InformacionMotoresElectronicosNEFT3

8/13/2019 InformacionMotoresElectronicosNEFT3

1/41

Common Rail Next Generation Engines

68

EDC 7 electronic engine control unit

A Injectors connector B Connector for power input and functions provided for in theapplication C Sensors connector

The control unit is installed on flexible mounts to reduce vibration transmitted by the engine. It isinstalled over a fuel heat exchanger which limits the engine heat transmitted to the controller.The unit is supplied with power by a 20 A fuse. The main relay normally used to supply the systemis located inside the control unit.


2/41

Common Rail Next Generation Engine

69

Injectors connector (A)

12 16

11

51

6

Wire input side view

ECU PIN WIRE COLOR FUNCTION

1 - -

2 - -

3 RU Red/Blue Cylinder 2 injector

4 WP White/Purple Cylinder 3 injector

5 WV White/Blue??? Cylinder 4 injector

6 RW Red/White Cylinder 2 injector

7 - Ground

8 - Ground

9 RG Red/Green Cylinder 1 injector

10 UN Blue/Brown Cylinder 6 injector 11 UG Blue/Green Cylinder 5 injector

12 WR White/Red Cylinder 3 injector

13 RY Red/Yellow Cylinder 1 injector

14 W White Cylinder 4 injector

15 UO Blue/Orange Cylinder 6 injector

16 UY Blue/Yellow Cylinder 5 injector

Color keyB black

R redU blueW whiteP purpleG greenN brownY yellowO orange

50350


3/41


70

Connector (B) for component power supplies and for the functions specified in theapplication

Wire input side view

PinECU CABLE FUNCTION

1 8150 Direct positive from battery

2 0087 Negative for fuel filter heating / starter engine contactor

3 0000 Ground

4 8885 Positive for pre-post heating resistor


8 7777Positive for blink code button / oil low pressure light/ pre-heating light/

conditioned air switch () / EDC unit

9 0000 Ground



14 0000 Ground

15 0000 Ground

16 0094 Negative for pre-post heating resistor

19 0150Negative for start/stop from engine compartment () / accelerator pedal

pressed () buttons

20 8153 Positive from key switch in start phase (+50)

27 0156 Positive from blink code button

28 5535 Positive for EDC diagnostics light

() F4AE0684H E (O & K application)

() F4AE0684F (Fiat Hitachi application)

003210t


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71

PinECU

CABLE FUNCTION

31 2298 Line K for 30-pin diagnosis connector (pin 2)

36 8837 Positive for fuel filter heater relay37 8888 Positive for starter motor

39 8051Positive from key switch (+15) / Line L for 30-pin diagnosis connector(pin 11)

44 9905 Positive from start from engine compartment button ()

45 9906 Positive from stop from engine compartment button ()

46 5553 Negative for pre-heating ON light

49 5584 Diagnosis connector (pin 28)

52 6109 CAN line, diagnosis connector (pin 22)53 6108 CAN line, diagnosis connector (pin 21)

55 5158 Positive for accelerator pedal position sensors () / positive multiswitch ()

63 5503 Negative for engine oil low pressure light

64 0535 Negative for EDC diagnosis light

72 0159 Negative from accelerator pressed switch ()/ multiswitch signal ()

73 0159 Redundant negative from accelerator pressed switch ()

78 8162 Negative for air conditioning control signal() (if equipped)

81 0157 Negative for accelerator pedal position sensor () / Ground multiswitch ()

83 5157 Signal from accelerator pedal position sensor () / multiswitch signal ()

COLOR. 1 Blue 2 White 3 Yellow 4 Grey 5 OrangeCODE No. 6 Violet 7 Red 8 Green 9 Pink 0 Brown

() F4AE0684H E (O & K application)



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72

Sensors connector (C)

Wires input side view

ECU PIN WIRE COLOUR FUNCTION

2 - -

4 - -5 NW Brown/White Negative for pressure regulator

7 NP Brown/Purple Positive for pressure regulator

9 PY Purple/Yellow Positive for engine oil pressure/temperature sensor

10 NY Brown/Yellow Positive for air pressure/temperature sensor

12 GY Green/Yellow Positive for rail pressure sensor

17 YR Yellow/Red Negative for fuel temperature sensor

18 YN Yellow/Brown Negative for coolant temperature sensor

19 PN - Purple/Brown Negative for engine oil temperature/pressure sensor

20 GN Green/Brown Negative for rail pressure sensor

21 N Brown Positive for air pressure/temperature sensor

23 U Blue Camshaft sensor

24 U Blue Crankshaft sensor

25 R Red Crankshaft sensor

27 GO Green/Orange Rail pressure sensor signal

28 NG Brown/Green Air pressure sensor signal

29 UO Blue/Orange Air temperature signal

30 R Red Camshaft sensor

31 - -

32 - -33 PO Purple/Orange Engine oil temperature sensor signal

34 YU Yellow/Blue Fuel temperature sensor positive

35 PG Purple/Green Engine oil pressure sensor signal

36 YO Yellow/Orange Coolant temperature sensor positive

003211t


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73

Key to electric/electronic components

K1 = Intake air pre-post heater relay

K2 = Intermediate starter motor relay

K3 = Fuel filter heater relay

J1 J2 J3 = Electro-injectors, cylinders 1, 2, 3 respectively

J4 J5 J6 = Electro-injectors, cylinders 4, 5, 6 respectively

J7 = High pressure regulating solenoid valve on high pressure pump

J8 = Crankshaft speed/timing shaft sensor

J9 = Camshaft speed/timing sensor

J10 = High pressure sensor on common rail

J11 = Intake air pressure sensor

J12 = Oil pressure sensor

J13 = Engine cooling fluid temperature sensor

J14 = Fuel temperature sensor

J15 = Accelerator pedalAVM= Switch for starting from engine compartment () (if equipped)

CAC = Air conditioning switch () (if equipped)

CD = 30-pin diagnosis switch?

IA = Bodybuilder system?

LC = CAN line

PBC = Blink code button

SBPO = Low oil pressure light

SDE = EDC diagnosis light

SPE = Pre-heating light

SVM = Switch for stopping from engine compartment () (if equipped)TL = Torque limiter multiswitch () (if equipped)

MA = Engine starter

R1 = EDC load simulation resistor

R2 = Fuel heater grid

R3 = Pre-post heater grid

() F4AE0684H E (O &K applications)



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74

A C connector diagram (all applications)

System power supply (+24 V).

Edit graphic Centralina = ECM,Connector A &Connector C & size

ECM


8/41


75

F4AE0684F (B) connector diagram (Fiat Hitachi application)??

System power supply (+24 V). The power supplies for remote control switches K1, K2,K3, and for engine starter have appropriate protections implemented by the preparationpersonnel.

003213t

Rotate 180o,

Connector B &

size


9/41


76

F4AE0684H E (B) connector diagram (O & K applications)

System power supply (+24 V). The power supplies for remote control switches K1, K2,K3, and for engine starter have appropriate protections implemented by thepreparation personnel.

003214t


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77

Crankshaft speed/timing sensor

This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensorsends signals to the engine controller as the engine rotates.

The crankshaft sensor is connected to the control unit on pins 25C 24C. The sensor impedance

is 900 .

Camshaft speed/timing sensor

This is an inductive sensor located at the rear left hand side of the engine. The camshaft timingsensor sends signals to the engine controller as the engine rotates. The signal generated by this

sensor is utilized by the electronic control unit to control the injection timing.Although it is similar to the crankshaft sensor, these two devices are NOT interchangeable becausof the different external shape.

The timing sensor is connected to the control unit on pins 23C 30C. The sensor impedance

is 900 .

1 32

ECU pinRef. Description

Crankshaft sensor Camshaft sensor

1 Signal 24C 30C2 Signal 25C 23C3 Shield

CONNECTOR C

50342

WIRING DIAGRAM

50320

CRANKSHAFT SPEED/TIMING SENSOR

CAMSHAFT TIMING SENSOR

50288

50319


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78

Intake air temperature-pressure sensor

This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the temperature and boost pressure, whichserves 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 21C 29C 10C 28C.The power supply is 5 volt

Voltage at the sensor output is proportional to the detected pressure or temperature.

Pin 21C 29C Temperature

Pin 10C 28C Pressure

Engine oil temperature-pressure sensor

This component is similar to the intake air temperature-pressure sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter support in a verticalposition. This sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 19C- 33C- 9C- 35C.The sensor is supplied with 5 Volts. The pressure signal is transmitted to the EDC control unitwhich, in turn, sends a signal to the instrument panel (gauge + low pressure warning light).

The oil temperature is not displayed on any gauges this value is used exclusively by the controlunit.

Pin 19C 33C TemperaturePin 9C 35C Pressure

ECU PINREF. DESCRIPTION

OIL AIR

1 Ground 19C 21C

2 NTC signal (temperature) 33C 29C

3 +5 V power input 9C 10C

4 Signal (pressure) 35C 28C

WIRING DIAGRAM5034450324


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79

Common rail fuel high pressure sensor

Mounted on one end of the common rail, this sensor measures the internal fuel pressure andinforms the control unit of the value (feedback).

The injection pressure value is used by the controller to regulate the high pressure output flow fromthe pump and to determine the duration of the electrical injection command.

This sensor is connected to the control unit on pins 20C 27C 12C.The power supply is 5 Volt.

Ref. Description ECU pin

1 Ground 20C2 Signal 27C3 Power supply 12C

Fuel pressure sensor connector

002112t

12

3


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80

Electro-injectors

The electro-injectors are effectively N.C. solenoid valves.

Each injector is connected to the EDC control unit on connector A.

The resistance impedance of the coil of each injector is 0.56 - 0.57 .

Ref. Description ECU pin

CONNECTOR 1

1234

Cylinder 2 injectorCylinder 2 injectorCylinder 1 injectorCylinder 1 injector

3 A6 A

13 A9 A

CONNECTOR 2

1234


5 A14 A12 A4 A

CONNECTOR 3

1234


10 A15 A16 A11 A

1

2 3 50343

50349

2 3 4 5 6

321

1


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81

Intake air pre-post heater gridplate and relay

The intake air pre-post heater gridplate is located on the intake manifold.

The gridplate serves to heat the air in pre / post starting operations. This gridplate is powered by arelay on the left hand side of the chassis.

The gridplate resistance impedance is approximately 0.5 .

A. CONTROL RELAY

The control relay is connected to the control unit on pins 4B 16B.

The relay is tripped when either the water and/or fuel temperature is below 5 C (41oF).

The relay resistance impedance is approximately 15 .

GRIDPLATE HEATER

003215t

002371t


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82

Coolant temperature sensor

This coolant temperature sensor is a variable resistance sensor able to read the coolanttemperature and send this information to the control unit.

The same signal is used by the control unit to drive an instrument panel gauge, if present.

This sensor is connected to the control unit on pins 18C 36C.

The resistance of the coolant temperature sensor at 20 C (68oF) is approximately 2.50 k.

A. Coolant temperature sensor

003194t


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83

Fuel temperature sensor

This sensor is identical to the coolant temperature sensor.

This sensor measures the fuel temperature so that the controller can precisely inject fuel required.

The fuel temperature sensor is connected to the control unit on pins 17C 34C.The sensor resistance impedance at 20 C (68

oF) is approximately 2.50 k

1.Fuel temperature sensor - 2.Filter heater

The ECU activates the filter heater relay at fuel temperature 5 C (41oF).

ECU PINREF. DESCRIPTION

COOLANT FUEL

1 Ground 18C 17C2 Temperature signal 36C 34C

50348

FUEL TEMP SENSOR CONNECTOR

50322 NTC

50321

2

1


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84

High pressure pump pressure regulator solenoid valve

A.High pressure pump pressure regulator solenoid valve

The quantity of fuel supplied to the common rail by the high pressure pump is controlled by the highpressure regulator solenoid valve The high pressure regulator solenoid is managed by the EDC7control unit.

Delivery pressure to the rail is regulated between 250 and 1450 bar (3625 and 21030 psi) by theelectronic control unit by controlling the pressure regulator solenoid valve.

This high pressure regulator is a N.O.(normally open) solenoid valve.

The solenoid is connected to the control unit on pins C5 - C7.

The solenoid valve resistance impedance is approximately 3.2 .

000912t

A


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85

DIAGNOSTIC METHODS

Currently the following diagnosis systems are available:

BLINK CODE 30 pin diagnostics socket

Dedicated instrumentation

BLINK CODE DIAGNOSIS

EDC state indicator.

After turning the key to the on position, the EDC indicator light illuminates, after which, if noanomalies are detected, the indicator light must extinguish.

Depending on the presence or absence of possible faults, the indicator light can assume thefollowing states:

EDC indicator light off

1. No fault - or

2. Slight faultno impairment of performancefault can be interpreted with BLINK CODE and diagnostic tools.

EDC indicator light steadily illuminated

1. Serious faultperformance impaired in certain casesfault can be interpreted with BLINK CODE or diagnostic tools.

EDC indicator light flashing1. Very serious fault

performance impaired in many cases, otherwise engine cuts outfault can be interpreted with BLINK CODE or diagnostic tools.

Blink code activation / interpretation

The blink code is activated by pressing the BLINK CODE button.

The BLINK CODE identifies one fault at a time without distinguishing between currently activefaults and intermittent faults. To display all codes in the memory, the Blink Code button must bepressed several times.

The code is composed of two digits and it is displayed by low speed flashes followed by fasterflashes.

If there are no faults present in the system, the EDC indicator light will not communicate anyinformation, illuminating only once.

Each time you turn the key to the on position the EDC light must illuminate; if it does not, checkthe wiring and the light bulb.

IMPORTANT

The control unit wiring can only be detached and reattached when the battery is disconnected.


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86

EDC SW 3.3_1 (F4AE0684F) Blink CodeBlinkcode

Fault descriptionEDC Indicator

lightPower

reduction

VEHICLE

1.4 Accelerator pedal signal On 31.8 EDC indicator light Off 0

ENGINE 1

2.1 Coolant temperature sensor signal On 0

2.2 Turbocharger air temperature sensor signal Off 0

2.3 Fuel temperature sensor signal Off 0

2.4 Turbocharger pressure sensor signal On 0

2.5 Atmospheric pressure sensor signal Off 0

2.6 Oil pressure sensor signal On 0

2.7 Oil temperature sensor signal Off 0

2.8 Heated filter control relay Off 0

2.9 Pre-post heating resistance control relay Off 0ENGINE 2

3.7 Battery voltage On 0

3.8 Pre-post heating indicator light Off 0

3.9 Pre-post heating resistance gridplate Off 0

6 Cylinder INJECTORS

5.1 Cylinder 1 injector solenoid valve On 0





5.6 Cylinder 6 injector solenoid valve On 05.7 Power stage 1 (cylinders 1 2 3) On 0

5.8 Power stage 2 (cylinders 4 5 6) On 0

ENGINE SPEED

6.1 Crankshaft sensor signal On 2

6.2 Camshaft sensor signal On 2

6.3 Engine speed signal plausibility On 0

6.4 Engine overspeed Flashing 0

6.5 Starter motor relay Off 0

CHECK PANEL INTERFACES

7.2* CAN line Off 0

7.6 Oil pressure indicator light Off 0

* When CAN line is present on the electric system

Power reduction, based upon fault code:

0= No power reduction1= performances comparable to equivalent engine without a turbocharger2= 50% torque3= limited engine speed4= engine stop


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87

Blinkcode

Fault description EDC Ind. lightPower

reduction

FUEL PRESSURE

8.1 Fuel pressure control Flashing 38.2 Fuel pressure signal Flashing 3

8.3 Pressure regulator solenoid valve Flashing 3

8.4 Monitoring of rail pressure relief valve Flashing 3

8.5 Rail min/max pressure error Flashing 4

CONTROL UNIT

9.4 Main relay On 0

9.6 After-run interrupted repeatedly On 3

9.7 Sensors power supply On 0

Power reduction:

0= No power reduction1= performances compairable to equivalent engine without a turbocharger

2= 50% torque

3= limited engine speed

4= engine stopPower Reduction Code Torque Curves

with torque curves

torque

003216t

Ft-Lb

664

590

516

443

369

295

221

148

74

0


21/41


88

Power Reduction Code Power Curves

with power curves

Procedure for clearing the fault memory from the engine control unit using the Blink Codebutton:

Turn the Key switch to the OFF position.Hold down the Blink Code button for between 4 and 8 seconds and, during this interval, switch onthe key switch.

Attention:do not switch the key on immediately after turning it off, wait about ten seconds whileholding the Blink Code button before switching it ON again.

power

003217t

214

187

161134

107

80

54

27

0

HP


22/41


89

TROUBLESHOOTING SW 3.3_1

Troubleshooting information is given in two clearly distinguished sections:

- the first, Fault Code Diagnostics, concerns faults that can be directly recognised by the EDC 7

engine control unit. These fault types are mainly of an electrical electronic nature;- the second Symptom Based Diagnostics, describes the possible faults that cannot be directly

recognised by the electronic control unit. These faults are mainly of a mechanical hydraulic

nature.

- Troubleshooting is a supplementary activity that integrates rather than replaces fault diagnosis

performed with the specific electronic diagnostic instruments.

Notes for correct use.

- If the fault is among those that can be recognised directly by the engine control unit, consult

Troubleshooting section 1 for information and additional suggestions to assist in solution of the

problem.

- If there are no fault codes recorded and a problem persists, consult Symptom BasedTroubleshooting section 2 and base your research on the symptoms reported by the customer.


23/41


90

FAULT (BLINK) CODE TROUBLESHOOTINGSection 1

NOTES

TESTSOR

RECOM

MENDED

AC

TION

Readparame

terswiththe

diagnosticins

trumentto

checkthechangefrom0%

to100%ofth

e

potentiometersignaland

ON-OFFstatuschangeof

idlespeedsw

itch.

Ifresultisnegative,use

multitesterto

takeadirect

readingonth

ecomponent

connectortocheckfor

resistancech

angeswhen

thepotentiom

eteris

activatedand

forON-OFF

statuschangeoftheidle

speedswitch.

Ifthecompon

entisworking

correctly,che

ckwiringand

connectionsbetweenthe

componentandtheEDC

connectorpin

sB50B55

B73B81B83.

POSSIBLE

ASSO

CIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

Powerlo

ss.

Fastidle

speedwithno

changewhenpedalis

pressed,

or

withacc

eleratorpedalin

restpositiontheengine

runsatf

astidlespeed.

Pressing

theaccelerator

pedalca

usestheengine

rpmtoin

crease

progressivelyand

uncontrollably.

Whenpedaliscompletely

released

enginespeed

decreasesslowlyand

withoutcontroluntil

reaching

fastidlespeed.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

(*) Acceleratorpedal

potentiometershortedto

positiveorshortedto

gro

und;acceleratorpedal

powersupplyvoltagetoo

high;faultypotentiometer.

EDC

INDICATOR

LIGHT

On

BLINK

CODE

1.4


24/41


91

NO

TES

Dependingo

nthetypeof

fault,

theLEDontheBlink

Codebutton

mayhavethe

samebehaviourasthe

mainindicatorlight,orit

mayfunction

differently.

TESTSOR

RE

COMMENDED

ACTION

Checkwiringand

connectionsofindicator

lightwithEDCconnector

pinsB2

8B64.

Usemu

ltitestertotakea

directreadingonthesensor

(R=ap

prox.

2.5

kOhmat

20C).

Ifthese

nsorisworking

correctly,checkwiringand

connectionsbetween

sensorandEDCconnector

pinsC1

8-C36.

Takere

adingwith

multites

terdirectlyon

sensorbetweenpins1and

2(R=a

pprox.

2.5

kOhmat

20C).

Ifthese

nsorisworking

correctlycheckwiringand

connectionsbetween

sensorandEDCpinsC21

C29.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

(*) Th

eindicatorlightnever

illu

minateswhenkeyswitch

issettoON,orremains

illu

minatedwhenkeyswitch

issettoOFF.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

(*)

EDCindicatorlighton

dashboardisfaultyor

wiringisshortedtopositive,

shortedtoground,orin

opencircuit.

Enginecoolanttemperature

sensorshortcircuitto

positive,shortcircuitto

ground,oropencircuit.

Airtemperaturesensor

(integratedwithairpressure

sensor)onintakemanifold

isshortedtopositive,

shortedtoground,orin

opencircuit.

EDC

INDICATOR

LIGHT

Off

On

Off

BLINK

CODE

1.8

2.1

2.2


25/41


92

N

OTES

Ifengine/ED

Ccontrolunitis

givenapaintcoating,

the

sensorsab

ilitytodetect

atmosphericpressuremay

beimpaired

.

Onlywhenthesensoris

connectedtotheEDC

controlunit.

TESTSOR

R

ECOMMENDED

ACTION

Taker

eadingwith

multite

sterdirectlyon

sensor

(R=approx.

2.5

kOhmat

20C)

.Ifsensorisworking

correctlycheckwiringand

connectionsbetween


pinsC

17C34.

Usem

ultitestertocheck

sensorpowersupply

voltage.

Ifvolta

geisapproximately

5V,renewsensor.Ifvoltage

istoohighortoolow,check

wiring

andconnections

betweensensorandEDC

connectorpinsC10C28.

These

nsorcannotbe

replacedindividually.

Usem

ultitestertocheck

sensorpowersupply

voltage.

Ifvolta

geisapproximately

5V,renewsensor.Ifvoltage

istoohighortoolow,check

wiring

andconnections

betweensensorandEDC

connectorpinsC9C35.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Fueltemperaturesensor

shortingtoground,shorting

topositive,oropencircuit.

Airpressuresensor

(integratedwithair

temperaturesensor)on

intakemanifoldshortingto

ground,opencircuit,

shortingtopositive,or

suppliedwithcurrent

outsidetheminimumor

maximumlimits.

Atmosphericpressure

sensor(integratedincontrol

unit)shortingtoground,

shortingtopositive,oropen

circuit.

Oilpressuresensor

(incorporatedinoil

temperaturesensor)

shortingtoground,shorting

topositive,orinopen

circuit.

EDC

INDICATOR

LIGHT

Off

On

Off

On

BLINK

CODE

2.3

2.4

2.5

2.6


26/41


93

NO

TES

Onlywhenthesensoris

connectedto

theEDC

controlunit.

TESTSOR

RE

COMMENDED

ACTION

Takere

adingwith

multites

terdirectlyonthe

sensorbetweenpins1and

2(R=a

pprox.

2.5

kOhmat

20C).

Ifsenso

risworking

correctly,checkwiringand

connectionsbetween


pinsC1

9C33.

Activefaultdiagnosiswith

diagnos

ticinstrument.

Ifresult

isnegative,renew

relayan

drepeatactive

diagnos

is.

Iffaultp

ersists,check

wiringa

ndconnections

betweenrelayandEDC

connectorpinsB2B36.


diagnos

ticinstrument.

Ifresult

isnegative,use

multites

tertocheckrelay(R

=appro

x.

15Ohm).

Ifrelayisworkingcorrectly,

checkw

iringand

connectionsbetweenrelay

andED

CconnectorpinsB4

B16.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

Po

ssiblestartingdifficultyin

verylowambient

temperatures,smoking

exhaustimmediatelyafter

sta

rting.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Oiltemperaturesensor

(integratedwithoilpressure

sensor)shortingtoground,

shortingtopositive,oropen

circuit.

Fuelfilterheaterrelay

faulty.

Pre-postheatingresistance

controlrelayfaulty.

EDC

INDICATOR

LIGHT

Off

Off

Off

BLINK

CODE

2.7

2.8.

2.9


27/41


94

N

OTES

Mightnotbeaproblemof

excessively

highorlow

voltage,

butrathervoltage

thatisread

asbeingtoo

highorlow

bythecontrol

unit.

TESTSO

R

RECOMMENDED

ACTION

Performappropriatecheckson

batteriesa

ndchargingsystem.

Ifthebatte

riesareingood

conditiona

ndthecharging

circuitisw

orkingproperlycheck

theefficien

cyofthechassis

groundconnectionsandensure

thatconne

ctorssupplying

powertotheEDCcontrolunit

arefreeof

signsofincrustation

oroxidatio

n.

Activediag

nosiswithdiagnostic

instrument.

Ifresultisnegative,renewthe

indicatorlightandrepeatthe

activediag

nosisprocedure.

Ifproblem

persists,check

wiringand

connections

betweenth

eindicatorlightand

EDCconnectorpinB46.

Usemultitestertocheckthe

continuityofthepreheating

resistance

intheintake

manifold(R=approx.

0.5

Ohm).

Ifthecomponentisworking

correctly,c

heckwiringand

connection

sbetweenheating

resistance

andrelativecontrol

relay.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

Fastidlespeed.

Indicatorlightnever

illuminatesorremains

const

antlyilluminatedeven

when

thekeyswitchisset

toOF

F.

Possiblestartingdifficulty

(inthepresenceofverylow

ambienttemperature)and

smok

ingexhaustwhen

startingbecauseuserisnot

providedwithindicationson

prehe

ating.

Possiblestartingdifficulty

withv

erylowambient

temperature,smokefrom

exhaustimmediatelyafter

starting.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Batteryvoltagesignalisnot

plausible(toohighortoo

low).

Preheatingindicatorlight

bulbisfaultyorwiring

shortingtopositive,

shortingtoground,oropen

circuit.

Preheatingisnotworking

correctly.

EDC

INDICATOR

LIGHT

On

Off

Off

BLINK

CODE

3.7

3.8

3.9


28/41


95

NO

TES

Insomecasesthisproblem

couldcause

malfunctionsof

thepowerstageintheEDC

controlunitthatsupplies

powertothe

electro-

injector,resu

ltingin

operationof

onlyhalfofthe

totalnumber

ofcylinders

andgenerationoferror5.7.

TESTSOR

RE

COMMENDED

ACTION

Checkcorrecttightening

torque

(1.5

0

.25Nm)ofnuts

responsibleforfixingwires

oninjec

torsolenoidvalve.

Checkinjectorcoil

(R=ap

prox.

0.5

60.5

7

Ohm)a

ndreplaceinjectorif

coilisfoundtobefaulty.

If

coilisw

orkingcorrectly

checkw

iringand

connectionsbetweenthe

solenoidvalveandEDC

connectorpinsA9-A13by

meansofpins3and4of

over-he

adconnector1.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

En

ginerunningwithoutone

of

thecylinders.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Electricalfaultoninjector

no.

1.

EDC

INDICATOR

LIGHT

On

BLINK

CODE

5.1


29/41


96

NOT

ES

Insomecases

thisproblem

couldcausemalfunctionsof

thepowerstag

eintheEDC

controlunittha

tsupplies

powertotheelectro-

injector,resultingin

operationofon

lyhalfofthe

totalnumberofcylinders

andgeneration

oferror5.7.

Insomecases

thisproblem

couldcausemalfunctionsof

thepowerstag

eintheEDC

controlunittha

tsupplies

powertotheelectro-

injector,resultingin

operationofon

lyhalfofthe

totalnumberofcylinders

andgeneration

oferror5.7.

T

ESTSOR

REC

OMMENDED

ACTION

Checkthe

correct

tightening

torque(1.5

0.2

5Nm)

ofthecablefixing

nutsonth

einjector

solenoidv

alve.

Checkconditionofinjector

coil(R=a

pprox.

0.5

6

0.5

7Ohm

)andreplace

injectoriffaulty.

Ifcoilisin

goodworking

ordercheckwiringand

connectio

nsbetween

solenoidv

alveandEDC

connectorpinsA3A6by

meansof

pins1and2of

over-head

connector1.

Checkthe

correct

tightening

torque(1.5

0.2

5Nm)

ofthecablefixing

nutsonth

einjector

solenoidv

alve.


coil(R=a

pprox.

0.5

6

0.5

7Ohm

)andreplace

injectoriffaulty.

Ifcoilisin

goodworking

ordercheckwiringand

connectio

nsbetween

solenoidv

alveandEDC

connectorpinsA4A12by

meansof

pins3and4of

over-head

connector2.

POSSIBLE

AS

SOCIATED

FAULTS

(*

)=

ifpresen

tinthe

app

lica

tion

Enginerunswithoutoneof

thec

ylinders.


thec

ylinders.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Electricalproblemon

injectorno.

2.

Electricalproblemon

injectorno.

3

EDC

INDICATOR

LIGHT

On

On

BLINK

CODE

5.2

5.3


30/41


97

NO

TES


couldcause

malfunctionsof



powertothe

electro-

injector,resu

ltingin

operationof

onlyhalfofthe

totalnumber

ofcylinders



couldcause

malfunctionsof



powertothe

electro-

injector,resu

ltingin

operationof

onlyhalfofthe

totalnumber

ofcylinders


TESTSOR

RE

COMMENDED

ACTION

Checkthecorrect

tighteningtorque(1.5

0.2

5Nm

)ofthecablefixing

nutson

theinjector

solenoidvalve.


coil(R=approx.

0.5

6

0.5

7Oh

m)andreplace

injector

iffaulty.

Ifcoilis

ingoodworking

ordercheckwiringand

connectionsbetween

solenoidvalveandEDC

connectorpinsA5A14by

meansofpins1and2of

over-he

adconnector2.

Checkthecorrect

tighteningtorque(1.5

0.2

5Nm

)ofthecablefixing

nutson

theinjector

solenoidvalve.


coil(R=approx.

0.5

6

0.5

7Oh

m)andreplace

injector

iffaulty.

Ifcoilis

ingoodworking

ordercheckwiringand

connectionsbetween

solenoidvalveandEDC

connectorpinsA11A16

bymeansofpins3and4of

over-he

adconnector3.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

En

ginerunswithoutoneof

thecylinders.

En

ginerunswithoutoneof

thecylinders.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Electricalproblemon

injectorno.

4.

Electricalproblemon

injectorno.

5.

EDC

INDICATOR

LIGHT

On

On

BLINK

CODE

5.4

5.5


31/41


98

N

OTES


couldcause

malfunctionsof

thepowers

tageintheEDC

controlunit

thatsupplies

powertotheelectro-

injector,res

ultingin

operationofonlyhalfofthe

totalnumbe

rofcylinders

andgenera

tionoferror5.8.

Itmayoccu

rthatthecase

oftheelectroniccontrolunit

isshortingwiththebattery

positive(accidental

connection

madeviaa

wrenchoro

thermetal

object).

TESTSOR

R

ECOMMENDED

ACTION

Check

thecorrect

tighten

ingtorque(1.5

0.2

5N

m)ofthecablefixing

nutsontheinjector

soleno

idvalve.

Check

conditionofinjector

coil(R

=approx.

0.5

6

0.5

7O

hm)andreplace

injecto

riffaulty.

Ifcoilisingoodworking

ordercheckwiringand

connectionsbetween

soleno

idvalveandEDC

connectorpinsA10A15

bymeansofpins1and2of

over-h

eadconnector3.

Clearfaultsmemoryand

restart

engine.

Ifthefaultpersists,make

sureth

atitisnotcausedby

injecto

rfailure(seenote

5.X

).T

hepartcannotbe


POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

E

nginerunswithoutoneof

th

ecylinders.

E

nginerunsonjust3

cylinders.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Electricalproblemon

injectorno.

6.

Powerstage1forsupplying

powertoelectro-injectors

1-2-3.

EDC

INDICATOR

LIGHT

On

On

BLINK

CODE

5.6

5.7


32/41


99

NO

TES

Thismayoccurifthe

externalenclosureofthe

unithasbeenshortedwith

thebattery+

(accidental

connectionv

iawrenchor

othermetalobject).

Thisfailureisnotdetected

withtheengineoff.

Theenginedoesnotstart

becausethe

startermotoris

deactivatedbythecontrol

unit.

Thefailureis

notdetected

withtheengineoff.

Ifthe

camshaftsig

nalisincorrect,

thecranksha

ftphase

sensorsigna

lisusedinits

place.

Thiserroris

always

associatedto6.3.

TESTSOR

RECOMMENDED

A

CTION

Clearfaultsme

moryandrestart

engine.

Ifthefaultpersists,makesurethat

itisnotcaused

byinjectorfailure

(seenote5.X).

Thepartcannotbe


Checkthatthe

sensoriscleanand

correctlysecured.

Checkthatthe

phonicwheelis

cleanandthatitworkscorrectly.

Checkthatthe

sensorworks

correctly(R9

20).

Ifthesensorworkscorrectly,check

thewiringbetw

eenthesensor

connector(wiringside)pin1and

EDCconnectorpinC25;between

sensorconnector(wiringside)pin

2andtheEDC

connectorpinC24.

Checkthatthe

sensoriscleanand

correctlysecured.

Checkthatthe

phonicwheelis

cleanandthatitworkscorrectly.

Checkthatthe

sensorworks

correctly(R9

20).

Ifthesensorworkscorrectly,check

thewiringbetw

eenthesensor

connector(wiringside)pin1and

EDCconnectorpinC25;between

sensorconnector(wiringside)pin

2andtheEDC

connectorpinC24.

P

OSSIBLE

ASSOC

IATED

FAULTS

(*)=

if

presen

tinthe

app

lica

tion

Enginerunson3cylinders.

Theenginedoesnotstart.

Slightreductioninpower

andincrea

sednoiseasthe

controlunitisunableto

handlethe

advanceand

durationo

ftheinjectionas

thereforereferstoa

recoverym

ap.

Engineha

rdtostartinany

condition.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Powerstage2supplying

powertoelectro-

in

jectors

4-5-6.

Crankshaftsensor:

signalnotpresentornot

plausible.

Camshaftsensor:signal

notpresentornot

plausible.

EDC

INDICATOR

LIGHT

On

On

On

BLINK

CODE

5.8

6.1

6.2


33/41


100

N

OTES

Attimesonlyerror6.3

is

storedwhile

inrealitythe

camshaftsignalisfaulty.

Inthiscase

performthe

checksindicatedtosolve

error6.2.

Thiserrorcouldbestored

randomlyif

theengineis

turnedoffu

singthepush-

buttonunde

rneaththe

cabin.

Ifthedamperflywheelis

deteriorated

,itresultsas

beinglocallydeformedand,

ifthecover

junctionareas

havestartedtogive,

traces

ofsiliconew

illbenotedin

thesurroundingarea.

Checkthatthephonic

wheeliscle

anandthatit

rotateswith

outaxial

Onlywhenthestartingof

theengineishandledby

theEDCco

ntrolunit.

TESTSOR

RECOM

MENDED

ACTION

Failurem

emoryread:check

theenvironmentalconditions

associatedwiththistypeof

error.

Iftheerrorwasstoredatan

enginera

telowerthan650

r.p.m.,clearthefailure

memoryandreleasethe

vehicle.

Onthecontrary,checkthat

thedamp

erflywheeland

phonicw

heelonthe

cranksha

ftareworking

correctly

andthatthetwo

sensorsarecleanand

correctly

secured.

Checkfo

rcausesthatcould

haveresultedinasuddenloss

ofengine

loadwith

consequentoverspeed,or(in

thecase

ofroadvehicle

applications)instructtheuser

oncorrectdrivingtechniques.

Useamultitestertocheckthe

relay.

Iftherela

yisingoodworking

order,ch

eckthewiringand

connectionsbetweentherelay

andEDC

connectorpinB27.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

Eng

inefailstostartorcuts

out.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Enginespeedreadingisnot

plausible.

Engineoverspeed.

Faultystartermotorrelay.

EDC

INDICATOR

LIGHT

On

Flashing

On

BLINK

CODE

6.3

6.4

6.5


34/41


101

NO

TES

Onapplicationsthatdonot

usetheCAN

line,

thisis

maskedbya

120Ohm

resistor.

Onlywhenthelowoil

pressuresignaland

indicatorligh

tarenot

controlledby

theEDCunit.

TESTSOR

RE

COMMENDED

ACTION

Checkwiring,connections

andburdenresistor

(120oh

m).


diagnos

ticinstrument.

Ifresult

isnegative,renew

indicato

rlightandrepeat

actived

iagnosis.

Iffaultp

ersists,check

wiringa

ndconnections

betweenindicatorlightand

EDCco

nnectorpinB63and

checkc

orrectpowersupply

topressuregaugewith

integralindicatorlight.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

(*) Po

ssiblemalfunctionor

errorsignalsinelectronic

controldevicesconnected

on

CAN.

Se

ttingthekeyswitchto

ON

theindicatorlightfails

to

illuminate,

or remainsconstantlylit.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

(*)

CANlinehardwarefault.

Oilpressureindicatorlight

faulty,orwiringshortedto

positive,shortedtoground,

orinopencircuit.

EDC

INDICATOR

LIGHT

Off

Off

BLINK

CODE

7.2

7.6


35/41


102

N

OTES

Furtherdetailsregarding

checkstocarryoutonthe

fuelcircuita

regivenin

TroubleshootingSection2.

TESTSOR

R

ECOMMENDED

ACTION

Check

toensurethatfuelis

reachingthehighpressure

pumpwithoutobstruction

(airho

leinaspirated

section,

filterorprefilter

clogge

d,pipesblocked,

substa

ntialfuelleakage).

Check

thattherearenofuel

leaksinthehighpressure

sectionbetweenpumpand

railorinsidethecylinder

head.

Ifaflowlimitervalvehas

tripped

,identifythe

malfun

ctioninginjectorand

renew

bothinjectorand

relativehighpressureinlet

connector.

Readparameterswithfault

diagno

sisinstrument.

Check

wiringand

connectionsbetween


pinsC

12C20C27.

Ifallis

inorder,renewthe

sensor.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

S

ubstantialpowerloss.

In

theeventofaninjector

re

mainingoccasionally

ja

mmedopen,suddenand

te

mporaryperformance

im

pairment,withstarting

possibleandgood

operationatlowengine

speedsandlowloads,

but

problemoccurringathigh

speedsandwithhighloads.

S

ubstantialpowerloss

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Faultinfuelpressure

modulation

(thecontrolunitmust

modifythecontrolsignalto

thepressureregulator

excessivelyinorderto

modulatethecalculated

pressureintherail).

Railpressuresensorsignal

shortedtopositive,shorting

toground,oropencircuit.

EDC

INDICATOR

LIGHT

Flashing

Flashing

BLINK

CODE

8.1

8.2


36/41


103

NO

TES

Itisnotposs

ibletoreplace

onlythepres

sureregulator.

TESTSOR

RE

COMMENDED

ACTION

Usemu

ltitestertocheck

conditio

nofpressure

regulatorsolenoidvalve.

Ifcomponentisfunctional,

checkw

iringand

connectionsbetween

regulatorandEDC

connectorpins

C4C5.

Renew

railreliefvalve.

Checktoseewhetherfuel

isreach

inghighpressure

pumpw

ithoutobstructions

(cloggedairholein

aspirate

dsection,

filter,or

prefilter

,pipesblocked,

ampleleakageoffuel).

Checkthattherearenofuel

leaksin

thehighpressure

section

betweenpumpand

railorin

sidethecylinder

head.

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

Significantpowerdrop.

Co

de8.1couldbepresent.

Significantpowerdrop

Significantpowerdrop.

Po

ssiblesimultaneous

sig

nallingofcodes8.1and

8.4.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Pressureregulatorground

fault,orshortingtopositive,

oropencircuit.

Faultinoperationofrail

reliefvalve(onlyregards

dualstagereliefvalves).

Anomalyofpressurevalues

inrail

(pressurehasfallento

minimumorexceeded

maximumvalues).

EDC

INDICATOR

LIGHT

Flashing

Flashing

Flashing

BLINK

CODE

8.3

8.4

8.5


37/41


104

N

OTES

Themainre

layis

incorporatedintheEDC

controlunit

andcannotbe

renewedse

parately.

Errorcould

bestoredin

memoryals

oincaseof

engineoperatingin

conditionso

therthanthose

oftheapplication(e.g.

engineontestbench

withoutiner

tialloads).

TESTSOR

R

ECOMMENDED

ACTION

Tryremovingandthen

refittingthefuse(toreset

thecontrolunit).

Warm

upengine,

bringitto

slowid

lespeedandthen

performcorrectshut-down.

Check

conditionandcorrect

installa

tionofEDCsensors

connector(C).

POSSIBLE

ASSOCIATED

FAULTS

(*)=

ifpresen

tinthe

app

lica

tion

C

ontrolunitremains

constantlypoweredand

E

DCindicatorlightremains

O

nevenwithkeyswitchset

to

Off.

B

atterydischarges.

S

ubstantialpower

re

duction.

S

torageoferroronall

sensorssuppliedfromthe

E

DCcontrolunit.

E

nginefailstostartorcuts

out,orstartingisdifficult

andenginemalfunctions.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Mainrelayfailsto

disconnect.

Anomalyincheckroutine

thatcontrolunitexecutes

onsystemeachtime

engineisstopped.

Sensorspowersupplyfault.

EDC

INDICATOR

LIGHT

On

On

On

BLINK

CODE

9.4

9.6

9.7


38/41


105

Section 2 Symptom Based Troubleshooting Blink Codes Not Recorded

NOTES

Possibleexhaustsmo

ke

derivesfromthefactthatif

insufficientfuelissup

plied,

thecontrolunitattemptsto

compensatebyexten

dingthe

injectorsenergization

time.

RECOMMENDED

TESTSOR

ACTION

Checkfuellevelintank.

Checkthattheprimingpumponthe

prefilterisworkingcorrectly.

Iftheknobonthepumpremainsdrawn

tothebottomofthedepressio

nstroke,

disassemblethefueltankliftp

ipeand

inspectit.

Iftheliftpipeisingood

condition,renewtheprefilter.

POSSIBLECAUSE

(*)=

ifpresen

tinthe

app

lica

tion

Lowfuellevelintank.

Fuelliftpipeintankpartly

cloggedwithdebrisordu

e

todistortioncausedby

overheating.

SIGNALLED

FA

ULT

Poorperformanceu

nder

loaddemands.

Possiblehuntingand

exhaustsmoke.

Possibleerror8.1.


39/41


106

NO

TES

Unlessthelea

kiscopious,no

performanceanomalieswill

benoted.

Tochecktheconditionofthe

O-Rings,extractthefuel

returnlinefromthetank,plug

theendofthe

line

hermetically,andactivatethe

primingpump

inorderto

pressurizethe

lowpressure

NO

TES

Remedycaus

eoffuelfilter

clogging(emp

tyandclean

tankandthep

artofthe

hydrauliccircuituplinefrom

thefilter,refill

tankwithclean

fuel).

RECOMMENDEDTE

STSOR

ACTION

CheckO-Ringsandco

rrectconnectionof

unionsonpipelinesbe

tweentankand

feedpump(clipsmust

beprotrudingand

unionssecurelyfasten

ed).

CheckO-Ringsandco

rrectconnectionof

unionsonpipelinesdo

wnlinefromfeed

pump(clipsmustbeprotrudingand

unionssecurelyfasten

ed).

Visuallycheckconditio

noflowpressure

pipelines.

Disconnectpipelinesa

ndvisuallycheck

forsignificantpassage

offuelthroughthe

reliefvalve:iffuelispr

esentin

substantialquantity,re

newthevalve.

RECOMMENDEDTE

STSOR

ACTION

Renewfuelfilter.

POSSIBLEC

AUSE

(*)=

ifpresen

tinthe

app

licat

ion

Airinletuplinefro

mthefuel

feedgearpump.

Leakageoffuelfromunions

orlowpressurep

ipelines

downlinefromthe

fuelfeed

pump.

Excessivepassageoffuel

throughtherailre

liefvalve.

POSSIBLEC

AUSE

(*)=

ifpresen

tinthe

app

licat

ion

Cloggedfuelfilter.

SIGNAL

LED

FAULT

(con

td

.)

Poorperform

anceunder

loaddemands.

Possiblehuntingand

exhaustsmo

ke.

Possibleerror8.1

SIGNAL

LED

FAULT

Enginecuts

outsuddenly

(withnoprio

runeven

running)and

failstorestart.


40/41


107

NO

TES

NO

TES

Intheeventof

slightleakage,

suchastopreventthe

mechanicaloperationofthe

injectorbutnotsufficientto

causetheflow

limiterto

operate,noerr

orwillbe

generatedinth

econtrolunit.

Ifflowlimiteroperates,also

error8.1willbegenerated.

RECOMMENDED

TESTSOR

ACTION

Afterhavingexcludeda

llotherpossible

causes,renewhighpre

ssurepump.

RECOMMENDED

TESTSOR

ACTION

Faultyinjectorcanbee

asilyidentifiedby

touchduetotheabsenceofpulsingin

therelativehighpressu

repipeline.

POSSIBLECAUSE

(*)=

ifpresent

inthe

app

lica

tio

n

Highpressurepum

pnot

workingproperly.

POSSIBLECAUSE

(*)=

ifpresent

inthe

app

lica

tio

n

Injectorwithshutte

ror

solenoidcore(mechanical

part)jammedopen.

SIGNALL

ED

FAULT

Difficultstartingandpoor

performance

inall

conditions.

SIGNALL

ED

FAULT

Difficultstarting,poor

performance,andengine

runswithoutonecylinder.


41/41


NO

TES

NO

TES

Itisveryimporta

nt,apartfrom

correcttightenin

gofthescrews,

tomaintainthebracketsintheir

originalposition.

NO

TES

Theinjectorthatisnotworking

canbeidentified

bytouchdueto

theabsenceofpulsingofthe

correspondingh

ighpressure

pipeline.

RECOMMENDED

TES

TSOR

ACTION

Theinjectorthatisnotw

orkingcanbe

identifiedbytouchdueto

theabsenceof

pulsingofthecorrespondinghigh

pressurepipeline.

RECOMMENDED

TES

TSOR

ACTION

Renewthepipeline,

takingcaretofully

tightentheantivibrationbracketscrews.

RECOMMENDED

TES

TSOR

ACTION

Findtheinjectorthatisn

otworkingand

renewtheinjectorandre

lativehigh

pressureinletconnector.

POSSIBLECA

USE

(*)=

ifpresen

tinthe

app

lica

tion

Injectorirreversibly

jammed

open.

POSSIBLECA

USE

(*)=

ifpresen

tinthe

app

lica

tion

Anomalousvibration

causedbylooseningofpipe

brackets.

POSSIBLECA

USE

(*)=

ifpresen

tinthe

app

lica

tion

Injectorjammedinclosed

position.

SIGNALLE

D

FAULT

Startingtheen

ginetakesat

least20secon

dswithlarge

quantitiesofw

hitesmoke

fromtheexhaustandodour

offuel.

SIGNALLE

D

FAULT

Ruptureofhighpressure

pipelinefromp

umptorail.

SIGNALLE

D

FAULT


thecylindersthoughno

faultisgeneratedonthe

controlunit.

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