.8 361.8 404.2 446.8 489.5 532.1 574.8 617.5 660.1
1 ECS-DC6 Aftertreatment operation status SCR warmi... 5 ECS-DC6 Common rail fuel pressure (C... 1141.63 bar
4 ECS-DC6 Common rail fuel pressure (A... 673 bar
5:58 20:16
i405018-2
A Engine torque mode; Engine Speed
Control
B Aftertreatment operation status; SCR
warming up
C Aftertreatment operation status; SCR
warming up slowly

3 Engine speed
In the 'SCR warming up' operating status (B) the

commanded common rail fuel pressure at 1200
RPM (ESC (A)) with no load is approximately 325
bars (according to the table). The fault pulls up
the signal with 200 bars. This means that the
actual fuel pressure inside the rail is only 325
bars- 200 bars= 125 bars. In the 'SCR warming
up' status the actual fuel quantity injected is 62%
less then without fault.
In the 'SCR warming up slowly' operating status
(C) the commanded common rail fuel pressure at
1200 RPM (ESC (A)) with no load is
is only 325 bars- 200 bars= 125 bars. In the 'SCR
warming up slowly' status the actual fuel quantity
injected is 62% less then without fault.
©
201628 8-11
In this monitor screen the actual fuel injected

0 quantity is for both aftertreatment operating
statuses the same (62% less). But depending on
the VTG strategy and EGR strategy of each
aftertreatment operating status the fuel pressure
problem can be more or less noticeable for the
driver. The problem is less noticeable in the 'SCR
warming up' operating status.
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
8-12 201628
8.3 FAULT FINDING CASE: NOX SENSOR DRIFTED HIGH

0

Chassis number
Component NOx sensor before catalyst
System ECS-DC6

The driver gets a yellow warning on DIP-5, when
the truck comes to a standstill.
DAVIE4.
- Engine load
- engine speed
- vehicle speed
- accelerator pedal position
Failure description
The NOx sensor before catalyst is contaminated.
The following DTC's are set by ECS-DC6 system:
- 3216-20 NOx sensor before catalyst - Data
not rational, drifted high
- 5840-31 AdBlue dosing valve - Internal error
- 5842-31 SCR catalyst - Error
longer detected.
Block the nozzle of the NOx sensor before
catalyst with a thick layer of exhaust cement /
assembly paste .
Place the prepared NOx sensor into the exhaust
tube.
Perform a test drive with a vehicle without faults
and a test drive with a vehicle prepared with the
failure. Make a monitor recording of both test
drives. Compare both monitor recordings and
then study the monitor recordings with the correct
fault analysis.
i405050
©
201628 8-13
Necessary tools
0 - DAVIE4 diagnostic tool
the contaminated NOx sensor before catalyst.
For the diagnostics the participant can use
DAVIE4 and the DAVIE4 monitor recordings. The
participant must compare the values from the
monitor recordings to find the problem. The
participant must make a 'step by step' plan how to
solve the problem.
Explanation Davie4 monitor with a fault case
and a good case
4.4.1 | 15.05.2 | VCD: 31-03-2015 14:56:28
Monitoring
ECS-DC6 All signals
Signals
3000
A
PPM
0 sec
0.0 53.8 107.7 161.5 215.3 269.2 323.0 376.9 430.7 484.5 538.4 592.2 646.0 699.9 753.7
1 ECS-DC6 Engine load (Actual) 52.73
2 ECS-DC6 Engine torque mode Cruise
3 ECS-DC6 NOx concentration before catalyst 826.88 PPM
4 ECS-DC6 Accelerator pedal position 0.00
2:07 13:27
i405020-2
A Engine load 0% - NOx concentration
drifted high
4 Accelerator pedal position
©
8-14 201628
Fault case
4.4.1 | 15.05.2 | VCD: 01-04-2015 11:19:03

0
Monitoring
ECS-DC6 All signals
Signals
3000
A
PPM
0 sec
257.7 279.7 301.6 323.5 345.4 367.4 389.3 411.2 433.1 455.1 477.0 498.9 520.9 542.8 564.7
2 ECS-DC6 Engine torque mode Running
6:27 13:27
i405022-2

drifted high
©
201628 8-15
0 Good case
4.4.1 | 15.05.2 | VCD: 31-03-2015 14:56:28
Monitoring
ECS-DC6 All signals
Signals
3000
A
PPM
0 sec
0.0 55.5 110.9 166.4 221.8 277.3 332.7 388.2 443.6 499.1 554.5 610.0 665.4 720.9 776.3
2 ECS-DC6 Engine torque mode Cruise
2:06 13:51
i405021-2

approximately 0%
The NOx sensor before the catalyst measures

the amount of NOx that leaves the engine. This
measurement is used to check and adapt the
predicted NOx values that are sent as a CAN
message to the engine management system. The
NOx sensor before catalyst consists of a ceramic
sensor element and an electronic control unit.
The ceramic sensor element is placed in the
exhaust pipe and measures the NOx
concentration in the exhaust gas flow.
If the surface of the ceramic sensor element is
contaminated with soot or the breathing holes
from the elements nozzle are blocked with soot,
the reading of NOx values take longer (the
contaminated NOx sensor has a delay time).
Contamination can also express it selves in a
smaller amplitude, but the average of the
measured amount of NOx concentration can still
be the same compared to a sensor without
contamination.
At point (A) of the good and the bad case the
vehicle is decelerating and the engine load is
zero percent. If the vehicle is decelerating there is
no fuel injected and the expected NOx value out
of the engine should be zero. Because the sensor
©
8-16 201628
is contaminated there is a delay time at this point

(A) in the measured NOx out of the engine. If at
this particular point the diagnostic condition are 0
met ECS-DC6 will set the following DTC: 3216-
20, NOx sensor before catalyst - Data not
rational, drifted high.
NOTE:
©
201628 8-17
8.4 FAULT FINDING CASE: COOLANT TEMPERATURE SENSOR

0

Chassis number
Component Wiring of coolant temperature sensor
System ECS-DC6

A fleet owner has a couple of vehicles. One of the
vehicles has a to high AdBlue consumption
compared to the other vehicles. All vehicles drive
on the same route.
DAVIE4.
- Engine load
- AdBlue dosing rate (actual)
- NOX concentration after catalyst
- EGR valve position
- EGR pressure difference
- AdBlue dosing valve
without faults and a test drive with a
vehicle prepared with the failure. Make
a monitor recording of both test drives.
Compare both monitor recordings and
then study the monitor recordings with
the correct fault analysis.
procedure.
Failure description
Set the coolant temperature at 25 degrees by
using the a resistance.
©
8-18 201628

D431 ECS-DC6 ECU
F684 sensor, coolant temperature
0
F832 sensor, EGR low temperature D431
D34 D83 D65
1 2 1 2
R R
T T
F684 F832
I402869-2
D431 F684 Function

D34 1 Earth
D83 2 Signal, coolant temperature
Resistance of temperature sensor in relation to measured temperature

Temperature (° C) Resistance value ( Ω )
Minimum Maximum
0 30000 37000
25 9300 10700
50 3200 3800
80 1100 1300
95 700 800
Disconnect the connector of the coolant

temperature sensor. Attach a wire with resistance
between pin 1 and 2 of the harness coolant
sensor connector.
2 1
I402585
Necessary tools
©
201628 8-19
coolant temperature sensor. For the diagnostics
the participant can use DAVIE4 and the DAVIE4
monitor recordings. The participant must
compare the values from the monitor recordings
to find the problem. The participant must make a
Explanation DAVIE4 monitor with a fault case
and a good case
Fault case
4.4.1 | 15.05.2 | VCD: 31-03-2015 14:56:28
Monitoring
ECS-DC6 All signals
Signals
100
0 sec
0.0 46.6 93.3 139.9 186.5 233.2 279.8 326.5 373.1 419.7 466.4 513.0 559.6 606.3 652.9
2 ECS-DC6 AdBlue dosing rate (Actual) 1533.59 g/h 6 ECS-DC6 Coolant temperature 24.78
7:26 11:39
i405023-2

6 Coolant temperature
©
8-20 201628
Good case
4.4.1 | 15.05.2 | VCD: 31-03-2015 14:56:28

0
Monitoring
ECS-DC6 All signals
Signals
100
0 sec
0.0 47.1 94.1 141.2 188.3 235.4 282.4 329.5 376.6 423.7 470.7 517.8 564.9 612.0 659.0
2 ECS-DC6 AdBlue dosing rate (Actual) 532.14 g/h 6 ECS-DC6 Coolant temperature 81.38
7:32 11:46
i405024-2

6 Coolant temperature
In both cases, the vehicle drives the same route

and cruise control is activated. Therefore, the
engine load and the NOx out of the engine should
be simular for both cases. The faulty engine has
a higher NOx out concentration before the
catalyst. If the NOx sensor is correct then the
problem must be before the aftertreatment
system. The NOx out is being monitored by the
ECS-DC6 system and controlled by the EGR
system. When ECS-DC6 activates the EGR
valve, cooled exhaust gasses are forced back
into the engine. These cooled exhaust gases are
mixed with the clean air. This compressed mixed
gas mass reduces the amount of oxygen
molecules available for combustion. Fewer
oxygen molecules and a combustion heat which
is divided over a higher mass, causes a slower
flame front during combustion, resulting in less
high-temperature peaks. These lower
combustion peak temperatures reduce the
production of nitrogen oxides (NOx). During cold
operating conditions ECS-DC6 closes the EGR
valve more. Because there is a faulty engine
coolant temperature sensor the engine appears
©
201628 8-21
to be cold and the EGR valve is almost closed. As

0 a result, the NOx levels will be too high. The ECS-
DC6 control system tries to compensate for this
by adding more AdBlue to the SCR (which is the
complaint of the driver).
NOTE:
©
8-22 201628
8.5 FAULT FINDING CASE: FAULTY INJECTOR

0

Chassis number
Component Injector coil cylinder 4
System ECS-DC6

engine sets no DTC.
Use DAVIE4 to perform all the relevant
diagnostics tests.
procedure.
Failure description
The contribution of cylinder 4 is too low and / or
the engine is misfiring.
A Injector coil
B Hole crankcase ventilation system
A B
i405047
©
201628 8-23
Prepare the case by mounting an extra injector

0 coil parallel over the fourth injector.
i405048
Necessary tools
- Basic toolkit
the injector coil. For the diagnostics the
the values and descriptions in Service Rapido.
The participant must make a 'step by step' plan
how to solve the problem. The focus must be on
cylinder cut out test' in DAVIE4.
NOTE:
©
8-24 201628
8.6 FAULT FINDING CASE: INLET AIR PRESSURE IN INLET MANIFOLD

0

Chassis number
Component Inlet air boost pressure and temperature sensor
System ECS-DC6

The truck is in the workshop with an active DTC.
The truck comes from another dealer where they
replaced the inlet air pressure and temperature
sensor to solve the problem.
Use DAVIE4 to monitor the inlet and
exhaust system.
Failure description
ECS-DC6 sets DTC:
- 102-2 Inlet air pressure in inlet manifold -
Data erratic, intermittent, or incorrect
- 5840-31 AdBlue dosing valve - Internal error
- 5842-31 SCR catalyst - Error
©
201628 8-25

0 F881
i402684
Remove the turbo inlet pressure and temperature

sensor (F881) from the inlet pipe. Replace this
sensor with the same type of sensor as used for
the inlet air boost pressure and temperature
sensor (F875).
i402909
©
8-26 201628
Necessary tools
-
-
Basic toolkit
0
the wrong type of sensor. For the diagnostics the
NOTE:
©
201628 8-27
8.7 FAULT FINDING CASE: EXHAUST GAS PRESSURE BEFORE TURBINE

0

Chassis number
Component Pressure sensor before turbine
System ECS-DC6

The driver complaints about an irregular running
engine.
Use DAVIE4 to monitor the inlet and
exhaust system.
Failure description
©
8-28 201628

0
F826
i402605
Remove the pressure sensor before turbine
(F826). Block the tube with a bearing ball with a
size of approximately 6 mm. Install the pressure
sensor back to tube. If the bearing ball is to small
and it does not block the tube, then fill the
remaining space with a washer of the correct
thickness.
Necessary tools
- Basic toolkit
©
201628 8-29
the blocked sensor. For the diagnostics the
'step by step' plan on how to solve the problem.
NOTE:
©
8-30 201628
8.8 FAULT FINDING CASE: ADBLUE MODULE UNABLE TO PRIME

0

Chassis number
Component AdBlue temperature and level sensor
System ECS-DC6

The truck has a problem with the AdBlue system.
The truck is coming from another dealer where
they replaced the AdBlue pump module to solve
the problem.
The ECS-DC6 system cannot prime the system.
The driver gets a warning on DIP-5 and ECS-
DC6 sets a DTC.
pressure and perform the AdBlue prime
test.
Failure description
The DTC 3362-31 pump module pressure -
Unable to prime and the DTC 5840-31 AdBlue
dosing valve - Internal error is set by ECS-DC6.
longer detected.
A Outlet connection AdBlue temperature
and level sensor
Remove the AdBlue inlet connection from the

AdBlue temperature and level sensor. Block the
AdBlue inlet connection with a bolt and install the
AdBlue inlet connection back to the AdBlue level
and temperature sensor.
A
i405049
©
201628 8-31
Necessary tools
0 -
-
Basic toolkit
the blocked AdBlue inlet connection. For the
diagnostics the participant can use DAVIE4. He
must compare the values and descriptions of the
problem.
Fault case
4.4.1 | 15.05.2 | VCD: 01-04-2015 11:19:03
Monitoring
Operating phase
Signals
15
A A A B
0 sec
0.0 63.9 127.7 191.6 255.4 319.3 383.1 447.0 510.9 574.7 638.6 702.4 766.3 830.1 894.0
1 ECS-DC6 Pump module status (AdBlue) Off
2 ECS-DC6 AdBlue pressure (Absolute) 0.07 bar
3 ECS-DC6 AdBlue dosing valve position (Commanded) Closed
4 ECS-DC6 Reverting valve position Closed
13:14 15:57
i405027-3
A Pump module status (AdBlue); Initialising

- Priming
B Pump module status (AdBlue); Off
1 Pump module status (AdBlue)

2 AdBlue pressure (Absolute)
3 AdBlue dosing valve position
(Commanded
4 Reverting valve position
©
8-32 201628
Good case
4.4.1 | 15.05.2 | VCD: 01-04-2015 11:19:03

0
Monitoring
Operating phase
Signals
15
A B C D E
0
0.0 47.0 94.0 141.0 188.1 235.1 282.1 329.1 376.1 423.1 470.1 517.2 564.2 611.2 658.2 sec
1 ECS-DC6 Pump module status (AdBlue) Dosing
2 ECS-DC6 AdBlue pressure (Absolute) 8.95 bar
3 ECS-DC6 AdBlue dosing valve position (Commanded) Closed
4 ECS-DC6 Reverting valve position Closed
4:38 11:45
i405028-2
A Pump module status (AdBlue); Initialising

B Pump module status (AdBlue); Priming
C Pump module status (AdBlue); Dosing
D Pump module status (AdBlue); Purging
E Pump module status (AdBlue); Off
1 Pump module status (AdBlue)

2 AdBlue pressure (Absolute)
3 AdBlue dosing valve position
(Commanded)
4 Reverting valve position
NOTE:
©
201628 8-33
8.9 FAULT FINDING CASE: BLOCKED ADBLUE DOSER

0

Chassis number
Component AdBlue dosing valve
System ECS-DC6

problem.
standstill.
dosing test.
Failure description
ECS-DC6 sets DTC:
- Emission Aftertreatment System - engine
torque derate active
- 5394-7 - AdBlue dosing valve - Not
responding or out of adjustment
Block the supply pipe (1) from the AdBlue doser.
1 AdBlue connection 2
2 Coolant connection
1
I402241
©
8-34 201628
Necessary tools
-
-
Basic toolkit
0
the blocked AdBlue doser. For the diagnostics
the participant can use DAVIE4. He must
compare the values and descriptions of the
problem.
NOTE:
©
201628 8-35
©
8-36 201628
Fault finding cases/preparation information PX-5 engine
9. FAULT FINDING CASES/PREPARATION INFORMATION PX-5

ENGINE 0
9.1 FAULT-FINDING CASE: FUEL SYSTEM
Fault-finding case No. 6.1 Training module Date


MX-13 engine has not enough power at all engine speeds.
Vehicle series and type LF_E6
Chassis number 0L423030
Component Fuel line before fuel fine filter
System Fuel system

enough power. Fault code 157-18 is also set after
a certain amount of time.
description.
Failure description
Restriction in fuel line.
Preparation of the failure (1)
Make a small blockage in line number 1 for fuel
fine filter.
1
i403373
©
201628 9-1
Place a prepared pop rivet in the connection pipe

0 of the filter house before connecting the line.
The prepared pop rivet is a compound of two pop
rivets. The smaller one is almost closed on the
end. The bigger one fits exactly in the fuel pipe of
the fuel filter house.
i403374

Make a small blockage in line number 1 for fuel
fine filter.
of the filter house before connecting the line.
The second preparation is easier, but if you want
you can change it during the training.
I403422
Necessary tools
- Toolbox 1453163 and adapter set for
pressure gauge set 1809977.
the narrowing in the fuel line before the fuel fine
filter. The participant has to measure the fuel
pressure at more places. For some
measurements he can use the toolbox. He has to
compare the values with the values in Service
Rapido. After this he has to decide in which part
the pressure is too low or too high. The technician
must plan how to solve the problem
©
9-2 201628
8
a a a a
b 0
7 U a c
b P
3
4 6 d
e e
c
c
B g
M
f a
i
a
M b
b d f
2 b
C 5 a D
a
E
A
1 R
U
i403342
D fuel pressure after fuel fine filter
E fuel return pressure

The fuel pressure before the fuel fine filter (gauge
C) is too high and after the fuel fine filter (gauge
D) it is too low.
©
201628 9-3
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
9-4 201628
9.2 FAULT FINDING CASE: EGR VALVE

0
Practical case no. 6.2 Training module Date
Description of the complaint or the instruction related to the test case

Vehicle series and type LF
Component EGR valve
Self-made training material The EGR valve does not operate the valve shaft stem.
Note:
Necessary tools
DAVIE DAVIE diagnostic tool, pressure gauges
Description of the complaint or instruction

related to the test case.
The engine issues an EGR-related fault code.
Locate it using the tools.
Failure description
Failure in the EGR valve.
Order component with DAF number of EGR
valve. Prepare the EGR valve by removing the
spindle.
I403383
©
201628 9-5
Necessary tools
0 - DAVIE4 diagnostic tool
the EGR valve. The participant must read out the
fault code and check the EGR valve using
DAVIE. The conclusion must be to replace the
EGR valve.
©
9-6 201628
9.3 FAULT FINDING CASE: EXHAUST GAS RECIRCULATION

0

Component EGR valve
Self-made training material The EGR valve flow is blocked.
Note:
Necessary tools

The engine issues an EGR-related fault code
DTC 3058-18, which is set after a certain time.
Failure description
©
201628 9-7

0 Order component with DAF number of EGR
valve. Prepare the EGR valve by blocking the
port to the inlet manifold.
I403390

Place the prepared blockage on the other side of
the EGR crossover tube.
I403423
Necessary tools
EGR valve.
©
9-8 201628
10.FAULT FINDING CASES/PREPARATION INFORMATION PX-7

ENGINE 0
10.1 FAULT FINDING CASE: FUEL SYSTEM


Vehicle series and type LF _E6
Component Fuel line before fuel fine filter
System Fuel system

enough power. Fault code DTC 157-18 is also set
after a certain time.
Failure description
Restriction in fuel line.
Make a small blockage in line number 1 before
the fuel fine filter.
1
i403373
©
201628 10-1

0 of the filter housing before connecting the line.
The prepared pop rivet consists of two pop rivets.
The smaller one is almost closed on the end. The
larger one exactly fits in the fuel pipe of the fuel
filter housing
i403374

Make a small blockage in the fuel supply line
direction in the fuel tank connection.
Place a prepared plastic plug with two small holes
in the connection pipe of the fuel supply line on
the fuel tank.
The second preparation is easier. You can
change it during the training if desired.
I403422
Necessary tools
- Toolbox 1453163 and adapter set 1809977
the narrowing in the fuel line before the fuel fine
filter. The participant must measure the fuel
pressure at more places. For some
measurements he can use the toolbox. He must
compare the values with the values in Service
Rapido. After this he must decide in which part
the pressure is too low or too high. The technician
must plan how to solve the problem
©
10-2 201628
8
a a a a a a
b 0
7 U a c
b P
3 4 6 d
e e
c
c
B g
M
f a
i
a
M b
b d f
2 b
C 5 a D
a
A
E
1 R
U
i403316
D fuel pressure after fuel fine filter
E fuel return pressure

The fuel pressure before the fuel fine filter (gauge
C) is too high and after the fuel fine filter (gauge
D) is too low.
©
201628 10-3
0
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
10-4 201628
10.2 FAULT FINDING CASE: EGR VALVE

0

Component EGR valve
Self-made training material The EGR valve does not operate the valve shaft stem.
Note:
Necessary tools

The engine issues an EGR-related fault code.
Failure description
Order component with DAF number of EGR
valve. Prepare the EGR valve by removing the
spindle.
I403383
©
201628 10-5
Necessary tools
0 - DAVIE diagnostic tool
EGR valve.
©
10-6 201628
10.3 FAULT FINDING CASE: EXHAUST GAS RECIRCULATION

0

Chassis number
Component EGR valve
Self-made training material The EGR valve flow is blocked.
Note:
Necessary tools

The engine issues an EGR-related fault code
DTC 3058-18, which is set after a certain time.
Failure description
©
201628 10-7

0 Order component with DAF number of EGR
valve. Prepare the EGR valve by blocking the
port to the inlet manifold.
I403390

Place the prepared blockage on the other side of
the EGR crossover tube.
I403423
Necessary tools
EGR valve.
©
10-8 201628
Required materials
11.REQUIRED MATERIALS
11.1 ROOM ARRANGEMENTS 0
See the requirements on the DAF Academy info
site, accessible via ePortal (Chapter "Partners &
Facilities").
©
201628 11-1
Required materials
11.2 REQUIRED MATERIAL FOR THE TRAINER

0 - Laptop/desktop
- Projector and projector screen
- Markers for writing on the flipchart/
whiteboard
- Trainer document/guide
- Participant attendance list (TMS)
©
11-2 201628
Required materials
11.3 REQUIRED MATERIAL FOR THE PARTICIPANTS
- Notebook
0
- Name card
- Pen
- Diagnostic vehicle information file
©
201628 11-3
Required materials
11.4 REQUIRED TRAINING MATERIAL TO SUPPORT THE TRAINING

0 This is a summary of the materials required to
support this training module.
Generic training materials are listed in the DAF
Academy sharepoint site (Partner & Facilities).
Required materials:
- All components relevant to this subject.
(EAS-3 module with sensors etc.)
- EAS-3 model to support the theoretical
exercise
- Multimeter
- Scope meter Fluke 123
- MX11/MX 13 engine
- Prepared trucks for the practical exercises
(Trucks must be prepared and tested before
the training)
- AdBlue Dosing system Bosch Denoxtronic
2.2
Advised materials:
- breakout box for PCI. This tool fits on the PCI
connectors of the PCI for MX-11 and MX-13.
- Part number Breakout Box: 1785372
- Part number cable: 1696719
T00210
- PICO scope meter with integrated DAF

software.
I403276
©
11-4 201628
Required materials
I403277
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
.....................................................................................................................................................
©
201628 11-5
Required materials
©
11-6 201628

DD4-1 Dignostico Motor DW63239101 - DD4 - 1

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Trainer document/guide:

Diagnostic methodology: Engine, DD4/1

TRAINING SUPPORT INFORMATION

2. TRAINING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 201628

3. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 201628

4. DIAGNOSTIC VEHICLE INFORMATION FILE. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 201628

5. FAULT FINDING CASES/PREPARATION INFORMATION PCI & EAS-3 . . . . 5-1 . . . . . 201628

6. FAULT FINDING CASES/PREPARATION INFORMATION MX-11 ENGINE . . 6-1 . . . . . 201628

7. FAULT FINDING CASES/PREPARATION INFORMATION MX-13 ENGINE . . 7-1 . . . . . 201628

8. FAULT FINDING CASES/PREPARATION INFORMATION ECS-DC6 . . . . . . . 8-1 . . . . . 201628

9. FAULT FINDING CASES/PREPARATION INFORMATION PX-5 ENGINE. . . . 9-1 . . . . . 201628

11. REQUIRED MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . . 201628

1.2 ICON DEFINITION

2.2 BRIEF DESCRIPTION DD4/1

By applying the DAF Diagnostic Methodology,

Does not operate as designed

Contact Service Helpdesk

7.1 Identify cause

Sequence of the steps

To make sure that the diagnostic information

is relevant and specific for this vehicle. Reproducable concern

To understand the customers concern and Operates as designed

- 'Cause' represented in blue. This step gives

Contact Service Helpdesk

To make sure that the vehicle operates as c

To check if there is publication available for Publication identified

Of the DTC's No publication identified

- 'Correction' represented in green. This step 7.1 Identify cause

The concern that is solved or not

Feedback provided to the customer c

flow chart (without text)

The image above represents the DAF

4. DIAGNOSTIC VEHICLE INFORMATION FILE

Step 1: Identify vehicle

Step 2: Understand & verify customer’s concern

Name: ……….................................................................................. (same as step1) □

0 Step 3: Customer expectation mismatch

Name: ……….................................................................................. (same as step1) □

Step 4: Perform visual and operational primary checks

Name: ……….................................................................................. (same as step1) □

Step 5: Perform diagnostic quick check

Name: ……….................................................................................. (same as step1) □

Step 6: Check for relevant Bulletins

Name: ……….................................................................................. (same as step1) □

Step 7.1: Identify cause - Rationality type DTC

Name: ……….................................................................................. (same as step1) □

Step 7.2. Identify cause - Communication concern or DTC

Name: ……….................................................................................. (same as step1) □

0 Step 7.3. Identify cause - Plausibility type DTC

Name: ……….................................................................................. (same as step1) □

Step 7.4. Identify cause - Symptom - no DTC

Name: ……….................................................................................. (same as step1) □

Step 7.5. Identify cause - no published diagnostics

Name: ……….................................................................................. (same as step1) □

Step 8: Repair and validate remedy