Volkswagen tdi 4 2l v8 diesel marine engine service repair manual

3

Workshop Manual Marine Boat Engine 2011 ▜ 8-cylinder diesel engine (4.2 l engine, common rail) Edition 05.2011 Engine code

CEM

3 Repair Group overview for workshop manual

Marine Boat Engine 2011 ▶

8-cylinder diesel engine (4.2 l engine, common rail) Edition 05.2011 When filing a Technical Bulletin, enter the bulletin number in the column adjacent to the Repair Group. When using the Maintenance Manual you can then see at a glance whether Technical Bulletins have been published which refer to the Repair Group you are looking for.

Repair Group

Technical Bulletins

00 Technical data 01 Self-diagnosis 10 Removing and installing engine 13 Crankshaft group 15 Cylinder head, valve gear 17 Lubrication 19 Cooling 20 Fuel supply system 21 Turbocharging/supercharging 23 Mixture preparation - injection 26 Exhaust system 27 Starter motor, alternator 48 Hydraulic system 90 Instrument panel 97 Central electrics

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

Not to be modified, used, sold, distributed, made public or reproduced without the consent of the publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg

Printed in Germany

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

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Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1 1.1 1.2

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine codes / engine numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1

2

Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3 3.1

General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rules for cleanliness when working on fuel supply system, injection system and turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routing and securing lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking for leaks in the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 4 5 5 5

01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

3.2 3.3 3.4

1 1.1 1.2 1.3 1.4

Features of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selectable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 6 6 7 9

2 2.1 2.2 2.3 2.4

Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B0271…17083/P0699 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17428/P1020…18316/P1908 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18512/P2080…18727/P2295 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19463/P3007…19464/P3008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 11 19 25 26

3 3.1 3.2

Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Conduct final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adapting idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4 4.1 4.2 4.3 4.4

Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Read data blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaluating measured value blocks with ignition ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaluating measured value blocks at idling speed (engine warm, coolant temperature not below 73 °C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 29 29 30 47

5

Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Display group 100 -Quantity injected- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Display group 101 -starting conditions- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Display group 102 -Temperatures- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Display group 103 -Activation of common rail injectors- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Display group 104 -Torque limit moments- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Display group 105 -Limiting factors- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Display group 106 -Charge pressure control I- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 Display group 107 -Charge pressure control II- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 Display group 108 -Exhaust temperature- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 Display group 109 -Fuel consumption- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

68 68 69 70 71 73 74 75 76 77 78

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Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 5.11 Display group 110 -Fuel rail pressure regulation l- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12 Display group 111 -Fuel rail pressure regulation II- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 Display group 112 -Fuel rail pressure regulation Ill- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14 Display group 113 -Quantities injected, specification- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15 Display group 114 -Activation period of pilot injection 1- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16 Display group 115 -Activation period of pilot injection 2- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.17 Display group 116 -Injection coordinator- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.18 Display group 117 -idling speed- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.19 Display group 118 - Rotational speed registration- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 80 81 83 84 86 87 88 89

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing gearbox bell housing to engine (reverse gear gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly mounting/engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine with connection for external heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 90 93 94 95 96 97 98

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

iv

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Removing and installing tensioning element for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Removing and installing idler roller (left and right) for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Assembly overview - vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Assembly overview - shaft oil seal and sealing flange at belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . 106 Replacing oil seal for crankshaft at belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Removing and installing sealing flange at belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

2 2.1 2.2 2.3

Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly overview - drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing oil seal for crankshaft at gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Removing and installing engine speed sender -G28- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3 3.1 3.2 3.3 3.4 3.5 3.6

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Allocation of main bearing shells for new crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Allocation of crankshaft bearing shells for retaining frame without visible colour coding . . . . . . . 118 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Measuring axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Measuring radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

4 4.1 4.2 4.3

Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Measuring piston projection at „TDC“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Contents

111 111 111 112

Marine Boat Engine 2011 ▜ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 4.4 4.5

3

Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Allocation of conrod bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 1 1.1 1.2 1.3 1.4 1.5

Timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Assembly overview - timing chain covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Renewing oil seal for toothed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Removing and installing timing chain cover (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Removing and installing timing chain cover (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Removing and installing timing chain cover (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Assembly overview - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Removing camshaft timing chains from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Assembly overview - drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Removing and installing drive chain for valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Assembly overview - drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Removing and installing drive chain for auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Assembly overview - auxiliary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Renewing oil seal for vane pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Removing and installing spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4 4.1 4.2 4.3

Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11

Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing valve stem seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 182 183 184 185 190 192 196 199 199 199 200

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 1 1.1 1.2

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Engine oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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Marine Boat Engine 2011 ▜ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 1.3 1.4

Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Draining engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

2 2.1 2.2 2.3 2.4

Oil pump, lower part of sump, upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Assembly overview - oil pump, lower part of sump, upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . 204 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

3 3.1

Engine oil cooler, pressure regulating valve for crankcase breather, oil filter housing . 212 Assembly overview - engine oil cooler, pressure regulating valve for crankcase breather, oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Removing and installing pressure regulating valve for crankcase breather system . . . . . . . . . . . . 215

3.2 3.3 3.4 3.5 3.6 3.7 3.8

Removing and installing mounting plate for engine oil cooler, pressure regulating valve for crankcase breather system and oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Removing and installing oil pressure switch -F1- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Removing and installingoil temperature sender -G8- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Assembly overview - cooling system plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Assembly overview - main heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Assembly overview - servo/gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Assembly overview - charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Assembly overview - seawater filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

2 2.1 2.2 2.3 2.4 2.5 2.6

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Draining seawater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Assembly overview - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Removing and installing coolant temperature sender -G62- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Assembly overview - seawater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 1 1.1 1.2 1.3 1.4

Parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Assembly overview - fuel system microfilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Assembly overview - circulation pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

vi

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Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

2 2.1

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Assembly overview - right turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

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Marine Boat Engine 2011 ▜ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

2.2

Assembly overview - left turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

3 3.1

Charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Assembly overview - air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

4 4.1 4.2 4.3 4.4 4.5

Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check charge pressure control solenoid valve -N75- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking bank 1 exhaust gas temperature sender -G235- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking bank 2 exhaust gas temperature sender -G236- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252 252 253 255 257 Checking charge air pressure sender -G31- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 1 1.1 1.2

Safety precautions and rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Rules for cleanliness and instructions for working on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

2

Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13

Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Schematic overview of fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Assembly overview - injectors and high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Removing and installing fuel temperature sender -G81- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Removing and installing fuel pressure regulating valve -N276- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Removing and installing fuel pressure sender -G247- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Assembly overview - toothed belt for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Removing and installing toothed belt for high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Bleeding fuel system after installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 Intake manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

4 4.1 4.2 4.3 4.4

Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking voltage supply for diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking engine speed sender -G28- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking coolant temperature sender -G62- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking oil temperature sender -G8- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 4.6 4.7 4.8 4.9 4.10 4.11

Checking fuel temperature sender -G81- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Checking intake air temperature sender -G42- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Checking Hall sender 2 -G40- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Checking fuel pressure sender -G247- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Checking fuel pressure regulating valve -N276- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Checking and setting injector correction values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

5 5.1 5.2

Engine control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Removing and installing master engine control unit and slave engine control unit . . . . . . . . . . . . . 316 Checking matching resistor for data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Contents

293 293 295 297 299

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Marine Boat Engine 2011 ▜ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 1 1.1 1.2

Exhaust manifold and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Assembly overview - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Assembly overview - exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

27 - Starter motor, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 1 1.1

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Assembly overview - alternator with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Removing and installing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Removing and installing poly V-belt pulley with freewheel, manufacturer: Bosch . . . . . . . . . . . . . . 326 Removing and installing poly V-belt pulley with freewheel, manufacturer: Valeo . . . . . . . . . . . . . . . 328 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Specified torques: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

48 - Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 1 1.1 1.2 1.3

Parts of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Functional overview: Hydraulic pump, oil cooler, hydraulic pipes, reservoir . . . . . . . . . . . . . . . . . . . . 334 Checking hydraulic pump delivery pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Removing and installing vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

90 - Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Overview of individual instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Overview of operating unit for individual instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Overview of contact assignment of individual instrumentation multi-pin connectors . . . . . . . . . . . 341 Individual instrumentation connector assignment to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Changing a fuse of the individual instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Overview of optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Optional instrumentation connector assignment to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Overview of terminal strip -A- contact assignment, optional instrumentation . . . . . . . . . . . . . . . . . . . 346 Overview of multipin connector assignment of optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . 346 Connection variants of optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 DIP switch on optional instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Neutral position with Z-drive or reverse gear gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

97 - Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7

viii

Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing component/circuit board of central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector assignment to central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing relay/fuse carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis connection for system tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harness variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

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Marine Boat Engine 2011 ▜ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 2 2.1 2.2

3

Electronic propulsion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Electronic throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Assembly overview - components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Contents

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Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

00 - Technical data 1

Technical data

1.1

Engine codes / engine numbers

The engine code consists of three characters (e.g. CEM) followed by the engine number consisting of six digits.. The engine code and engine number are stamped onto the left side of the cylinder block. In addition, they are also located on the type plate.

1.2

Engine data

Engine codes

CEM

Emissions fulfil

2003/44/EC

Capacity

l

Output

kW at rpm

257 / 4200

Torque

Nm at rpm

700 / 2000 - 3250

Bore Stroke

Ø mm

83,0

mm

95,5

Compression ratio CN

16,4 min.

51

Firing order

1-5-4-8-6-3-7-2

Turbocharging/supercharging

2 turbochargers with variable turbine geometry.

Self-diagnosis

yes

Charge air cooling

yes

Weight (the weight is for a dry engine with ancillaries, cooling system and clutch flange)

kg

368

Power to weight ratio (weight compared to output, to allow comparisons of efficiency of engines of different weight and output)

kg/PS

1,05

Certificate No. according to BSO 2

M1 03 3 08 04

1 Technical data

1

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

2

Health and Safety Precautions

Introduction This workshop manual contains technical data, descriptions and repair instructions for the 8 cylinder TDI boat engine.

The table of contents shows all the individual repair groups of the boat engine.

General information Replacement parts for the electrical systems and fuel systems comply with legal requirements. Genuine parts comply with these requirements. Any damage caused by the use of nongenuine parts would not be covered by the warranty.

The boat engine is certified according to BSO 2 under certificate number: M1 03 3 08 04.

Note Carefully read all safety precautions before starting repairs. All danger and safety precautions which must always be complied with when operating and maintaining the engine are listed in the following.

General notes ◆ Maintenance work may only be undertaken when the engine is not running. Some adjustments must be carried out when the engine is running. Ensure when engine is running that no loose clothing, long hair or tools become caught in rotating parts. This could result in serious injury. ◆ Ensure correct shoes (deck shoes) and clothing are worn when undertaking maintenance work or tests ◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compression, disconnect connector from injection pump. ◆ Only use engine oils authorised by Volkswagen Marine ⇒ Operating instructions for Volkswagen Marine Boat Engines. ◆ Start engine only in a well ventilated area. When starting engine in a closed room ensure, exhaust gases are piped a away from the work area with a suitable ventilation system.

Torque ◆ Always use a torque wrench to tighten nuts / bolts etc. to specified torque. All torques in this repair manual are for cleaned threads, bolt heads and contact surfaces. ◆ When tightening components, first tighten to prescribed torque using a torque wrench then turn further to required angle.

When working on the fuel system note the following warnings:

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Repair Group 00 - Technical data

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

WARNING Risk of injury - fuel system operates under high pressure. ◆ Wrap a clean cloth around the connection before opening the fuel system. Then release pressure by carefully loosening the connection. ◆ Extreme care is required when working on a leaking fuel system. Wear eye protection when testing injectors. The high pressure of the injecting fuel can cause serious injuries. ◆ Wear protective gloves. ◆ Wear eye protection.

Observe the following points to prevent personal injuries and damage to the injection system: ◆ The ignition must be switched off before connecting or disconnecting electrical wiring of the injection system or tester cables. ◆ Faults are stored in engine control unit if electrical connectors have been disconnected: – Connecting vehicle diagnosis, testing and information system, ScanDi tool or VAS 5052.

– Start „Vehicle self-diagnosis“ mode.

– Read fault memory ⇒ Page 9.

When working on the battery note the following: Caution ◆ Danger of destroying electronic components when disconnecting battery or danger of battery exploding when reconnecting battery. ◆ Observe notes on procedure for disconnecting the battery. ◆ Always switch off ignition before disconnecting battery. ◆ Incorrectly reconnecting the battery can cause sparks which can cause an explosion. Avoid naked flames or welding operations in the vicinity of the battery. ◆ When charging the battery, hydrogen gas escapes which when mixed with oxygen produces a highly explosive gas. Therefore wear eye protection and respective protective clothing. The gases are heavier than air and can collect in the bilges. Use only onboard chargers and, if possible, gel batteries.

Note the following if testers and measuring instruments have to be used during a sea test:

2 Health and Safety Precautions

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Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

WARNING Accidents can be caused by distractions and insufficiently secured test equipment. ◆ The use of test equipment while driving causes distraction. ◆ There is an increased risk of injury if test equipment is not secured.

When working on the cooling system note the following: WARNING Hot steam / coolant can escape - risk of scalding! ◆ When working on cooling system - switch off engine and close sea valves ◆ The cooling system is under pressure when the engine is hot. ◆ Use extreme caution when unscrewing cap on cooling system when engine is hot or even warm. Risk of scalding Cover cap of cooling system expansion tank with a cloth and open cap carefully to allow pressure to escape. Only remove cap when pressure has dissipated.

3

General repair notes

3.1

Rules for cleanliness when working on fuel supply system, injection system and turbocharger

Even small amounts of contamination / soiling can lead to defects. For this reason, when working on the fuel supply system, the injection system or the turbocharger, please observe the following basic rules carefully: ◆ Carefully clean connection points and the surrounding area with engine cleaner or brake cleaner and dry thoroughly before opening. When tightening components, first tighten to prescribed torque using a torque wrench then turn further to required angle. ◆ Immediately seal off open pipes and connections with suitable caps. ◆ Place removed parts on a clean surface and cover. Use only lint-free cloths. ◆ Install clean parts only: Only unpack replacement parts immediately prior to fitting. Do not use parts that have been previously unpacked and stored away loose (e.g. in toolboxes, etc.). ◆ When the system is open: Do not work with compressed air.

Do not move boat unless absolutely necessary.

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3

◆ Protect detached electrical connections against dirt and moisture and only connect when they are dry.

3.2

Routing and securing lines

Mark hydraulic lines, vacuum lines and electrical wiring before removal so they can be re-installed in the original positions and correctly connected. Make sketches or take photographs if necessary.

3.3

Checking for leaks in the fuel system

Proceed as follows: – Allow engine to run at average revs for a few minutes.

– Switch off ignition.

– Check complete fuel system for leaks.

– If leaks are found although the connections have been tightened to the correct torque, the relevant component must be renewed.

– Carry out a sea test and accelerate with full throttle at least once.

– Then inspect high-pressure section of fuel system again for leaks.

3.4

Contact corrosion

Contact corrosion can occur if unsuitable fastening elements (screws, bolts, nuts, washers etc.) are used. For this reason, only fasteners with a special surface coating are used. Additionally, all rubber and plastic parts and all adhesives are made of non-conductive materials.

Always install new parts if you are not sure whether used parts can be re-fitted ⇒ Parts catalogue.

Note ◆ We recommend using only genuine replacement parts; these have been tested and are compatible with aluminium. ◆ We recommend the use of Volkswagen Marine accessories. ◆ Damage caused by contact corrosion is not covered under warranty.

3 General repair notes

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Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

01 - Self-diagnosis 1

Features of self-diagnosis

The diesel direct injection system control unit is equipped with a fault memory.

If faults occur in the monitored sensors or components, they are stored in the memory together with an indication of the type of fault.

Faults which occur temporarily (sporadically), are printed out with the addendum „fault occurred sporadically“. These faults are indicated on display by the addendum „/SP“. The cause of sporadic faults can be e.g. a loose contact or a brief open circuit. If a sporadic fault does not occur again within 50 engine starts, it will be erased from the fault memory.

If faults are recognised which affect the Multifunction indicator „Service“ is displayed.

The stored faults can be read using the ScanDi tool ⇒ Page 9.

The fault memory must be erased after the faults have been eliminated ⇒ Page 10.

Note General information for fault finding is located in the operating manual of the ScanDi tool

1.1

Technical data of self-diagnosis

Equipment ◆ Fault memory: Non-volatile and volatile memories1).

Read control unit version The control unit version is displayed when the ScanDi tool is connected and engine electronics control unit is selected ⇒ Page 7.

Selectable functions on ScanDi tool when address word 01 „Engine electronics“ is entered.

1.2

Selectable functions Note

The prerequisites for selecting the desired functions can be determined from the following table.

1) Will be cancelled after 50th engine start if fault has not occurred again.

6

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Function Functions on ScanDi tool / VAS 5052

Prerequisite

Engine stationary, ignition switched on

Engine running at idling speed

Boat underway

yes

yes

yes

yes1)

yes

yes

03 Final control diagnosis

yes

no

no

05 Clear fault memory

yes

yes

yes

06 End output

yes

yes

yes

08 Reading measured value block

yes

yes

yes

34 Adaption

yes

yes

no

01 Read control unit version 02 Read fault memory

1)

3

Only carry out with ignition switched on, when engine does not start.

1.3

Connecting the fault reader

All functions which can be carried out on the ScanDi tool can also be carried out using the VAS 5052.

Connecting ScanDi tool Special tools and workshop equipment required ◆ ScanDi tool Test prerequisites: ◆ The battery voltage must be at least 11.5 V. ◆ Fuse 190 OK. Procedure – Unscrew cover of diagnosis connection on operating unit.

– Connect ScanDi tool.

Note The ScanDi tool can also be connected to the diagnosis connection in the central electrics ⇒ Page 353.

You must, depending on the function required: – Switch on ignition or – Start engine ⇒ Page 6, Selectable functions.

Note ◆ If display remains blank, check voltage supply for diagnosis connector according to fault finding programme: ⇒ Current flow diagram TDI 350-8. ◆ If the display is not as shown in the procedure or if „Connection problems“ are displayed: ⇒ Operating manual of ScanDi tool.

1 Features of self-diagnosis

7

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Indicated on display: ► – Operate ScanDi tool taking into account the information on the display:

W-Marine

v1.71

Enter address word XX

– Press keys 0 and 1 for address word „Engine electronics“ and confirm entry with Q key.

The control unit identification appears on the ScanDi tool display, e.g.: ▶

06V910401 TDI 225-6 MD 000AG 0010 Code xxxxxxx

WSC xxxxx

◆ 06V910401 = Part no. of control unit (for up-to-date control unit version see parts catalogue) ◆ TDI = Turbo Diesel Injection ◆ MD 0000AG = Injection system (Marine Diesel Electronic Control) ◆ 0010 = Control unit software version ◆ Code xxxxxxx (ignore) ◆ WSC xxxxx = Workshop code – Press

→

key.

Indicated on display: ► – Refer to repair operations for further procedure.

Connecting VAS 5052 Special tools and workshop equipment required ◆ Fault reader -VAS 5052Test prerequisites ◆ The battery voltage must be at least 11.5 V. ◆ Fuse 190 OK. Procedure – Unscrew cover of diagnosis connection on operating unit.

– Connect fault reader -VAS 5052-.

Note The VAS 5052 can also be connected to the diagnosis connection in the central electrics ⇒ Page 353.

Select operating mode – Press key on display for „Vehicle self-diagnosis“.

Select vehicle system: – Press „01 - Engine electronics“ key on display.

On the display, the control unit ID of the engine control unit is shown.

Select diagnosis function: All the available diagnosis functions are shown on the display.

– Press key on display for the desired function.

8

Repair Group 01 - Self-diagnosis

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Note ◆ The display fields will be displayed from top to bottom in functions 04 - Basic settings or 08 - Read measured value block. ◆ The following test procedures are described for the ScanDi tool.

1.4

Fault memory

1.4.1 Read fault memory Special tools and workshop equipment required ◆ ScanDi tool or Fault reader -VAS 5052Procedure – Connect ScanDi tool or Fault reader -VAS 5052- and select engine electronics control unit with „address word“ 01. The engine should be idling, for this.

Connect fault reader and select engine control unit ⇒ Page 7.

Only when engine does not start: – Switch on ignition.

Indicated on display: ► – Operate fault reader taking into account the information on the display:

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

– Press keys 0 and 2 for function „Read fault memory“ and confirm entry with Q key.

The display shows the number of stored faults or „No fault recognised“.

X faults recognised!

If one or more faults are stored: Using the → key you can now display the individual fault numbers along with the respective text.

Indicated on display: ► – Rectify faults using fault table ⇒ Page 11.

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

– Afterwards erase fault memory ⇒ Page 10.

If there are no faults stored: – Press

Q

key.

Indicated on display: ► – Press keys 0 and 6 for function „End data transfer“ and confirm entry with Q key.

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

1 Features of self-diagnosis

9

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

1.4.2 Clear fault memory Special tools and workshop equipment required ◆ ScanDi tool or Fault reader -VAS 5052Test prerequisite ◆ Fault eliminated Note After eliminating faults the fault memory must be read again as follows and then cleared.

Procedure – Connect ScanDi tool or Fault reader -VAS 5052- and select engine electronics control unit with „address word“ 01. The engine should be idling, for this.

Connect fault reader and select engine control unit ⇒ Page 7.

Indicated on display: ► – Press keys 0 and 2 for function „Read fault memory“ and confirm entry with Q key.

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

– Press → key until all faults still stored have been displayed and the display shows.

– Press keys 0 and 5 for function „Clear fault memory“ and confirm entry with Q key.

Indicated on display ▶ – If the fault memory will not erase there is a fault still in the system and this must be rectified.

– Press

→

→

No fault recognized

key.

Indicated on display: ► – Press keys 0 and 6 for function „End data transfer“ and confirm entry with Q key.

10

Fault memory erased

key.

Indicated on display: ► – Press

05 Clear fault memory

Repair Group 01 - Self-diagnosis

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

2

3

Fault table Note

◆ The fault table is listed in ascending order according to the 4-digit P-code. ◆ In the following tables, the 5-digit VAG fault code is also listed next to the 4-digit SAE P-code. ◆ Explanation of the fault types (e.g. open circuit / short circuit to earth): ⇒ Fault reader operating instructions. ◆ If components are shown as faulty: First check the wiring and connectors to these components as well as the system earth connections referring to current flow diagram. Only when no fault can be located here should the component be renewed. This is particularly important if faults are indicated as being sporadic. ◆ Erase fault memory after rectifying faults.

Output on ScanDi tool e.g. ◆ Fault number: P0118 ◆ Coolant temperature sender -G62◆ Fault type: Sporadic, signal too high Note ◆ Fault number: P0118 = P-code fault code ◆ Coolant temperature sender -G62- = faulty current path or fault location ◆ Fault type: Sporadic = Fault that is not always present e.g. loose contact ◆ Signal too high = Fault type as text B0271…17083/P0699 ⇒ Page 11.

17428/P1020…18316/P1908 ⇒ Page 19.

18512/P2080...18727/P2295 ⇒ Page 25.

19463/P3007…19464/P3008 ⇒ Page 26.

2.1

B0271…17083/P0699

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

xxxxx

◆ Max./Min. recovery occurred

◆ Engine stalls

– Erase fault and try to start again

ECU

B0271

– Replace control unit if fault appears again

2 Fault table

11

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

xxxxx

◆ Max./Min. recovery occurred

◆ Engine stalls

– Erase fault and try to start again

B0273

ECU

– Replace control unit if fault appears again 16496

P0112

◆ -G42- defective

Intake air temperature sender ◆ Wiring defective -G42- signal too low

16497

P0113

◆ -G42- defective

Intake air temperature sender ◆ Wiring defective -G42- signal too high

16501

P0117

◆ -G62- defective

Coolant temperature sender -G62- signal too low

◆ Wiring defective

16502

P0118

◆ -G62- defective

Coolant temperature sender ◆ Wiring defective -G62- signal too high

16565

P0181

◆ -G81- defective

Fuel temperature sender -G81- implausible signal

◆ Wiring defective

16566

◆ -G81- defective

P0182

Fuel temperature sender -G81- short to earth

◆ Wiring defective

16567

P0183

◆ -G81- defective

Fuel temperature sender -G81- open circuit / short to positive

◆ Wiring defective

12

Repair Group 01 - Self-diagnosis

◆ Replacement value 50 °C

– Check wiring and -G42- ⇒ Page 302

◆ Possible formation of smoke

– Check central earth point / earth connections

◆ Replacement value 50 °C

– Check wiring and -G42- ⇒ Page 302

◆ Possible formation of smoke

– Check central earth point / earth connections

◆ Replacement value 90 °C

– Check wiring and -G62- ⇒ Page 297

◆ Poor cold starting ◆ „Knocking“

– Check central earth point / earth connections

◆ Replacement value 90 °C

– Check wiring and -G62- ⇒ Page 297

◆ Poor cold starting ◆ „Knocking“

– Check central earth point / earth connections

◆ Replacement value 40 °C

– Check wiring and -G81- ⇒ Page 300

◆ Increased exhaust emissions

– Check central earth point / earth connections

◆ Replacement value 40 °C

– Check wiring and -G81- ⇒ Page 300

◆ Increased exhaust emissions

– Check central earth point / earth connections

◆ Replacement value 40 °C

– Check wiring and -G81- ⇒ Page 300

◆ Increased exhaust emissions

– Check central earth point / earth connections

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

16575

◆ -G247- defective

◆ Reduced performance

– Check wiring and -G247- ⇒ Page 306

◆ Exceeded max. fuel rail pressure of 1150 bar

– Check central earth point / earth connections

P0191

Fuel pressure sender -G247- ◆ Wiring defective signal voltage too low or too high

◆ Exceeded min. fuel rail pressure of 300 bar 16576

P0192

◆ -G247- defective

Fuel pressure sender -G247- ◆ Wiring defective short to earth

◆ Reduced performance

– Check wiring and -G247- ⇒ Page 306

◆ Exceeded max. fuel rail pressure of 1150 bar

– Check central earth point / earth connections

◆ Exceeded min. fuel rail pressure of 300 bar 16580

P0196

Oil temperature sender -G8implausible signal

◆ -G8- defective ◆ Wiring defective

◆ Reduced performance

– Check wiring and -G8- ⇒ Page 299

◆ Replacement value 140 °C

– Check central earth point / earth connections – Measure oil temperature manually

16581

P0197

Oil temperature sender -G8signal too low

◆ -G8- defective ◆ Wiring defective

◆ Reduced performance

– Check wiring and -G8- ⇒ Page 299

◆ Replacement value 140 °C

– Check central earth point / earth connections – Measure oil temperature manually

16582

P0198

Oil temperature sender -G8signal too high

◆ -G8- defective ◆ Wiring defective

◆ Reduced performance

– Check wiring and -G8- ⇒ Page 299

◆ Replacement value 140 °C

– Check central earth point / earth connections – Measure oil temperature manually

16584

P0200

Injectors electrical fault in current circuit

◆ Wiring defective ◆ One or more injectors defective ◆ Poor starting characteristics

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

2 Fault table

13

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

16603

◆ Reaches 5250 rpm

P0219

Possible effects

Fault remedy

Maximum engine revs surpassed static 16610

P0226

Throttle position sender -G79- and throttle position sender -2- -G185- (see note1)) implausible signal 16618

P0234

Charge pressure control regulating limit surpassed static

◆ Signal voltage from ◆ Increased idling EMMA for engine speed 1000 rpm control unit implausible ◆ Wiring defective ◆ Turbocharger defective

◆ Charge pressure too high

– Check turbocharger ⇒ Page 252

◆ Air in fuel system

◆ Reduced performance

– Check charge pressure control ⇒ Page 253.

◆ Fuel system leaking 16619

P0235

Charge pressure control regulating limit not achieved static

– Check EMMA (see note1))

◆ Turbocharger defective

◆ Charge pressure too low

– Check turbocharger ⇒ Page 252

◆ Leaks between turbocharger and intake manifold (charge air routing)

◆ Reduced performance

– Check charge pressure control ⇒ Page 253.

◆ Fuel system leaking

◆ Air in fuel system 16620

P0236

◆ -G31- defective

Charge pressure sender -G31- implausible signal

◆ Wiring defective

16621

◆ -G31- defective

P0237

Charge pressure sender -G31- signal too low

◆ Wiring defective

16622

◆ -G31- defective

P0238

Charge pressure sender -G31- signal too high

◆ Wiring defective

16627

P0243

◆ -N75- defective

Charge pressure control solenoid valve -N75- open circuit/ short to earth

◆ Wiring defective ◆ Vacuum line defective

◆ Reduced performance

– Check wiring and -G31- ⇒ Page 258

◆ Replacement value = ambient pressure

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -G31- ⇒ Page 258

◆ Replacement value = ambient pressure

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -G31- ⇒ Page 258

◆ Replacement value = ambient pressure

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N75- ⇒ Page 253

◆ Charge pressure control is switched off

– Check central earth point/earth connections – Check vacuum line

14

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

16629

P0245

◆ -N75- defective

Charge pressure control solenoid valve -N75- open circuit/ short to earth

◆ Wiring defective

◆ Reduced performance

– Check wiring and -N75- ⇒ Page 253

◆ Charge pressure control is switched off

– Check central earth point/earth connections

◆ Vacuum line defective

– Check vacuum line 16630

P0246

◆ -N75- defective

Charge pressure control solenoid valve -N75- open circuit/ short to positive

◆ Wiring defective ◆ Vacuum line defective

◆ Reduced performance

– Check wiring and -N75- ⇒ Page 253

◆ Charge pressure control is switched off

– Check central earth point/earth connections – Check vacuum line

16645

P0261

◆ -N30- defective

Injector, cylinder 1 -N30short to positive

◆ Wiring defective

16646

◆ -N30- defective

P0262

Injector, cylinder 1 -N30short to earth

◆ Wiring defective

16648

◆ -N31- defective

P0264

Injector, cylinder 2 -N31short to earth

◆ Wiring defective

16649

◆ -N31- defective

P0265

Injector, cylinder 2 -N31short to positive

◆ Wiring defective

16651

◆ -N32- defective

P0267

Injector, cylinder 3 -N32short to earth

◆ Wiring defective

16652

◆ -N32- defective

P0268

Injector, cylinder 3 -N32short to positive

◆ Wiring defective

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

2 Fault table

15

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

16654

◆ -N33- defective

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

P0270

Injector, cylinder 4 -N33short to earth

◆ Wiring defective

16655

◆ -N33- defective

P0271

Injector, cylinder 4 -N33short to positive

◆ Wiring defective

16657

◆ -N83- defective

P0273

Injector, cylinder 5 -N83short to earth

◆ Wiring defective

16658

◆ -N83- defective

P0274

Injector, cylinder 5 -N83short to positive

◆ Wiring defective

16660

◆ -N84- defective

P0276

Injector, cylinder 6 -N84short to earth

◆ Wiring defective

16661

◆ -N84- defective

P0277

Injector, cylinder 6 -N84short to positive

◆ Wiring defective

16663

◆ -N85- defective

P0279

Injector, cylinder 7 -N85short to earth

◆ Wiring defective

16664

◆ -N85- defective

P0280

Injector, cylinder 7 -N85short to positive

◆ Wiring defective

16666

◆ -N86- defective

P0282

Injector, cylinder 8 -N86short to earth

16

◆ Wiring defective

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

16667

◆ -N86- defective

◆ Reduced performance

– Check wiring of injectors ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections – Check wiring and -G28- ⇒ Page 295

P0283

Injector, cylinder 8 -N86short to positive

◆ Wiring defective

16705

P0321

◆ -G28- defective

◆ Engine will not start

Engine speed sender -G28implausible signal static

◆ Wiring defective

◆ Engine stalls

16706

P0322

◆ -G28- defective

◆ Engine will not start

Engine speed sender -G28implausible signal static

◆ Wiring defective

◆ Engine stalls

16725

◆ -G40- defective

◆ Reduced performance

– Check wiring and -G40- ⇒ Page 304

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

P0341

Camshaft position sensor ◆ Wiring defective sender -G40- implausible signal static

16928

P0544

◆ -G235- defective

Bank 1 exhaust temperature sender -1- -G235- electrical fault static

◆ Wiring defective

16929

P0545

◆ -G235- defective

Bank 1 exhaust temperature sender -1- -G235- short to earth static

◆ Wiring defective

16931

P0547

◆ -G236- defective

Bank 2 exhaust temperature sender -1- -G236- electrical fault

◆ Wiring defective

16932

P0548

◆ -G236- defective

Bank 2 exhaust temperature sender -1- -G236- short to earth

◆ Wiring defective

16988

◆ Control unit internally defective

P0604

Control unit defective DPRAM fault

◆ Engine starts using test injection

– Check central earth point / earth connections – Check wiring and -G28- ⇒ Page 295 – Check central earth point / earth connections

◆ Replacement value: t = G236 + 20 °C

– Check wiring and -G235- ⇒ Page 255

◆ Replacement value: 720 °C when -G235and -G236- defective

– Check central earth point / earth connections

◆ Replacement value: t = G236 + 20 °C

– Check wiring and -G235- ⇒ Page 255

◆ Replacement value: 720 °C when -G235and -G236- defective

– Check central earth point / earth connections

◆ Replacement value: t = G236 - 20 °C

– Check wiring and -G236- ⇒ Page 257

◆ Replacement value: 720 °C when -G235and -G236- defective

– Check central earth point / earth connections

◆ Replacement value: t = G236 - 20 °C

– Check wiring and -G236- ⇒ Page 257

◆ Replacement value: 720 °C when -G235and -G236- defective

– Check central earth point / earth connections

◆ Various running problems including engine will not start

– Renew engine control unit ⇒ Page 315

2 Fault table

17

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

16990

◆ Control unit internally defective

◆ Various running problems including engine will not start

– Renew engine control unit ⇒ Page 315

◆ Control unit internally defective

◆ Various running problems including engine will not start

– Renew engine control unit ⇒ Page 315

◆ NPL excessive temperature in end stage of measuring unit

◆ Reduced performance

– Check engine room temperature

◆ Various running problems including engine will not start

– Renew engine control unit ⇒ Page 315

◆ Terminal 15 or 30 voltage supply defective

◆ Reduced performance

– Check voltage supply for engine control unit ⇒ Page 293

P0606

Control unit defective analogue digital converter 16991

P0607

Control module implausible 17018

P0634

Control unit - temperature switch-off

17026

P0642

Sender reference voltage „A“ of control unit too low

◆ Voltage supply in engine control unit defective

◆ Increased idling speed

◆ Relay -J219- defective 17027

P0643

Sender reference voltage „A“ of control unit too high

◆ Terminal 15 or 30 voltage supply defective ◆ Voltage supply in engine control unit defective

◆ Reduced performance ◆ Increased idling speed

– Check voltage supply for engine control unit ⇒ Page 293

◆ Relay -J219- defective 17036

P0652

Sender reference voltage „B“ of control unit too low

◆ Terminal 15 or 30 voltage supply defective ◆ Voltage supply in engine control unit defective

◆ Reduced performance ◆ Increased idling speed

– Check voltage supply for engine control unit ⇒ Page 293

◆ Relay -J219- defective 17037

P0653

Sender reference voltage „B“ of control unit too high

◆ Terminal 15 or 30 voltage supply defective ◆ Voltage supply in engine control unit defective ◆ Relay -J219- defective

18

Repair Group 01 - Self-diagnosis

◆ Reduced performance ◆ Increased idling speed

– Check voltage supply for engine control unit ⇒ Page 293

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

17082

◆ Terminal 15 or 30 voltage supply defective

◆ Reduced performance

– Check voltage supply for engine control unit ⇒ Page 293

P0698

Sender reference voltage „C“ of control unit too low

◆ Voltage supply in engine control unit defective 17083

P0699

Sender reference voltage „C“ of control unit too high

◆ Terminal 15 or 30 voltage supply defective ◆ Voltage supply in engine control unit defective

1)

◆ Increased idling speed

◆ Reduced performance ◆ Increased idling speed

– Check voltage supply for engine control unit ⇒ Page 293

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

2.2

17428/P1020…18316/P1908

Output on ScanDi tool / VAS 5052 17428

Possible cause of fault

P1020

◆ Fuel pressure regulating valve -N276Fuel pressure regulation defective -N276- control limit exceeded ◆ Air in fuel system 17448

P1040

◆ Wiring defective

Supply for injectors of bank 1 ◆ Solenoid valve fault of master control unit, electrion all solenoids of cal fault in current circuit bank 1 for master control unit 17450

P1042

◆ Wiring defective

Supply for injectors of bank 2 ◆ Solenoid valve fault of master control unit, electrion all solenoids of cal fault in current circuit bank 2 for master short circuit control unit 17452

P1044

◆ Wiring defective

Supply for injectors of bank 1 ◆ Solenoid valve fault of slave control unit, electrion all solenoids of cal fault in current circuit bank 1 for slave control unit 17454

P1046

◆ Wiring defective

Supply for injectors of bank 2 ◆ Solenoid valve fault of slave control unit, electrion all solenoids of cal fault in current circuit bank 2 for slave short circuit control unit

Possible effects

Fault remedy

◆ Reduced performance

– Check wiring and -N276- ⇒ Page 307

◆ Fuel system leaking

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring / lines ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring / lines ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring / lines ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring / lines ⇒ Page 310 – Check central earth point / earth connections

2 Fault table

19

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

17471

◆ Air in fuel system

◆ Reduced performance

– Check wiring and -N276- ⇒ Page 307

P1063

Fuel pressure regulation con- ◆ Fuel filter blocked trol difference -N276- + ◆ Fuel regulating valve -N290-N276- defective

– Possibly renew highpressure pump with fuel metering valve -N290- ⇒ Page 286

◆ Fuel metering valve -N290- defective

– Check central earth point / earth connections – Check fuel system ⇒ Page 287 – Check fuel level

17601

P1193

◆ -G247- defective

Fuel pressure sender -G247- ◆ Wiring defective open circuit / short to positive

◆ Reduced performance

– Check wiring and -G247- ⇒ Page 306

◆ Exceeded max. fuel rail pressure of 1150 bar

– Check central earth point / earth connections

◆ Exceeded min. fuel rail pressure of 300 bar 17602

P1194

◆ -N276- defective

Fuel pressure regulating ◆ Wiring defective valve -N276-Short to positive

17603

P1195

◆ -N276- defective

Fuel pressure regulating valve -N276-Open circuit/ Short to earth

◆ Wiring defective

17609

P1201

◆ -N30- defective

Injector, cylinder 1 -N30electrical fault in current circuit

◆ Wiring defective

17610

P1202

◆ -N31- defective

Injector, cylinder 2 -N31electrical fault in current circuit

◆ Wiring defective

17611

P1203

◆ -N32- defective

Injector, cylinder 3 -N32electrical fault in current circuit

◆ Wiring defective

20

Repair Group 01 - Self-diagnosis

◆ Measuring unit closed

– Check wiring and -N276- ⇒ Page 307

◆ Engine stops

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N276- ⇒ Page 307

◆ Engine stops

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N30- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N31- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N32- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

17612

P1204

◆ -N33- defective

Injector, cylinder 4 -N33electrical fault in current circuit

◆ Wiring defective

◆ Reduced performance

– Check wiring and -N33- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

17613

P1205

◆ -N83- defective

Injector, cylinder 5 -N83electrical fault in current circuit

◆ Wiring defective

◆ Reduced performance

– Check wiring and -N83- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

17614

P1206

◆ -N84- defective

Injector, cylinder 6 -N84electrical fault in current circuit

◆ Wiring defective

◆ Reduced performance

– Check wiring and -N84- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

17615

P1207

◆ -N85- defective

Injector, cylinder 7 -N85electrical fault in current circuit

◆ Wiring defective

◆ Reduced performance

– Check wiring and -N85- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

17616

P1208

◆ -N86- defective

Injector, cylinder 8 -N86electrical fault in current circuit

◆ Wiring defective

◆ Reduced performance

– Check wiring and -N86- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

xxxxx

◆ Injector

◆ Reduced performance

– Check connecting wiring between injectors and master control unit and/or check master control unit injector connections ⇒ Page 310

P120A

Injector short circuit to earth or positive on master control unit electrical fault in current circuit

◆ Short to earth

xxxxx

◆ Injector

P120B

◆ Short to battery

Injector short circuit to earth or positive on slave control unit electrical fault in current circuit

◆ Short to earth

16645

◆ -N30- defective

P1237

Injector, cylinder 1 -N30open circuit

◆ Short to battery

◆ Wiring defective

◆ Lumpy engine (not running smoothly)

◆ Reduced performance ◆ Lumpy engine (not running smoothly)

– Check connecting wiring between injectors and slave control unit and/or check slave control unit injector connections ⇒ Page 310

◆ Reduced performance

– Check wiring and -N30- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

2 Fault table

21

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

16646

◆ -N31- defective

◆ Reduced performance

– Check wiring and -N31- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N32- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N33- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N83- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N84- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N85- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

◆ Reduced performance

– Check wiring and -N86- ⇒ Page 310

◆ Lumpy engine (not running smoothly)

– Check central earth point / earth connections

P1238

Injector, cylinder 2 -N31open circuit

◆ Wiring defective

16647

◆ -N32- defective

P1239

Injector, cylinder 3 -N32open circuit

◆ Wiring defective

16648

◆ -N33- defective

P1240

Injector, cylinder 4 -N33open circuit

◆ Wiring defective

16649

◆ -N83- defective

P1241

Injector, cylinder 5 -N83open circuit

◆ Wiring defective

16650

◆ -N84- defective

P1242

Injector, cylinder 6 -N84open circuit

◆ Wiring defective

16651

◆ -N85- defective

P1243

Injector, cylinder 7 -N85open circuit

◆ Wiring defective

16652

◆ -N86- defective

P1244

Injector, cylinder 8 -N86open circuit

◆ Wiring defective

16652

◆ Fuel rail pressure regulation

◆ Reduced performance

– Check fuel system ⇒ Page 287

◆ Air in fuel system

◆ Lumpy engine (not running smoothly)

– Check fuel level

P1250

Fuel level too low static

◆ Fuel level too low 17686

P1278

◆ -N290- defective

Fuel metering valve -N290short to positive

◆ Wiring defective

22

Repair Group 01 - Self-diagnosis

◆ Engine will not start ◆ Reduced performance

– Possibly renew highpressure pump with fuel metering valve -N290- ⇒ Page 286

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

xxxxx

P1281

◆ -N290- defective

Fuel metering valve -N290short to earth

◆ Wiring defective

◆ Reduced performance

– Possibly renew highpressure pump with fuel metering valve -N290- ⇒ Page 286

17690

P1282

◆ -N290- defective

Fuel metering valve -N290open circuit

◆ Wiring defective

17795

◆ Atmospheric pressure sensor in control unit defective

– Renew engine con◆ Replacement value trol unit ⇒ Page 315 from charge pressure sensor when stopped

◆ Turbocharger defective

◆ Charge pressure too high

– Check turbocharger ⇒ Page 252

◆ Leaks between turbocharger and intake manifold (charge air routing)

◆ Reduced performance

– Check charge pressure control ⇒ Page 253.

◆ Turbocharger defective

◆ Charge pressure too low

– Check turbocharger ⇒ Page 252

◆ Leaks between turbocharger and intake manifold (charge air routing)

◆ Reduced performance

– Check charge pressure control ⇒ Page 253.

P1387

Control unit 17964

P1556

Charge pressure control Regulating limit not reached

17965

P1557

Charge pressure control Regulating limit surpassed

17978

P1570

Engine control unit blocked

◆ Lumpy engine (not running smoothly) ◆ Reduced performance ◆ Lumpy engine (not running smoothly)

◆ Fuel system leaking

◆ Fuel system leaking

◆ Attempted manipula- ◆ Engine starts briefly tion and then stops again

– Possibly renew highpressure pump with fuel metering valve -N290- ⇒ Page 286

– Check charge air routing

– Check charge air routing – Renew engine control unit ⇒ Page 315

◆ Incorrect control unit 18009

P1601

Terminal 30 voltage supply relay -J317- implausible signal 18011

P1603

Defective control unit

xxxxx

P160A

Defective control unit

◆ Terminal 30 voltage supply relay -J317defective

◆ Engine will not start

◆ Internal control unit communications malfunctioning

◆ Engine will not start

◆ Internal voltage monitoring engine control unit

◆ Reduced performance

◆ Various running problems including engine will not start ◆ Various running problems including engine will not start

– Renew engine control unit ⇒ Page 315

– Renew engine control unit ⇒ Page 315

– Renew engine control unit ⇒ Page 315

◆ Various running problems including engine will not start

2 Fault table

23

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Output on ScanDi tool / VAS 5052

Possible cause of fault

xxxxx

◆ NPL recovery occurred

P160B

Control unit has been reset for internal reasons and reinitialised 18018

P1610

Defective control unit

◆ Control unit internally defective

Possible effects

Fault remedy – Erase fault memory ⇒ Page 10

◆ Reduced performance

– Renew engine control unit ⇒ Page 315

◆ Fault in master control unit caused system to switch off 18033

P1625

◆ Neutral switch de◆ Engine will not start fective Communication between en◆ „Neutral“ in instrugine control unit and EMMA ◆ Line between engine ment flashes (1)) malfunctioning control unit and EMMA ( 1)) defective

– Check wiring / lines – Check central earth point / earth connections – Check EMMA ( 1)) – Check neutral switch (1))

18034

P1626

◆ Neutral switch de◆ Engine will not start fective Communication between en◆ „Neutral“ in instrugine control unit and EMMA ◆ Line between engine ment flashes (1)) malfunctioning control unit and EMMA ( 1)) defective

– Check wiring / lines – Check central earth point / earth connections – Check EMMA ( 1)) – Check neutral switch (1))

18038

P1630

Throttle position sender -G79- (1)) signal too low

◆ Signal voltage from EMMA ( 1)) for engine control unit implausible

◆ Increased idling speed 1000 rpm

P1631

Throttle position sender -G79- (1)) signal too high

◆ Signal voltage from EMMA ( 1)) for engine control unit implausible

◆ Increased idling speed 1000 rpm

P1640

Defective control unit 18055

P1647

Check drivetrain control unit coding / variants

24

◆ Control unit internally defective

◆ Engine will not start

◆ Data differences between master and slave

◆ Reduced performance

Repair Group 01 - Self-diagnosis

– Check EMMA ( 1)) – Check wiring / lines – Check central earth point / earth connections

◆ Wiring defective 18048

– Check wiring / lines – Check central earth point / earth connections

◆ Wiring defective 18039

– Check EMMA ( 1))

◆ Engine stalls

– Renew engine control unit ⇒ Page 315 – Check coding in control units

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Output on ScanDi tool / VAS 5052 18315

Possible cause of fault

Possible effects

P1907

◆ Fault in internal CAN ◆ Reduced performtransfer ance Engine / engine data bus defective ◆ Potential difference ◆ No injection for injecbetween engines

◆ Wiring defective

18316

P1908

◆ Check limit difference between masEngine/engine data bus softter and slave ware version monitoring 1)

tors of slave control unit

3

Fault remedy – Check matching resistor ⇒ Page 317 – Check central earth point / earth connections

◆ No charge air regulation

– On twin engine systems - check earth wire between both engines

◆ Reduced performance

– Check coding in control units

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

2.3

18512/P2080…18727/P2295

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

18512

◆ -G235- defective

◆ Replacement value: t = G236 + 20 °C

– Check wiring and -G235- ⇒ Page 255

P2080

Exhaust temperature sender ◆ Wiring defective -1- -G235- implausible signal

18514

P2082

◆ -G236- defective

Exhaust temperature sender ◆ Wiring defective -2- -G236- implausible signal

18584

P2152

Injector(s) supply electrical fault 18727

P2295

Fuel pressure regulating valve -N276-Short to earth

◆ Short circuit two or more injector wiring

◆ Replacement value: 720 °C when -G235and -G236- defective ◆ Replacement value: t = G236 - 20 °C ◆ Replacement value: 720 °C when -G235and -G236- defective ◆ Reduced performance ◆ Lumpy engine (not running smoothly)

◆ -N276- defective ◆ Wiring defective

– Check wiring and -G236- ⇒ Page 257

◆ Reduced performance

– Check injector wiring for short circuit ⇒ Page 310 – Check wiring and -N276- ⇒ Page 307 – Check central earth point / earth connections

2 Fault table

25

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

2.4

19463/P3007…19464/P3008

Output on ScanDi tool / VAS 5052

Possible cause of fault

Possible effects

Fault remedy

19463

◆ -G40- defective

◆ Engine will not start

– Check wiring and -G40- ⇒ Page 304

P3007

Camshaft position sensor -G40- no signal

◆ Wiring defective

19464

-G40- defective

P3008

– Check central earth point / earth connections ◆ Engine will not start

Camshaft position sensor -G40- signal outside tolerance

– Check wiring and -G40- ⇒ Page 304 – Check central earth point / earth connections

Note ◆ G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine. ◆ Check function of control units of Electronic Marine Engine Adaption „EMMA“ using prescribed diagnosis software. The details are located in the document for the function and diagnosis of the Electronic Marine Engine Adaption "EMMA".

3

Final control diagnosis

3.1

Conduct final control diagnosis

Special tools and workshop equipment required ◆ ScanDi tool or Fault reader -VAS 5052Final control diagnosis activates the following components in the given sequence: Final control test number 0: Charge pressure control solenoid valve -N75Final control test number 1: Fuel metering valve -N290Final control test number 2: Fuel pressure regulating valve -N276Final control test number 3: Activation of service display (MIL) Note ◆ Activation of individual control elements is limited to 60 s but can be stopped at any time by pressing the → key. ◆ The ignition must be switched off before repeating the final control diagnosis.

26

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Procedure – Connect ScanDi tool or -VAS 5052- and select engine electronics control unit with „address word“ 01. Engine should be running at idling speed (connect fault reader and select engine control unit ⇒ Page 7).

Indicated on display: ► – Operate ScanDi tool taking into account the information on the display: – Press keys

0

and

3

Q

key.

Indicated on display (ignore): ▶ The first final control test (0) is activated automatically. As the control of the turbocharger is not performed with electric actuators at the vacuum unit ( -J724- AUTO), but by a PWM guided solenoid valve ( -N75-), a fault code is created! According to application the correct display is: Charge pressure control solenoid valve -N75-. The control of the charge pressure valve is applied correctly and can be checked with the following display.

– Press

→

→

key.

Indicated on display: ► – Press

→

key.

Indicated on display: ► – Press

→

K-Ltg 2000

01-Engine electronics

C +/- Q

03 Final control diagnosis

03-Control test - next?

C +/- Q

Fault number: 01410 P0582 003

key.

Indicated on display (ignore): ▶ – Press

+/- Q

Select function XX

for function „Final control diagnosis“.

Indicated on display: ► – Confirm entry with

01-Engine electronics

key.

Indicated on display: ►

03 Control test runs 0/min

03 Control test runs 12.3 U

to

-> 0/min

03 Control test - next

up

->

Fuel metering valve

03 Control test runs 0 rpm

Both display values must change between 35% and 11% every 4 seconds. The rod to change the position of the vane on the turbocharger must move back and forth. If the displays do not change and the rod does not move:

->

12.3 V

303.6 bar

-> 0.0 bar

35%

0.0 bar

11%

03 Control test runs 0 rpm

303.6 bar

->

– Check rod for ease of movement.

– Press

→

– Press

C

key. key.

Indicated on display: ► – Press

→

key.

Indicated on display: ►

03 Control test - next

03 Control test runs 0 rpm

– Press

→

key.

->

Fuel pressure regulating valve

303.6 bar

-> 0.0 bar

0%

0.0 bar

40%

03 Control test runs 0 rpm

303.6 bar

->

Both display values must change between 0% and 40% every 4 seconds.

3 Final control diagnosis

27

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Indicated on display: ► Service display (MIL) in display of rev counter is activated.

Indicated on display: ► – Press

→

03 Control test - next

->

Request for fault lamp ON

03 Control test runs

->

12.2 V

key.

Indicated on display: ► – Press keys 0 and 6 for function „End data transfer“ and confirm entry with Q key.

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

– Switch ignition off.

3.2

Adapting idling speed

The idling speed is set to 650 rpm in the factory and can only be increased (not lowered).

The maximum idling speed possible is 1900 rpm.

Special tools and workshop equipment required ◆ ScanDi tool or Fault reader -VAS 2052Procedure – Connect ScanDi tool or -VAS 5052- and select engine electronics control unit with „address word“ 01. Engine should be running at idling speed (connect fault reader and select engine control unit ⇒ Page 7).

Indicated on display: ► – Operate fault reader taking into account the information on the display.

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

– Press keys 3 and 4 for the function Long adaption and confirm input with Q key.

Indicated on display: ► – Press keys Q key.

0

and

6

for „channel 6“ and confirm entry with

Indicated on display e.g.: ▶ – Press

→

key.

Indicated on display: ► – Enter the required idling speed.

Example: ◆ Required idling speed 720 rpm – Enter additive value 70.

– Press

28

Q

key.

Repair Group 01 - Self-diagnosis

34- Long adaption Enter channel number xx

Channel 06

Adaption 00000

660 rpm

Channel 06 Adaption 00000 Enter adaption value XXXXX

+/- Q

->

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Indicated on display: ► If a non-acceptable adaption value was entered: Indicated on display: ►

Channel 06 Adaption 00000

3

+/- Q

Enter adaption value 00070

VW Marine v1.71

C

Outside value range

Q

0x3131

Note The maximum possible value of 01250 = 1900 rpm is set.

– Press

C

key and repeat adaption.

– Press

Q

key.

Indicated on display: ► – Press

Q

key.

Indicated on display e.g.: ▶ – Press keys 0 and 6 for function „End data transfer“ and confirm entry with Q key.

4

Measured value blocks

4.1

Safety precautions

Channel 06

Adaption

00070

Q

Changed value stored

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

Observe following if test and measuring instruments are required during a sea test: ◆ Test equipment must always be secured in the boat and operated by a 2nd person.

4.2

Read data blocks

Special tools and workshop equipment required ◆ ScanDi tool or -VAS 5052Test prerequisites ◆ Fuses must be OK. ◆ The battery voltage must be at least 11.5 V. ◆ Earth connection OK. ◆ Coolant temperature must be at least 73 °C. ◆ All electrical consumers, such as, heater or refrigerator must be switched off. ◆ No faults must be stored in fault memory ⇒ Page 9.

Procedure – Connect ScanDi tool or -VAS 5052- and select engine electronics control unit with „address word“ 01. Engine should be running at idling speed (connect fault reader and select engine control unit ⇒ Page 7).

Indicated on display: ► – Press keys 0 and 8 for function „Read measured value block“ and confirm entry with Q key.

01-Engine electronics Select function XX

+/- Q K-Ltg 2000

4 Measured value blocks

29

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Indicated on display: ►

08-Read measured value block

+/- Q

Input display group number XXX

Note The display group number 001 is an example to illustrate the sequence.

– Press keys 1“.

0

,

0

and

1

for function „Display group number

Indicated on display: ►

Display group 1

(1…4 = Display zones) – Press

C

C+/-

1

2

3

4

key twice.

Indicated on display: ► – Press keys 0 and entry with Q key.

6

01-Engine electronics

+/- Q

Select function XX

for function „End output“ and confirm

K-Ltg 2000

Note To change to another display group proceed as follows: Display group

ScanDi tool

Higher

Press key

+

Lower

Press key

-

Skip

Press

C

key

Evaluating measured value blocks with ignition ON ⇒ Page 30.

Evaluating measured value blocks at idling speed ⇒ Page 47.

Evaluating measured value blocks at full throttle ⇒ Page 68.

4.3

Evaluating measured value blocks with ignition ON

4.3.1 Display group 100 -Quantity injectedIndicated on display: ►

Display group 100 rpm

Display zones

Operating condition or component

%

mg/s

Specification

Evaluation

0 rpm

---

1

Engine speed

2

Throttle position

0%

⇒ Page 31

3

Quantity injected

0 mg/stroke

---

4

High-pressure fuel pressure

0 bar.

---

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

30

Repair Group 01 - Self-diagnosis

/

Fault remedy /

bar

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Throttle position Display on ScanDi tool

Possible cause of fault

Fault remedy

More than 0%

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Quantity injected Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.2 Display group 101 -starting conditionsIndicated on display: ►

Display group 101 rpm

Display zones

Operating condition or component

1

Engine speed

2

Starting quantity

3

Starting synchronization

4

Battery voltage

mg/s

-

Specification

Evaluation

0 rpm

---

0 mg/stroke

---

0…2

⇒ Page 31

11…15 V

⇒ Page 32

V

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Starting quantity Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Starting synchronization Display on ScanDi tool

Possible cause of fault

Fault remedy

When not 0 or 2

◆ Speed sender defective

– Check speed sender ⇒ Page 295

◆ Contact fault in wiring harness

– Check wiring connections

4 Measured value blocks

31

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Display „Start synchronization“ 0

Basic initialisation of automatic synchronization

2

No synchronization, all sender systems are inactive / defective

3

No synchronization, engine revs too low or crankshaft angle sender system implausible

8

No synchronization, crankshaft angle sender system implausible

32

Crankshaft gap detection successful, system waits for actual position from crankshaft angle sender

33

Synchronization available, but has not been tested

34

No synchronization, position not finalised, restart automatic synchronization, too many re-synchronization cycles (terminal 15: ON/OFF)

38

No valid camshaft signal, synchronization via evaluation of revolution acceleration

48

Synchronization completed, crankshaft and camshaft signals are synchronized

Evaluation: Battery voltage Display on ScanDi tool

Possible cause of fault

Fault remedy

Less than 12 V

◆ Battery defective

– Check battery

◆ Wiring connection defective

– Check wiring connections

4.3.3 Display group 102 -TemperaturesIndicated on display: ►

Display group 102 °C

Display zones

Operating condition or component

°C

°C

Specification

Evaluation

1

Fuel temperature

20…70 °C

⇒ Page 32

2

Oil temperature

20…120 °C

⇒ Page 32

3

Intake air temperature

<50 °C

⇒ Page 33

4

Coolant temperature

>65 °C

⇒ Page 33

°C

Evaluation: Fuel temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

When replacement value 40 °C

◆ Defective wiring connection or fuel temperature sender -G81-

– Check wiring and -G81- ⇒ Page 300 – If a fault is present the measured value block indicates a constant fuel temperature of 40 °C

Evaluation: Oil temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

When replacement value 140 °C

◆ Defective wiring connection or oil temperature sender -G8-

– Check wiring and -G8- ⇒ Page 299

32

Repair Group 01 - Self-diagnosis

– If a fault is present the measured value block indicates a constant oil temperature of 140 °C

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Intake air temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

When replacement value 50 °C

◆ Defective wiring connection or intake manifold temperature sender -G42-

– Check wiring and -G42- ⇒ Page 302

Above 50 °C

◆ Raw water (seawater) through flow too low

– If a fault is present the measured value block indicates a constant intake manifold temperature of 50 °C – Check raw water (seawater) pump

◆ Charge air cooler dirty

– Clean charge air cooler

◆ Engine room temperature too high

– Vent engine room

Evaluation: Coolant temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 65 °C

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check wiring and -G62- ⇒ Page 297 – Observe test conditions

= 90 °C

◆ Coolant temperature replacement value ◆ Defective wiring connection or coolant temperature sender -G62-

Above 95 °C

◆ Coolant temperature too high ◆ Coolant shell-and-tube heat exchanger dirty

– Check wiring and -G62– If a fault is present the measured value block indicates a constant coolant temperature of 90 °C – Clean coolant shell-and-tube heat exchanger

4.3.4 Display group 103 -Activation of common rail injectorsIndicated on display: ►

Display group 103 rpm

Display zones

Operating condition or component

°kW

ms

Specification

Evaluation

1

Engine speed

0 rpm

---

2

Activation of commencement of primary injection

0 °CA

---

3

Activation period of primary injection

0 ms

---

4

High-pressure fuel pressure

0 bar.

---

bar

Evaluation: Engine speed Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

4 Measured value blocks

33

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Activation of commencement of primary injection Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Activation period of primary injection Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.5 Display group 104 -Torque limit momentsIndicated on display: ►

Display group 104 Nm

Display zones

Operating condition or component

Nm

Nm

Specification

Evaluation

0…10 Nm

⇒ Page 34

1

Actual torque from engine

2

Torque limit moment

200…250 Nm

⇒ Page 34

3

Torque limit

200…250 Nm

⇒ Page 34

4

Smoke limit

200…300 Nm

⇒ Page 35

Evaluation: Actual torque from engine Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Torque limit moment Display on ScanDi tool

Possible cause of fault

Fault remedy

Less than 200 Nm

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

Evaluation: Torque limit Display on ScanDi tool

Possible cause of fault

Fault remedy

Less than 200 Nm

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

34

Repair Group 01 - Self-diagnosis

Nm

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Smoke limit Display on ScanDi tool

Possible cause of fault

Fault remedy

Less than 200 Nm

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Atmospheric pressure implausible ◆ Charge pressure sensor implausible

4.3.6 Display group 105 -Limiting factorsIndicated on display: ►

Display group 105 -

Display zones

Operating condition or component

-

-

Specification

Evaluation

1

Quantity limit correction factor

0,99…1,00

⇒ Page 35

2

Exhaust temperature quantity limit factor

0,99…1,00

⇒ Page 35

3

Oil temperature correction factor

0,99…1,00

⇒ Page 35

4

Fuel temperature correction factor

0,99…1,00

⇒ Page 36

-

Evaluation: Quantity limit correction factor Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 0.99

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Torque limit moment active, see display group 105

– Display group 105 values 2/3/4

Evaluation: Exhaust temperature quantity limit factor Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 0.99

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Exhaust temperature too high

– Check wiring and -G235- ⇒ Page 255

◆ Exhaust temperature sender -G235/G236- defective

– Check wiring and -G236- ⇒ Page 257

Evaluation: Oil temperature correction factor Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 0.99

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Oil temperature too high

– Check oil temperature sender -8⇒ Page 299

◆ Oil temperature sender -G8- defective

4 Measured value blocks

35

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Fuel temperature correction factor Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 0.99

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Fuel temperature too high

– Check oil temperature sender -81⇒ Page 300

◆ Fuel temperature sender -G81- defective

4.3.7 Display group 106 -Charge pressure control IIndicated on display: ►

Display group 106 mbar

Display zones

Operating condition or component

mbar

mbar

Specification

Evaluation

1

Atmospheric pressure

900…1100 mbar

---

2

Charge pressure, specified value

900…1100 mbar

---

3

Charge pressure, actual value

Display group 106/1 ±50 mbar

⇒ Page 36

4

Charge pressure actuator, activation

80 %

⇒ Page 36

Evaluation: Atmospheric pressure Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure, specified value Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure, actual value Display on ScanDi tool

Possible cause of fault

Fault remedy

Different display group 106 value 1 ±50 mbar

◆ Charge air pressure sender -G31- implausible

– Read fault memory ⇒ Page 9

◆ Charge air pressure sender -G31- defective

– Check charge air pressure sender -G31- ⇒ Page 258

Evaluation: Charge pressure actuator, activation Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 80%

◆ Charge air pressure sender -G31- defective

– Read fault memory ⇒ Page 9

36

Repair Group 01 - Self-diagnosis

– Check charge air pressure sender -G31- ⇒ Page 258

%

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

4.3.8 Display group 107 -Charge pressure control IIIndicated on display: ►

Display group 107 rpm

Display zones

Operating condition or component

%

Bit

Specification

Evaluation

1

Engine speed

0 rpm

---

2

Charge pressure actuator activation before linearisation

101 %

⇒ Page 37

3

Charge pressure regulation status

0000 0001

⇒ Page 37

4

Battery voltage

11…15 V

⇒ Page 37

V

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure actuator activation before linearisation Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 80%

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9 – Check charge air pressure sender -G31- ⇒ Page 258

Evaluation: Charge pressure regulation status Display on ScanDi tool

Possible cause of fault

Fault remedy

◆ 0000 0000 Charge pressure control/ regulation fault-free ◆ XXXX XXX1 Cold start regulation, off ◆ XXXX XX1X System switch-off request/system fault →

◆ XXXX X1XX Charge pressure control/ regulation, active, permanent regulating deviations occurred ◆ X1XX XXXX Control unit running in emergency mode

Evaluation: Battery voltage Display on ScanDi tool

Possible cause of fault

Fault remedy

Battery voltage

◆ Battery defective

– Check battery

◆ Wiring connection defective

– Check wiring connections

4 Measured value blocks

37

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

4.3.9 Display group 108 -Exhaust temperatureIndicated on display: ►

Display group 108 rpm

Display zones

Operating condition or component

1

Engine speed

2

Exhaust temperature quantity limit factor

3 4

-

°C

Specification

°C

Evaluation ---

0,99…1,00

⇒ Page 38

Exhaust temperature from EGT bank 1

-20…200 °C

⇒ Page 38

Exhaust temperature from EGT bank 2

-20…200 °C

⇒ Page 38

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Exhaust temperature quantity limit factor Display on ScanDi tool

Possible cause of fault

Fault remedy

See display group 105 value 2 ⇒ Page 35

◆ See display group 105 value 2 ⇒ Page 35

– See display group 105 value 2 ⇒ Page 35

Evaluation: Exhaust temperature from EGT bank 1 Display on ScanDi tool

Possible cause of fault

Fault remedy

More than 200 °C

◆ Exhaust temperature sensor implausible

– Read fault memory ⇒ Page 9

◆ Exhaust temperature sensor defective

– Check wiring and -G235- ⇒ Page 255

Evaluation: Exhaust temperature from EGT bank 2 Display on ScanDi tool

Possible cause of fault

Fault remedy

More than 200 °C

◆ Exhaust temperature sensor implausible

– Read fault memory ⇒ Page 9

◆ Exhaust temperature sensor defective

– Check wiring and -G236- ⇒ Page 257

4.3.10 Display group 109 -Fuel consumptionIndicated on display: ►

Display group 109 rpm

Display zones

38

Operating condition or component

1

Engine speed

2

Quantity injected

Repair Group 01 - Self-diagnosis

mg/s

l/h

Specification

Evaluation

0 rpm

---

0 mg/stroke

---

%

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Display zones

Operating condition or component

Specification

Evaluation

3

Fuel consumption

0 l/h

---

4

Throttle position

0%

⇒ Page 39

3

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Quantity injected Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Fuel consumption Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Throttle position Display on ScanDi tool

Possible cause of fault

Fault remedy

More than 0%

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

4.3.11 Display group 110 -Fuel rail pressure regulation lIndicated on display: ►

Display group 110 rpm

Display zones

Operating condition or component

bar

bar

Specification

Evaluation

1

Engine speed

0 rpm

---

2

High-pressure fuel pressure (specified)

0 bar.

---

3

High-pressure fuel pressure (actual figure)

0 bar.

---

4

Activation of fuel regulating valve for highpressure

0…10 %

---

4 Measured value blocks

%

39

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (specified) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Activation of fuel regulating valve for high-pressure Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.12 Display group 111 -Fuel rail pressure regulation IIIndicated on display: ►

Display group 111 rpm

Display zones

Operating condition or component

bar

bar

Specification

Evaluation

1

Engine speed

0 rpm

---

2

High-pressure fuel pressure (specified)

0 bar.

---

3

High-pressure fuel pressure (actual figure)

0 bar.

---

4

Activation of fuel metering valve

10…20 %

---

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (specified) Display on ScanDi tool

Possible cause of fault

/

40

Repair Group 01 - Self-diagnosis

/

Fault remedy /

%

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Activation of fuel metering regulation valve Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.13 Display group 112 -Fuel rail pressure regulation IllIndicated on display: ►

Display group 112 rpm

Display zones

Operating condition or component

1

Engine speed

2

Fuel temperature

3

Fuel rail pressure regulation, status

4

Coolant temperature

°C

-

Specification

Evaluation

0 rpm

---

20…70 °C

⇒ Page 41

0

⇒ Page 42

>65 °C

⇒ Page 42

°C

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Fuel temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

= 40 °C

Defective wiring connection or fuel temperature sender -G81-

– Check wiring and -G81- ⇒ Page 300 – If a fault is present the measured value block indicates a constant fuel temperature of 40 °C (ambient air temperature must also be read as reference) – Conspicuous deviations signify a possible faulty sender value (40 °C) – Check central earth point / earth connections

4 Measured value blocks

41

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Fuel rail pressure regulation, status Display on ScanDi tool

→

Possible cause of fault

Fault remedy

0 Control operation - Active initialisation or fault 1 Control operation - Start speed threshold exceeded 2 Regulating operation - Pressure regulation valve active, fuel rail pressure monitor off 3 Regulating operation - Measuring unit active, fuel rail pressure monitor off 4 Regulating operation - Pressure regulation valve active, normal operation, fuel rail pressure monitor active 5 Regulating operation - Measuring unit active, normal operation, fuel rail pressure monitor active 6 Regulating operation - Switch-over from fuel pressure regulating valve to measuring unit, fuel rail pressure monitor off 7 Control operation - Rapid pressure reduction in fuel rail, engine is shut-down 8 Control operation - New initial initialisation, pre-control values 9 - 14 n.v.

15 Regulating operation - CPC (pressure regulating valve and measuring unit), fuel rail pressure monitor PCV on, MeUn off 16 Regulating operation- Switch-over via pressure regulating valve after a regulating operation, fuel rail pressure monitor min/max 17 Regulating operation - Switch-over after a CPC regulating operation, fuel rail pressure monitor min/max 18 Regulating operation - Switch-over after a measuring unit regulating operation, fuel rail pressure monitor min/max

Evaluation: Coolant temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 65 °C

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check wiring and -G62- ⇒ Page 297 – Observe test conditions

= 90 °C

◆ Coolant temperature replacement value ◆ Defective wiring connection or coolant temperature sender -G62-

Above 95 °C

◆ Coolant temperature too high ◆ Coolant shell-and-tube heat exchanger dirty

– Check wiring and -G62- ⇒ Page 297 – If a fault is present the measured value block indicates a constant coolant temperature of 90 °C – Clean coolant shell-and-tube heat exchanger

4.3.14 Display group 113 -Quantity injected, specificationIndicated on display: ►

Display group 113 mg/s

42

Repair Group 01 - Self-diagnosis

mg/s

mg/s

mg/s

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Display zones

Operating condition or component

Specification

Evaluation

1

Quantity injected

0 mg/stroke

---

2

Quantity injected for primary injection, specification

0 mg/stroke

---

3

Pilot injection 1 quantity injected, specification

0 mg/stroke

---

4

Pilot injection 2 quantity injected, specification

0 mg/stroke

---

3

Evaluation: Quantity injected Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Quantity injected for primary injection, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Pilot injection 1, quantity injected, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Pilot injection 2, quantity injected, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.15 Display group 114 -Activation period of pilot injection 1Indicated on display: ►

Display group 114 mg/s

Display zones

Operating condition or component

mg/s

ms

Specification

Evaluation

1

Quantity injected (specified)

0 mg/stroke

---

2

Quantity injected (actual)

0 mg/stroke

---

3

Pilot injection 1 activation period (actual)

0 ms

---

4

High-pressure fuel pressure (actual figure)

0 bar.

---

4 Measured value blocks

bar

43

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Quantity injected (specified) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Quantity injected (actual) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Pilot injection 1 activation period (actual value) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.16 Display group 115 -Activation period of pilot injection 2Indicated on display: ►

Display group 115 mg/s

Display zones

Operating condition or component

mg/s

ms

Specification

Evaluation

1

Quantity injected (specified)

0 mg/stroke

---

2

Quantity injected (actual)

0 mg/stroke

---

3

Pilot injection 2 activation period (actual)

0 ms

---

4

High-pressure fuel pressure (actual figure)

0 bar.

---

Evaluation: Quantity injected (specified) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Quantity injected (actual) Display on ScanDi tool

Possible cause of fault

/

44

Repair Group 01 - Self-diagnosis

/

Fault remedy /

bar

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Pilot injection 2 activation period (actual value) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.17 Display group 116 -Injection coordinatorIndicated on display: ►

Display group 116 mg/s

Display zones

Operating condition or component

1

Quantity injected

2

Permitted number of injections

3

Switch-off request, injectors

4

Number of fault entries

-

Bit

Bit

Specification

Evaluation

0 mg/stroke

---

3

---

0000 0100

---

0000 0000…1111 1111

---

Evaluation: Quantity injected Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Permitted number of injections Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Switch-off request, injectors Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Number of fault entries Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.3.18 Display group 117 -idling speedIndicated on display: ►

Display group 117 rpm

rpm

Bit

4 Measured value blocks

%

45

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Display zones

Operating condition or component

Specification

Evaluation

0 rpm

---

640…660 rpm

---

1

Engine speed

2

Idling speed, specification

3

Gear information

0000 0000

---

4

Throttle position

0%

⇒ Page 46

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Idling speed, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Gear information Display on ScanDi tool

Possible cause of fault

→

0000 0000 gear 0 active 0000 0001 gear 1 active

Fault remedy /

Evaluation: Throttle position Display on ScanDi tool More than 0%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

4.3.19 Display group 118 - Rotational speed registrationIndicated on display: ►

Display group 118 rpm

Display zones

46

Operating condition or component

rpm

rpm

Specification

Evaluation

1

Engine speed

0 rpm

---

2

Crankshaft speed

0 rpm

---

3

Camshaft speed

0 rpm

---

4

Starting synchronization

0…2

⇒ Page 47

Repair Group 01 - Self-diagnosis

-

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Crankshaft speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Camshaft speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Starting synchronization Display on ScanDi tool

→

4.4

Possible cause of fault

Fault remedy

0 Basic initialisation of automatic synchronization 2 No synchronization, all crankshaft/camshaft sender systems are inactive/defective 3 No synchronization, Engine speed too low or crankshaft sender system implausible 8 No synchronization, crankshaft sender system implausible 32 Crankshaft gap detection successful, system waiting for final position from camshaft signal 33 Synchronization available, is still being tested 34 No synchronization, Position not finalised, restart of automatic synchronization, too many resynchronization cycles (terminal 15: OFF/ON) 35 Synchronization available, rotational angle between crankshaft and camshaft too high 38 No valid camshaft signal, synchronization performed via evaluation of acceleration of engine revolutions 48 Synchronization completed, crankshaft and camshaft are synchronized

Evaluating measured value blocks at idling speed (engine warm, coolant temperature not below 73 °C)

4.4.1 Display group 100 -Quantity injectedIndicated on display: ►

Display group 100 rpm

Display zones

Operating condition or component

%

mg/s

Specification

Evaluation

630…670 rpm1)

---

1

Engine speed

2

Throttle position

0%

⇒ Page 48

3

Quantity injected

3…5 mg/stroke

⇒ Page 48

4

High-pressure fuel pressure

280…350 bar

⇒ Page 48

4 Measured value blocks

bar

47

3 1)

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

All measurements at idling speed may only be carried out within a rev range of 630…670 rpm If an idling speed of 630 rpm is not achieved or the max. permissible idling speed of 670 rpm is exceeded, the idling speed must be reset to the factory default of 650 rpm before the measured value blocks are evaluated. The idling speed cannot be reduced, only increased whereby the max. possible idling speed is 1900 rpm.

Evaluation: Engine speed display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Throttle position display Display on ScanDi tool More than 0%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Quantity injected display Display on ScanDi tool Above 5 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up and repeat check

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: High-pressure fuel pressure display Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ Fuel metering valve -N290- defective ◆ Defective fuel pressure sender -G247◆ High-pressure system leaking

Over 350 bar

– Check wiring and -N276- ⇒ Page 307 – Check wiring and -G247- ⇒ Page 306

◆ Fuel pressure regulating valve -N276defective ◆ Defective fuel pressure sender -G247◆ Engine too cold

4.4.2 Display group 101 -starting conditionsIndicated on display: ►

Display group 101 rpm

48

Repair Group 01 - Self-diagnosis

mg/s

-

V

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Display zones

1)

Operating condition or component

1

Engine speed

2

Starting quantity

3

Starting synchronization

4

Battery voltage

Specification

3

Evaluation

630…670 rpm1) 19…22 mg/stroke

⇒ Page 49

48

⇒ Page 49

13…15 V

⇒ Page 50

All measurements at idling speed may only be carried out within a rev range of 630…670 rpm If an idling speed of 630 rpm is not achieved or the max. permissible idling speed of 670 rpm is exceeded, the idling speed must be reset to the factory default of 650 rpm before the measured value blocks are evaluated. The idling speed cannot be reduced, only increased whereby the max. possible idling speed is 1900 rpm.

Evaluation: Engine speed display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Starting quantity display Display on ScanDi tool

Possible cause of fault

Larger than 22 mg/ ◆ Engine too cold stroke ◆ Defective coolant temperature sender -G62-

Fault remedy – Check coolant temperature sender -G62- ⇒ Page 297

Evaluation: Start synchronization display Display on ScanDi tool When 38

Possible cause of fault

Fault remedy

◆ Voltage supply under 10 V

– The battery is checked – Check charging system – Check wiring connections – Check consumers

8 (not always)

◆ Hall sender -G40 - defective

– Check wiring and -G40- ⇒ Page 304

◆ Voltage supply under 10 V

– The battery is checked – Check charging system – Check wiring connections – Check consumers

Defective engine speed sender -G28-

– Check wiring and -G28- ⇒ Page 295

4 Measured value blocks

49

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Battery voltage display Display on ScanDi tool Less than 12 V

Greater than 12 V

Possible cause of fault

Fault remedy

◆ Alternator defective

– Check battery

◆ Battery defective

– Check charging system

◆ Wiring connection defective

– Check wiring connections

◆ Consumer current draw too high

– Check consumers

◆ Voltage regulator defective

– Check regulator

4.4.3 Display group 102 -TemperaturesIndicated on display: ►

Display group 102 °C

Display zones

Operating condition or component

°C

°C

Specification

Evaluation

1

Fuel temperature

20…70 °C

⇒ Page 50

2

Oil temperature

20…120 °C

⇒ Page 50

3

Intake air temperature

<50 °C

⇒ Page 51

4

Coolant temperature

>65 °C

⇒ Page 51

°C

Evaluation: Fuel temperature display Display on ScanDi tool When replacement value 40 °C

Possible cause of fault

Fault remedy

◆ Defective wiring connection or fuel temperature sender -G81-

– Check wiring and -G81- ⇒ Page 300 – If a fault is present the measured value block indicates a constant fuel temperature of 40 °C

Evaluation: Oil temperature display Display on ScanDi tool When replacement value 140 °C

50

Possible cause of fault

Fault remedy

◆ Defective wiring connection or oil temperature sender -G8-

– Check wiring and -G8- ⇒ Page 299

Repair Group 01 - Self-diagnosis

– If a fault is present the measured value block indicates a constant oil temperature of 140 °C

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Intake air temperature display Display on ScanDi tool When replacement value 50 °C

Above 50 °C

Possible cause of fault

Fault remedy

◆ Defective wiring connection or intake manifold temperature sender -G42-

– Check wiring and -G42- ⇒ Page 302

◆ Raw water (seawater) through flow too low

– Check raw water (seawater) pump

◆ Charge air cooler dirty

– Vent engine room

– If a fault is present the measured value block indicates a constant intake manifold temperature of approx. 50 °C – Clean charge air cooler

◆ Engine room temperature too high Evaluation: Coolant temperature display Display on ScanDi tool Below 65 °C

Possible cause of fault

Fault remedy

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check coolant temperature sender -G62- ⇒ Page 297 – Observe test conditions

= 90 °C

Above 95 °C

◆ Coolant temperature replacement value

– Check coolant temperature sender -G62- ⇒ Page 297

◆ Defective wiring connection or coolant temperature sender -G62-

– If a fault is present the measured value block indicates a constant coolant temperature of 90 °C

◆ Coolant temperature too high

– Clean coolant shell-and-tube heat exchanger

◆ Coolant shell-and-tube heat exchanger dirty

4.4.4 Display group 103 -Activation of common rail injectorsIndicated on display: ►

Display group 103 U/

Display zones

1)

Operating condition or component

°kW

ms

bar

Specification

Evaluation

630…670 rpm1)

---

-5 … -3 °crank angle

⇒ Page 52

1

Engine speed

2

Activation of commencement of primary injection

3

Activation period of primary injection

0.35…0.45 ms

⇒ Page 52

4

High-pressure fuel pressure

280…350 bar

⇒ Page 52

All measurements at idling speed may only be carried out within a rev range of 630…670 rpm If an idling speed of 630 rpm is not achieved or the max. permissible idling speed of 670 rpm is exceeded, the idling speed must be reset to the factory default of 650 rpm before the measured value blocks are evaluated. The idling speed cannot be reduced, only increased whereby the max. possible idling speed is 1900 rpm.

4 Measured value blocks

51

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Engine speed display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Commencement of primary injection display Display on ScanDi tool Outside value range

Possible cause of fault

Fault remedy

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check coolant temperature sender -G62- ⇒ Page 297 – The general prerequisites must be fulfilled for the specified references (operating temperature = min. 73 °C, idling speed value range = 630…670 rpm)

Evaluation: Primary injection activation period display Display on ScanDi tool Outside value range

Possible cause of fault

Fault remedy

◆ Rail pressure implausible

– Check rail pressure, display group 103, value 4

Evaluation: Primary injection, fuel pressure display Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ Fuel metering valve -N290- defective

– Check wiring and -N276- ⇒ Page 307 – Check wiring and -G247- ⇒ Page 306

◆ Defective fuel pressure sender -G247◆ High-pressure system leaking Over 350 bar

◆ Fuel pressure regulating valve -N276defective

– Check central earth point / earth connections

◆ Defective fuel pressure sender -G247◆ Engine too cold

4.4.5 Display group 104 -Torque limit momentsIndicated on display: ►

Display group 104 Nm

52

Repair Group 01 - Self-diagnosis

Nm

Nm

Nm

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011 Display zones

Operating condition or component

Specification

Evaluation

40…80 Nm

⇒ Page 53

1

Actual torque from engine

2

Torque limit moment

330…390 Nm

⇒ Page 53

3

Torque limit

330…390 Nm

⇒ Page 53

4

Smoke limit

330…390 Nm

⇒ Page 53

3

Evaluation: Actual torque from engine Display on ScanDi tool Above 80 Nm

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up and repeat check

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Torque limit moment display Display on ScanDi tool Less than 330 Nm

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

Evaluation: Torque limit display Display on ScanDi tool Less than 330 Nm

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

Evaluation: Smoke limit display Display on ScanDi tool Less than 330 Nm

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Read fault memory ◆ Atmospheric pressure implausible ◆ Charge pressure sensor implausible

4.4.6 Display group 105 -Limiting factorsIndicated on display: ►

Display group 105 -

Display zones

Operating condition or component

-

-

Specification

Evaluation

1

Quantity limit correction factor

0,99…1,00

⇒ Page 54

2

Exhaust temperature quantity limit factor

0,99…1,00

⇒ Page 54

3

Oil temperature correction factor

0,99…1,00

⇒ Page 54

4

Fuel temperature correction factor

0,99…1,00

⇒ Page 54

4 Measured value blocks

-

53

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Quantity limit correction factor display Display on ScanDi tool Below 0.99

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Torque limit moment active, see display group 105

– Check display group 105, values 2/3/4

Evaluation: Exhaust temperature quantity limit factor display Display on ScanDi tool Below 0.99

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Exhaust temperature too high

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257

◆ Exhaust temperature sender -G235/G236- defective Evaluation: Oil temperature quantity limit factor display Display on ScanDi tool Below 0.99

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Oil temperature too high

– Check oil temperature sender -G8⇒ Page 299

◆ Oil temperature sender defective Evaluation: Fuel temperature quantity limit factor display Display on ScanDi tool Below 0.99

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Fuel temperature too high

– Check fuel temperature sender -G81⇒ Page 300

◆ Fuel temperature sender -G81- defective

4.4.7 Display group 106 -Charge pressure control IIndicated on display: ►

Display group 106 mbar

Display zones

54

Operating condition or component

mbar

mbar

Specification

Evaluation

1

Atmospheric pressure

900…1100 mbar

---

2

Charge pressure, specified value

900…1150 mbar

---

3

Charge pressure, actual value

900…1150 mbar

⇒ Page 55

4

Charge pressure actuator, activation

25…32%

⇒ Page 55

Repair Group 01 - Self-diagnosis

%

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Atmospheric pressure display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure, specified value display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure, actual value display Display on ScanDi tool

Possible cause of fault

Fault remedy

Less than 900 mbar

◆ Charge pressure sensor implausible

– Read fault memory ⇒ Page 9

Larger than 1150 mbar

◆ Charge pressure sensor defective

– Check charge pressure sensor

Evaluation: Charge pressure actuator, activation display Display on ScanDi tool Over 32% / under 25%

Possible cause of fault

Fault remedy

◆ Rods of guide vane on turbocharger are difficult to move/sticking

– Check rods of guide vane on turbocharger for ease of movement ⇒ Page 253

4.4.8 Display group 107 -Charge pressure control IIIndicated on display: ►

Display group 107 rpm

Display zones

%

Bit

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

Charge pressure actuator activation before linearisation

23…30 %

⇒ Page 56

3

Charge pressure regulation status

0000 0000

⇒ Page 56

4

Battery voltage

13…15 V

⇒ Page 56

V

Evaluation: Engine speed display Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

4 Measured value blocks

55

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Charge pressure actuator activation before linearisation display Display on ScanDi tool Over 42% / under 23%

Possible cause of fault

Fault remedy

◆ Rods of guide vane on turbocharger are difficult to move/sticking

– Check rods of guide vane on turbocharger for ease of movement ⇒ Page 253

Evaluation: Charge pressure regulation status display Display on ScanDi tool

Possible cause of fault

Fault remedy

0000 0000 Charge pressure control /charge pressure control regulation fault-free XXXX XXX1 Cold start, regulation off XXXX XX1X Switch-off request / system fault XXX X1XX Charge pressure control /charge pressure control regulation active, permanent regulation deviations have occurred X1XX XXXX Control unit in emergency mode

→

Evaluation: Battery voltage display Display on ScanDi tool Less than 12 V

Greater than 12 V

Possible cause of fault

Fault remedy

◆ Alternator defective

– Check battery

◆ Battery defective

– Check charging system

◆ Wiring connection defective

– Check wiring connections

◆ Consumer current draw too high

– Check consumers

◆ Voltage regulator defective

– Check regulator

4.4.9 Display group 108 -Exhaust temperatureIndicated on display: ►

Display group 108 rpm

Display zones

-

°C

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

Exhaust temperature quantity limit factor

0,99…1,00

⇒ Page 57

3

Exhaust temperature from EGT bank 1

80…120 °C

⇒ Page 57

4

Exhaust temperature from EGT bank 2

80…120 °C

⇒ Page 57

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

56

°C

Repair Group 01 - Self-diagnosis

/

Fault remedy /

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Exhaust temperature quantity limit factor Display on ScanDi tool See display group 105 value 2 ⇒ Page 35

Possible cause of fault

Fault remedy

◆ See display group 105 value 2 ⇒ Page 35

– See display group 105 value 2 ⇒ Page 35

Evaluation: Exhaust temperature from EGT bank 1 Display on ScanDi tool

Possible cause of fault

Fault remedy

Display group 108 / Defective wiring connection or bank 1 ex- – Check wiring and -G235- ⇒ Page 255 3 (-G235-) haust temperature sender -G235– Check central earth point / earth con+ 20 °C nections – When -G235- and -G236- are defective, a constant replacement value of 720 °C is used and displayed Evaluation: Exhaust temperature from EGT bank 2 Display on ScanDi tool

Possible cause of fault

Fault remedy

Display group 108 / Defective wiring connection or bank 2 ex- – Check wiring and -G236- ⇒ Page 257 4 (-G236-) haust temperature sender -G236– Check central earth point / earth con- 20 °C nections – When -G235- and -G236- are defective, a constant replacement value of 720 °C is used and displayed

4.4.10 Display group 109 -Fuel consumptionIndicated on display: ►

Display group 109 rpm

Display zones

mg/s

l/h

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

Quantity injected

3…5 mg/stroke

⇒ Page 58

3

Fuel consumption

0.5…0.7 l/h

⇒ Page 58

4

Throttle position

0%

⇒ Page 58

%

Evaluation: Engine speed Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

4 Measured value blocks

57

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Quantity injected Display on ScanDi tool Above 5 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Fuel consumption Display on ScanDi tool Above 0.7 l/h

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Throttle position Display on ScanDi tool More than 0%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

4.4.11 Display group 110 -Fuel rail pressure regulation lIndicated on display: ►

Display group 110 rpm

Display zones

bar

bar

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

High-pressure fuel pressure (specified)

290…320 bar

⇒ Page 59

3

High-pressure fuel pressure (actual figure)

280…350 bar

⇒ Page 59

4

Activation of fuel regulating valve for highpressure

15-25%

---

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

58

Repair Group 01 - Self-diagnosis

/

Fault remedy /

%

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: High-pressure fuel pressure (specified) Display on ScanDi tool Over 320 bar

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective

– Check wiring and -N276- ⇒ Page 307

◆ Fuel metering valve -N290- defective ◆ Defective fuel pressure sender -G247◆ High-pressure system leaking Over 350 bar

– Check wiring and -G247- ⇒ Page 306 – Check central earth point / earth connections

◆ Fuel pressure regulating valve -N276defective ◆ Defective fuel pressure sender -G247◆ Engine too cold

Evaluation: High-pressure fuel pressure regulating valve Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.4.12 Display group 111 -Fuel rail pressure regulation IIIndicated on display: ►

Display group 111 rpm

Display zones

bar

bar

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

High-pressure fuel pressure (specified)

290…320 bar

⇒ Page 60

3

High-pressure fuel pressure (actual figure)

280…350 bar

⇒ Page 60

4

Activation of fuel metering valve

25-35%

⇒ Page 60

%

Evaluation: Engine speed Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

4 Measured value blocks

59

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: High-pressure fuel pressure (specified) Display on ScanDi tool Over 320 bar

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ Fuel metering valve -N290- defective ◆ Defective fuel pressure sender -G247◆ High-pressure system leaking

Over 350 bar

– Check wiring and -N276- ⇒ Page 307 – Check wiring and -G247- ⇒ Page 306 – Check central earth point / earth connections

◆ Fuel pressure regulating valve -N276defective ◆ Defective fuel pressure sender -G247◆ Engine too cold

Evaluation: Activation of fuel metering regulation valve Display on ScanDi tool Below 25 %

Possible cause of fault

Fault remedy

◆ Defective wiring connection or fuel pressure regulating valve -N290-

– Check central earth point / earth connections – Possibly renew high-pressure pump with fuel metering valve -N290⇒ Page 286

4.4.13 Display group 112 -Fuel rail pressure regulation -IllIndicated on display: ►

Display group 112 rpm

Display zones

60

°C

-

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

Fuel temperature

20…70 °C

⇒ Page 61

3

Fuel rail pressure regulation, status

15

⇒ Page 61

4

Coolant temperature

>65 °C

⇒ Page 62

Repair Group 01 - Self-diagnosis

°C

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Fuel temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

= 40 °C

Defective wiring connection or fuel temperature sender -G81-

– Check wiring and -G81- ⇒ Page 300 – If a fault is present the measured value block indicates a constant fuel temperature of 40 °C (ambient air temperature must also be read as reference) – Conspicuous deviations signify a possible faulty sender value ⇒ 40 °C – Check central earth point / earth connections

Evaluation: Fuel rail pressure regulation, status Display on ScanDi tool

→

Possible cause of fault

Fault remedy

0 Control operation - Active initialisation or fault 1 Control operation - Start speed threshold exceeded 2 Regulating operation - Pressure regulation valve active, fuel rail pressure monitor off 3 Regulating operation - Measuring unit active, fuel rail pressure monitor off 4 Regulating operation - Pressure regulation valve active, normal operation, fuel rail pressure monitor active 5 Regulating operation - Measuring unit active, normal operation, fuel rail pressure monitor active 6 Regulating operation - Switch-over from fuel pressure regulating valve to measuring unit, fuel rail pressure monitor off 7 Control operation - Rapid pressure reduction in fuel rail, engine is shut-down 8 Control operation - New initial initialisation, pre-control values 9 - 14 n.v.

15 Regulating operation - CPC (pressure regulating valve and measuring unit), fuel rail pressure monitor PCV on, MeUn off 16 Regulating operation- Switch-over via pressure regulating valve after a regulating operation, fuel rail pressure monitor min/max 17 Regulating operation - Switch-over after a CPC regulating operation, fuel rail pressure monitor min/max 18 Regulating operation - Switch-over after a measuring unit regulating operation, fuel rail pressure monitor min/max

4 Measured value blocks

61

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Coolant temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 65 °C

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check wiring and -G62- ⇒ Page 297 – Observe test conditions

= 90 °C

– Check wiring and -G62- ⇒ Page 297

◆ Coolant temperature replacement value ◆ Defective wiring connection or coolant temperature sender -G62-

Above 95 °C

◆ Coolant temperature too high

– If a fault is present the measured value block indicates a constant coolant temperature of 90 °C – Clean coolant shell-and-tube heat exchanger

◆ Coolant shell-and-tube heat exchanger dirty

4.4.14 Display group 113 -Quantity injected, specificationIndicated on display: ►

Display group 113 mg/s

Display zones

mg/s

mg/s

Operating condition or component

Specification

Evaluation

1

Quantity injected

2…6 mg/stroke

⇒ Page 62

2

Quantity injected for primary injection, specification

3…5 mg/stroke

⇒ Page 62

3

Pilot injection 1 quantity injected, specification

1.85…2.15 ms

---

4

Pilot injection 2 quantity injected, specification

280…350 bar

---

Evaluation: Quantity injected Display on ScanDi tool Above 5 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Quantity injected for primary injection, specification Display on ScanDi tool Above 5 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

62

Repair Group 01 - Self-diagnosis

– Switch consumers off

mg/s

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Pilot injection 1, quantity injected, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Pilot injection 2, quantity injected, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

4.4.15 Display group 114 -Activation period of pilot injection 1Indicated on display: ►

Display group 114 mg/s

Display zones

mg/s

ms

Operating condition or component

Specification

Evaluation

1

Quantity injected (specified)

2…6 mg/stroke

⇒ Page 63

2

Quantity injected (actual)

3…5 mg/stroke

⇒ Page 63

3

Pilot injection 1 activation period (actual)

1.85…2.15 ms

---

4

High-pressure fuel pressure (actual figure)

280…350 bar

⇒ Page 64

bar

Evaluation: Quantity injected (specified) Display on ScanDi tool Above 6 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Quantity injected (actual) Display on ScanDi tool Above 5 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Pilot injection 1 activation period (actual value) Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

4 Measured value blocks

63

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective

– Check wiring and -N276- ⇒ Page 307

◆ Fuel metering valve -N290- defective ◆ Defective fuel pressure sender -G247◆ High-pressure system leaking Over 350 bar

– Check wiring and -G247- ⇒ Page 306 – Check central earth point / earth connections

◆ Fuel pressure regulating valve -N276defective ◆ Defective fuel pressure sender -G247◆ Engine too cold

4.4.16 Display group 115 -Activation period of pilot injection 2Indicated on display: ►

Display group 115 mg/s

Display zones

mg/s

ms

Operating condition or component

Specification

Evaluation

1

Quantity injected (specified)

2…6 mg/stroke

⇒ Page 64

2

Quantity injected (actual)

3…5 mg/stroke

⇒ Page 64

3

Pilot injection 2 activation period (actual)

3.5…3.8 ms

---

4

High-pressure fuel pressure (actual figure)

280…350 bar

⇒ Page 65

Evaluation: Quantity injected (specified) Display on ScanDi tool Above 6 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

– Switch consumers off

Evaluation: Quantity injected (actual) Display on ScanDi tool Above 5 mg/stroke

Possible cause of fault

Fault remedy

◆ Engine too cold

– Run engine at increased speed to warm up, and repeat test

◆ Engine strained due to consumers

64

Repair Group 01 - Self-diagnosis

– Switch consumers off

bar

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Pilot injection 2 activation period (actual value) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ Fuel metering valve -N290- defective ◆ Defective fuel pressure sender -G247◆ High-pressure system leaking

Over 350 bar

– Check wiring and -N276- ⇒ Page 307 – Check wiring and -G247- ⇒ Page 306 – Check central earth point / earth connections

◆ Fuel pressure regulating valve -N276defective ◆ Defective fuel pressure sender -G247◆ Engine too cold

4.4.17 Display group 116 -Injection coordinatorIndicated on display: ►

Display group 116 mg/s

Display zones

-

Bit

Operating condition or component

Specification

Evaluation

1

Quantity injected

3…5 mg/stroke

⇒ Page 65

2

Permitted number of injections

3

---

3

Switch-off request, injectors

0000 0000

⇒ Page 66

4

Number of fault entries

0000 0000…1111 1111

⇒ Page 66

Bit

Evaluation: Quantity injected Display on ScanDi tool

Possible cause of fault

Fault remedy

◆ Engine too cold Above 5 mg/stroke

◆ Engine strained due to consumers

– Run engine at increased speed to warm up, and repeat test – Switch consumers off

Evaluation: Permitted number of injections Display on ScanDi tool /

Possible cause of fault

/

Fault remedy

//

4 Measured value blocks

65

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Switch-off request, injectors Display on ScanDi tool > 0000 0000

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

Evaluation: Number of fault entries Display on ScanDi tool > 0000 0000

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

4.4.18 Display group 117 -idling speedIndicated on display: ►

Display group 117 rpm

Display zones

rpm

Bit

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

Idling speed, specification

640…660 rpm

⇒ Page 66

3

Gear information

0000 0000

---

4

Throttle position

0%

⇒ Page 67

%

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Idling speed, specification Display on ScanDi tool > 660 rpm

1)

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Fault detected by EMMA

– EMMA diagnosis 1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Gear information

66

Display on ScanDi tool

Possible cause of fault

→

0000 0000 gear 0 active 0000 0001 gear 1 active

Repair Group 01 - Self-diagnosis

Fault remedy /

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Throttle position Display on ScanDi tool More than 0%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

4.4.19 Display group 118 - Rotational speed registrationIndicated on display: ►

Display group 118 rpm

Display zones

rpm

rpm

Operating condition or component

Specification

Evaluation

1

Engine speed

630…670 rpm

---

2

Crankshaft speed

630…670 rpm

---

3

Camshaft speed

315…335 rpm

---

4

Starting synchronization

48

⇒ Page 68

-

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Crankshaft speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Camshaft speed Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

4 Measured value blocks

67

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Starting synchronization Display on ScanDi tool

Fault remedy

0 Basic initialisation of automatic synchronization 2 No synchronization, all crankshaft/camshaft sender systems are inactive/defective 3 No synchronization, Engine speed too low or crankshaft sender system implausible 8 No synchronization, crankshaft sender system implausible 32 Crankshaft gap detection successful, system waiting for final position from camshaft signal 33 Synchronization available, is still being tested 34 No synchronization, Position not finalised, restart of automatic synchronization, too many resynchronization cycles (terminal 15: OFF/ON) 35 Synchronization available, rotational angle between crankshaft and camshaft too high 38 No valid camshaft signal, synchronization performed via evaluation of acceleration of engine revolutions 48 Synchronization completed, crankshaft and camshaft are synchronized

→

5

Possible cause of fault

Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C) Note

◆ Gearbox and propeller design must be correct to archive the nominal revolutions. ◆ When testing, accelerate the boat at full throttle. ◆ The measured values must be printed out or read (2nd person required) when the revolutions reach specifications.

5.1

Display group 100 -Quantity injected-

Indicated on display: ►

Display group 100 rpm

Display zones

Operating condition or component

%

mg/s

Specification

Evaluation

4150…4250 rpm

---

1

Engine speed

2

Throttle position

100 %

⇒ Page 69

3

Quantity injected

60…65 mg/stroke

⇒ Page 69

4

High-pressure fuel pressure

1580…1650 bar

⇒ Page 69

Evaluation: Engine speed display Display on ScanDi tool

Possible cause of fault

/

68

Repair Group 01 - Self-diagnosis

/

Fault remedy /

bar

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Throttle position display Display on ScanDi tool Less than 100%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Quantity injected display Display on ScanDi tool Below 60 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high

– Check wiring and -G235- ⇒ Page 255

◆ Coolant temperature too high

– Check wiring and -G236- ⇒ Page 257

◆ Error: PWG not 100%

– Check coolant temperature/coolant temperature sender ⇒ Page 297

◆ Charge pressure is too low

– Check EMMA1) – Check charge pressure control ⇒ Page 252.

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: High-pressure fuel pressure display Display on ScanDi tool Below 1580 bar

Over 1650 bar

5.2

Possible cause of fault

Fault remedy

◆ Air in fuel system

– Bleeding fuel system

◆ Fuel or circulation filter blocked

– Clean circulation filter

◆ Fuel pressure regulating valve -N276defective

– Renewing fuel filter

◆ High-pressure system leaking

– Check vacuum lines for leaks

◆ Air in fuel system

– Bleeding fuel system

◆ Fuel pressure regulating valve -N276defective

– Check wiring and -N276- ⇒ Page 307

– Check wiring and -N276- ⇒ Page 307

Display group 101 -starting conditions-

Indicated on display: ►

Display group 101 rpm

Display zones

Operating condition or component

mg/s

-

Specification

Evaluation

1

Engine speed

4150…4250 rpm

---

2

Starting quantity

19…22 mg/stroke

---

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

V

69

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Display zones

Operating condition or component

3

Starting synchronization

4

Battery voltage

Specification

Evaluation

48

---

13…15 V

⇒ Page 70

Evaluation: Engine speed display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Starting quantity display Display on ScanDi tool

Possible cause of fault

Fault remedy

Value stored after engine start Evaluation: Start synchronization display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Battery voltage display Display on ScanDi tool Less than 13V

Greater than 15 V

5.3

Possible cause of fault

Fault remedy

◆ Alternator defective

– Check battery

◆ Battery defective

– Check charging system

◆ Voltage regulator defective

– Check regulator

Display group 102 -Temperatures-

Indicated on display: ►

Display group 102 °C

Display zones

Operating condition or component

°C

°C

Specification

Evaluation

1

Fuel temperature

20…70 °C

⇒ Page 70

2

Oil temperature

80-140 °C

⇒ Page 71

3

Intake air temperature

<50 °C

⇒ Page 71

4

Coolant temperature

>65 °C

⇒ Page 71

°C

Evaluation: Fuel temperature display Display on ScanDi tool

Possible cause of fault

When replacement ◆ Defective wiring connection or fuel value 40 °C temperature sender -G81-

70

Repair Group 01 - Self-diagnosis

Fault remedy – Check wiring and -G81- ⇒ Page 300 – If a fault is present the measured value block indicates a constant fuel temperature of 40 °C

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Oil temperature display Display on ScanDi tool

Possible cause of fault

When replacement ◆ Defective wiring connection or oil temvalue 140 °C perature sender -G8-

Fault remedy – Check wiring and oil temperature sender -G8- ⇒ Page 299 – If a fault is present the measured value block indicates a constant oil temperature of 140 °C

Evaluation: Intake air temperature display Display on ScanDi tool

Possible cause of fault

When replacement ◆ Defective wiring connection or intake value 50 °C manifold temperature sender -G42-

Above 50 °C

Fault remedy – Check wiring and -G42- ⇒ Page 302 – If a fault is present the measured value block indicates a constant intake manifold temperature of approx.50 °C

◆ Raw water (seawater) through flow too low

– Clean charge air cooler

◆ Charge air cooler dirty

– Vent engine room

– Check raw water (seawater) pump

◆ Engine room temperature too high Evaluation: Coolant temperature display Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 65 °C

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check wiring and -G62- ⇒ Page 297 – Observe test conditions

= 90 °C

◆ Coolant temperature replacement value ◆ Defective wiring connection or coolant temperature sender -G62-

Above 95 °C

◆ Coolant temperature too high ◆ Coolant shell-and-tube heat exchanger dirty

5.4

– Check wiring and -G62- ⇒ Page 297 – If a fault is present the measured value block indicates a constant coolant temperature of 90 °C – Clean coolant shell-and-tube heat exchanger

Display group 103 -Activation of common rail injectors-

Indicated on display: ►

Display group 103 rpm

°kW

ms

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

bar

71

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Display zones

Operating condition or component

Specification

Evaluation

4150…4250 rpm

---

-19 … -21 °crank angle

⇒ Page 72

1

Engine speed

2

Activation of commencement of primary injection

3

Activation period of primary injection

0.75…0.85 ms

⇒ Page 72

4

High-pressure fuel pressure

280…350 bar

⇒ Page 72

Evaluation: Engine speed display Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Commencement of primary injection display Display on ScanDi tool Outside value range

Possible cause of fault

Fault remedy

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check wiring and -G62- ⇒ Page 297 – The general test prerequisites must be fulfilled for the referencing of the specifications. (operating temperature = min. 73 °C, idling speed value range = 4150…4250 rpm)

Evaluation: Primary injection activation period display Display on ScanDi tool Outside value range

Possible cause of fault

Fault remedy

◆ Rail pressure implausible

– Check rail pressure display group 103 / 4

Evaluation: Primary injection, fuel high-pressure display Display on ScanDi tool Below 1580 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ High-pressure system leaking

Over 1650 bar

◆ Air in fuel system ◆ Fuel pressure regulating valve -N276defective

72

Repair Group 01 - Self-diagnosis

– Check wiring and -N276- ⇒ Page 307 – Check central earth point / earth connections

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.5

3

Display group 104 -Torque limit moments-

Indicated on display: ►

Display group 104 Nm

Display zones

Nm

Nm

Operating condition or component

Specification

Evaluation

1

Actual torque from engine

690…750 Nm

⇒ Page 73

2

Torque limit moment

690…750 Nm

⇒ Page 73

3

Torque limit

690…750 Nm

⇒ Page 73

4

Smoke limit

760…820 Nm

⇒ Page 73

Nm

Evaluation: Actual torque from engine Display on ScanDi tool Above 690 Nm

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100%

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297

Evaluation: Torque limit moment display Display on ScanDi tool Less than 690 Nm

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Torque limit moment active

– Check display group 105 ⇒ Page 74

◆ Revolutions not achieved Evaluation: Torque limit display Display on ScanDi tool Less than 690 Nm

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Torque limit moment active

– Check display group 105 ⇒ Page 74

◆ Revolutions not achieved Evaluation: Smoke limit display Display on ScanDi tool Less than 760 Nm

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Charge pressure is too low

– Check charge pressure control ⇒ Page 252.

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

73

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.6

Display group 105 -Limiting factors-

Indicated on display: ►

Display group 105 -

Display zones

Operating condition or component

-

-

Specification

Evaluation

1

Quantity limit correction factor

0,99…1,00

⇒ Page 74

2

Exhaust temperature quantity limit factor

0,99…1,00

⇒ Page 74

3

Oil temperature correction factor

0,99…1,00

⇒ Page 74

4

Fuel temperature correction factor

0,99…1,00

⇒ Page 74

-

Evaluation: Quantity limit correction factor display Display on ScanDi tool Below 0.99

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Torque limit moment active

– Check display group 105, values 2/3/4

Evaluation: Exhaust temperature quantity limit factor display Display on ScanDi tool Below 0.99

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Exhaust temperature too high

– Check exhaust gas temperature sender -G235/G236-

◆ Exhaust temperature sender -G235/G236- defective

– Check exhaust gas back pressure – Check coolant temperature

Evaluation: Oil temperature quantity limit factor display Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 0.99

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Oil temperature sender -G8- defective ◆ Coolant temperature too high

– Check coolant temperature

Evaluation: Fuel temperature quantity limit factor display Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 0.99

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Fuel temperature too high

– Check wiring and -G81- ⇒ Page 300

◆ Fuel temperature sender -G81- defective

74

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.7

3

Display group 106 -Charge pressure control I-

Indicated on display: ►

Display group 106 mbar

Display zones

Operating condition or component

mbar

mbar

Specification

Evaluation

900…1100 mbar

---

1

Atmospheric pressure

2

Charge pressure, specified value

2450…2550 mbar

⇒ Page 75

3

Charge pressure, actual value

2450…2520 mbar

⇒ Page 75

4

Charge pressure actuator, activation

34…42 %

⇒ Page 75

%

Evaluation: Atmospheric pressure Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure, specified value Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 2450

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

◆ Limit active

– Check display group 105 ⇒ Page 74

Evaluation: Charge pressure, actual value Display on ScanDi tool

Possible cause of fault

Below 2450 mbar

◆ Turbocharger defective

Fault remedy

◆ Leaks between turbocharger and intake manifold (charge air routing) ◆ Air in fuel system ◆ Adjustment linkage etc. for VTG regulation sticking/tight Over 2520 mbar

◆ Turbocharger defective

– Check charge pressure control ⇒ Page 252.

– -N75- Check. ⇒ Page 253 – Bleeding fuel system

◆ Air in fuel system ◆ Adjustment linkage etc. for VTG regulation sticking/tight Evaluation: Charge pressure actuator, activation Display on ScanDi tool

Possible cause of fault

Fault remedy

Above 42%

◆ Rods of guide vane on turbocharger are difficult to move/sticking

– -N75- Check. ⇒ Page 253

◆ Air filter blocked

– Renew air filter

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

75

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.8

Display group 107 -Charge pressure control II-

Indicated on display: ►

Display group 107 rpm

Display zones

Operating condition or component

%

Bit

Specification

Evaluation

4150…4250 rpm

---

1

Engine speed

2

Charge pressure actuator activation before linearisation

42…52 %

⇒ Page 76

3

Charge pressure regulation status

0000 0000

⇒ Page 76

4

Battery voltage

13…15 V

⇒ Page 76-

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Charge pressure actuator activation before linearisation Display on ScanDi tool

Possible cause of fault

Fault remedy

Above 52%

◆ Rods of guide vane on turbocharger are difficult to move/sticking

– -N75- Check. ⇒ Page 253 – Renew air filter

◆ Air filter blocked Evaluation: Charge pressure regulation status Display on ScanDi tool

Possible cause of fault

Fault remedy

◆ 0000 0000 Charge pressure control/ regulation fault-free ◆ XXXX XXX1 Cold start regulation, off ◆ XXXX XX1X System switch-off request/system fault →

◆ XXXX X1XX Charge pressure control/ regulation, active, permanent regulating deviations occurred ◆ X1XX XXXX Control unit running in emergency mode

Evaluation: Battery voltage display Display on ScanDi tool Less than 13 V

Greater than 15 V

76

Possible cause of fault

Fault remedy

◆ Alternator defective

– Check battery

◆ Battery defective

– Check charging system

◆ Voltage regulator defective

– Check regulator

Repair Group 01 - Self-diagnosis

V

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.9

3

Display group 108 -Exhaust temperature-

Indicated on display: ►

Display group 108 rpm

Display zones

Operating condition or component

-

°C

°C

Specification

Evaluation

4150…4250 rpm

---

0,99…1,00

⇒ Page 77

1

Engine speed

2

Exhaust temperature quantity limit factor

3

Exhaust temperature from EGT bank 1

660…710 °C

⇒ Page 77

4

Exhaust temperature from EGT bank 2

670…720 °C

⇒ Page 77

Evaluation: Engine speed Display on ScanDi tool /

Possible cause of fault

Fault remedy

/

/

Evaluation: Exhaust temperature quantity limit factor Display on ScanDi tool See display group 105 value 2

Possible cause of fault

Fault remedy

◆ See display group 105 value 2

– See display group 105 value 2 ⇒ Page 74

Evaluation: Exhaust temperature from EGT bank 1 Display on ScanDi tool

Possible cause of fault

Fault remedy

Display group 108 / Defective wiring connection or bank 1 ex- – Check wiring and -G235- ⇒ Page 255 3 (-G235-) haust temperature sender -G235– Check central earth point / earth con+ 20 °C nections – When -G235- and -G236- are defective, a constant replacement value of 720 °C is used and displayed Evaluation: Exhaust temperature from EGT bank 2 Display on ScanDi tool

Possible cause of fault

Fault remedy

Display group 108 / Defective wiring connection or bank 2 ex- – Check wiring and -G236- ⇒ Page 257 4 (-G236-) haust temperature sender -G236– Check central earth point / earth con- 20 °C nections – When -G235- and -G236- are defective, a constant replacement value of 720 °C is used and displayed

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

77

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.10 Display group 109 -Fuel consumptionIndicated on display: ►

Display group 109 rpm

Display zones

Operating condition or component

mg/s

l/h

Specification

Evaluation

1

Engine speed

4150…4250 rpm

---

2

Quantity injected

60…65 mg/stroke

⇒ Page 78

3

Fuel consumption

0.5…0.7 l/h

⇒ Page 78

4

Throttle position

100%

⇒ Page 79

%

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Quantity injected Display on ScanDi tool Below 60 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100% ◆ Charge pressure is too low

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1) – Check charge pressure control ⇒ Page 252.

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Fuel consumption Display on ScanDi tool Below 72 l/h

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100%

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1) – Check charge pressure control ⇒ Page 252.

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

78

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Throttle position Display on ScanDi tool Less than 100%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

5.11 Display group 110 -Fuel rail pressure regulation lIndicated on display: ►

Display group 110 rpm

Display zones

Operating condition or component

bar

bar

Specification

Evaluation

1

Engine speed

4150…4250 rpm

---

2

High-pressure fuel pressure (specified)

1580…1620 bar

⇒ Page 79

3

High-pressure fuel pressure (actual figure)

1580…1620 bar

⇒ Page 80

4

Activation of fuel regulating valve for highpressure

58-68%

---

%

Evaluation: Engine speed Display on ScanDi tool /

Possible cause of fault

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (specified) Display on ScanDi tool Below 1580 bar

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100% ◆ Revolutions not achieved 1)

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

79

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 1580 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ High-pressure system leaking

Over 1650 bar

– Check wiring and -N276- ⇒ Page 307 – Check central earth point / earth connections

◆ Air in fuel system ◆ Fuel pressure regulating valve -N276defective

Evaluation: High-pressure fuel pressure regulating valve Display on ScanDi tool Over 68% / under 58%

Possible cause of fault

Fault remedy

◆ Defective wiring connection or fuel pressure regulating valve -N276-

– Check wiring and -N276- ⇒ Page 307

◆ Air in fuel system

– Check central earth point / earth connections

◆ Fuel system leaking

5.12 Display group 111 -Fuel rail pressure regulation IIIndicated on display: ►

Display group 111 rpm

Display zones

Operating condition or component

bar

bar

Specification

Evaluation

1

Engine speed

4150…4250 rpm

---

2

High-pressure fuel pressure (specified)

1580…1620 bar

⇒ Page 81

3

High-pressure fuel pressure (actual figure)

1580…1650 bar

⇒ Page 81

4

Activation of fuel metering valve

20-35%

⇒ Page 81

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

80

Repair Group 01 - Self-diagnosis

/

Fault remedy /

%

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: High-pressure fuel pressure (specified) Display on ScanDi tool Below 1580 bar

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high

– Check wiring and -G235- ⇒ Page 255

◆ Coolant temperature too high

– Check wiring and -G236- ⇒ Page 257

◆ Error: PWG not 100%

– Check wiring and -G62- ⇒ Page 297

◆ Revolutions not achieved 1)

– Check EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 280 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ High-pressure system leaking

Over 350 bar

– Check wiring and -N276- ⇒ Page 307 – Check central earth point / earth connections

◆ Air in fuel system ◆ Fuel pressure regulating valve -N276defective

Evaluation: Activation of fuel metering regulation valve Display on ScanDi tool

Possible cause of fault

Over 35% or under ◆ Defective wiring connection or fuel 20% pressure regulating valve -N290◆ Air in fuel system ◆ Fuel system leaking

Fault remedy – Possibly renew high-pressure pump with fuel metering valve -N290⇒ Page 286 – Check central earth point / earth connections

5.13 Display group 112 -Fuel rail pressure regulation IllIndicated on display: ►

Display group 112 rpm

Display zones

Operating condition or component

1

Engine speed

2

Fuel temperature

3

Fuel rail pressure regulation, status

4

Coolant temperature

°C

-

Specification

Evaluation

4150…4250 rpm

---

20…70 °C

⇒ Page 82

5

⇒ Page 82

>65 °C

⇒ Page 83

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

°C

81

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Fuel temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

= 40 °C

Defective wiring connection or fuel temperature sender -G81-

– Check wiring and -G81- ⇒ Page 300 – If a fault is present the measured value block indicates a constant fuel temperature of 40 °C (ambient air temperature must also be read as reference) ⇒ Conspicuous deviations signify a possible faulty sender value ⇒ 40 °C – Check central earth point / earth connections

Evaluation: Fuel rail pressure regulation, status Display on ScanDi tool

→

82

Possible cause of fault

Fault remedy

0 Control operation - Active initialisation or fault 1 Control operation - Start speed threshold exceeded 2 Regulating operation - Pressure regulation valve active, fuel rail pressure monitor off 3 Regulating operation - Measuring unit active, fuel rail pressure monitor off 4 Regulating operation - Pressure regulation valve active, normal operation, fuel rail pressure monitor active 5 Regulating operation - Measuring unit active, normal operation, fuel rail pressure monitor active 6 Regulating operation - Switch-over from fuel pressure regulating valve to measuring unit, fuel rail pressure monitor off 7 Control operation - Rapid pressure reduction in fuel rail, engine is shut-down 8 Control operation - New initial initialisation, pre-control values 9 - 14 n.v.

15 Regulating operation - CPC (pressure regulating valve and measuring unit), fuel rail pressure monitor PCV on, MeUn off 16 Regulating operation- Switch-over via pressure regulating valve after a regulating operation, fuel rail pressure monitor min/max 17 Regulating operation - Switch-over after a CPC regulating operation, fuel rail pressure monitor min/max 18 Regulating operation - Switch-over after a measuring unit regulating operation, fuel rail pressure monitor min/max

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Coolant temperature Display on ScanDi tool

Possible cause of fault

Fault remedy

Below 65 °C

◆ Coolant temperature outside range of acceptable values

– Bring engine to normal operating temperature

◆ Test requirements not fulfilled

– Check wiring and -G62- ⇒ Page 297 – Observe test conditions

= 90 °C

◆ Coolant temperature replacement value ◆ Defective wiring connection or coolant temperature sender -G62-

Above 95 °C

◆ Coolant temperature too high ◆ Coolant shell-and-tube heat exchanger dirty

– Check wiring and -G62- ⇒ Page 297 – If a fault is present the measured value block indicates a constant coolant temperature of 90 °C – Clean coolant shell-and-tube heat exchanger

5.14 Display group 113 -Quantities injected, specificationIndicated on display: ►

Display group 113 mg/s

Display zones

Operating condition or component

mg/s

mg/s

Specification

Evaluation

0 mg/stroke

---

1

Quantity injected

2

Quantity injected for primary injection, specification

1.2…1.7 mg/stroke

---

3

Pilot injection 1 quantity injected, specification

61…63 mg/stroke

⇒ Page 84

4

Pilot injection 2 quantity injected, specification

60…65 mg/stroke

⇒ Page 84

mg/s

Evaluation: Quantity injected Display on ScanDi tool Below 60 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100%

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

83

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Quantity injected for primary injection, specification Display on ScanDi tool Below 61 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high

– Check wiring and -G235- ⇒ Page 255

◆ Coolant temperature too high

– Check wiring and -G236- ⇒ Page 257

◆ Error: PWG not 100%

– Check wiring and -G62- ⇒ Page 297

◆ Charge pressure is too low 1)

– Check EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Pilot injection 1 quantity injected, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Pilot injection 2 quantity injected, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

5.15 Display group 114 -Activation period of pilot injection 1Indicated on display: ►

Display group 114 mg/s

Display zones

84

Operating condition or component

mg/s

ms

Specification

Evaluation

1

Quantity injected (specified)

58…67 mg/stroke

⇒ Page 85

2

Quantity injected (actual)

60…65 mg/stroke

⇒ Page 85

3

Pilot injection 1 activation period (actual)

1.35…1.55 ms

---

4

High-pressure fuel pressure (actual figure)

1580…1650 bar

⇒ Page 85

Repair Group 01 - Self-diagnosis

bar

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: Quantity injected (specified) Display on ScanDi tool Below 58 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100% ◆ Charge pressure is too low

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1) – Check charge pressure control ⇒ Page 252.

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Quantity injected (actual) Display on ScanDi tool Below 60 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100% ◆ Charge pressure is too low

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1) – Check charge pressure control ⇒ Page 252.

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Pilot injection 1 activation period (actual value) Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 1580 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ High-pressure system leaking

Over 1650 bar

– Check wiring and -N276- ⇒ Page 307 – Check central earth point / earth connections

◆ Air in fuel system ◆ Fuel pressure regulating valve -N276defective

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

85

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

5.16 Display group 115 -Activation period of pilot injection 2Indicated on display: ►

Display group 115 mg/s

Display zones

Operating condition or component

mg/s

ms

Specification

Evaluation

1

Quantity injected (specified)

58…67 mg/stroke

⇒ Page 86

2

Quantity injected (actual)

60…65 mg/stroke

⇒ Page 86

3

Pilot injection 1 activation period (actual)

0 ms

---

4

High-pressure fuel pressure (actual figure)

1580…1650 bar

⇒ Page 87

bar

Evaluation: Quantity injected (specified) Display on ScanDi tool Below 58 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100% ◆ Charge pressure is too low

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1) – Check charge pressure control ⇒ Page 252.

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Quantity injected (actual) Display on ScanDi tool Below 60 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100%

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1)

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Pilot injection 1 activation period (actual value) Display on ScanDi tool

Possible cause of fault

/

86

Repair Group 01 - Self-diagnosis

/

Fault remedy /

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

Evaluation: High-pressure fuel pressure (actual figure) Display on ScanDi tool Below 1580 bar

Possible cause of fault

Fault remedy

◆ Air in fuel system ◆ Fuel or circulation filter blocked ◆ Fuel pressure regulating valve -N276defective ◆ High-pressure system leaking

Over 1650 bar

– Check wiring and -N276- ⇒ Page 307 – Check central earth point / earth connections

◆ Air in fuel system ◆ Fuel pressure regulating valve -N276defective

5.17 Display group 116 -Injection coordinatorIndicated on display: ►

Display group 116 mg/s

Display zones

Operating condition or component

1

Quantity injected

2

Permitted number of injections

3

Switch-off request, injectors

4

Number of fault entries

-

Bit

Specification

Evaluation

60…65 mg/stroke

⇒ Page 87

2

---

0000 0000

⇒ Page 88

0000 0000…1111 1111

⇒ Page 88

Bit

Evaluation: Quantity injected Display on ScanDi tool Below 60 mg/H

Possible cause of fault

Fault remedy

◆ Oil temperature too high

– Check wiring and oil temperature sender -G8- ⇒ Page 299

◆ Exhaust temperature too high ◆ Coolant temperature too high ◆ Error: PWG not 100%

– Check wiring and -G235- ⇒ Page 255 – Check wiring and -G236- ⇒ Page 257 – Check wiring and -G62- ⇒ Page 297 – Check EMMA1)

1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

Evaluation: Permitted number of injections Display on ScanDi tool /

Possible cause of fault /

Fault remedy /

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

87

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Evaluation: Switch-off request, injectors Display on ScanDi tool >0

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

Evaluation: Number of fault entries Display on ScanDi tool >0

Possible cause of fault

Fault remedy

◆ Fault detected by engine control unit

– Read fault memory ⇒ Page 9

5.18 Display group 117 -idling speedIndicated on display: ►

Display group 117 rpm

Display zones

Operating condition or component

rpm

Bit

Specification

Evaluation

4150…4250 rpm

---

640…660 rpm

---

1

Engine speed

2

Idling speed, specification

3

Gear information

0000 0000

⇒ Page 88

4

Throttle position

100 %

⇒ Page 88

%

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Idling speed, specification Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Gear information Display on ScanDi tool

Possible cause of fault

→

0000 0000 gear 0 active 0000 0001 gear 1 active

Fault remedy /

Evaluation: Throttle position Display on ScanDi tool Less than 100%

1)

Possible cause of fault

Fault remedy

◆ EMMA has faults

– Check EMMA1)

◆ Fault in wiring harness

– Check wiring harness1)

◆ Fault in throttle lever

– Throttle lever diagnosis EMMA1)

G79 and G185 are not physically present and are emulated by the Electronic Marine Engine Adaption „EMMA“. The signals created are passed directly to both engine control units (master and slave) to control the engine.

88

Repair Group 01 - Self-diagnosis

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

5.19 Display group 118 - Rotational speed registrationIndicated on display: ►

Display group 118 rpm

Display zones

Operating condition or component

rpm

rpm

Specification

Evaluation

1

Engine speed

4150…4250 rpm

---

2

Crankshaft speed

4150…4250 rpm

---

3

Camshaft speed

2075…2125 rpm

---

4

Starting synchronization

48

⇒ Page 89

-

Evaluation: Engine speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Crankshaft speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Camshaft speed Display on ScanDi tool

Possible cause of fault

/

Fault remedy

/

/

Evaluation: Starting synchronization Display on ScanDi tool

→

Possible cause of fault

Fault remedy

0 Basic initialisation of automatic synchronization 2 No synchronization, all crankshaft/camshaft sender systems are inactive/defective 3 No synchronization, Engine speed too low or crankshaft sender system implausible 8 No synchronization, crankshaft sender system implausible 32 Crankshaft gap detection successful, system waiting for final position from camshaft signal 33 Synchronization available, is still being tested 34 No synchronization, Position not finalised, restart of automatic synchronization, too many resynchronization cycles (terminal 15: OFF/ON) 35 Synchronization available, rotational angle between crankshaft and camshaft too high 38 No valid camshaft signal, synchronization performed via evaluation of acceleration of engine revolutions 48 Synchronization completed, crankshaft and camshaft are synchronized

5 Evaluating measured value blocks at full throttle (sea test with warm engine, coolant temperature not below 73 °C)

89

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

10 - Removing and installing engine 1

Removing and installing engine

Special tools and workshop equipment required ◆ Engine and gearbox support -VAS 6095- with universal mounting -VAS 6095/1- and bracket for V6 TDI engine -VAS 6095/1-3◆ Workshop hoist -V.A.S 6100◆ Torque wrench (5…50 Nm) -V.A.G 1331◆ Torque wrench (40…200 Nm) -V.A.G 1332◆ Spring-type clip pliers -VAS 5024◆ Hose clamps -3093- or hose clamps -3094-

◆ Wiring harness key, large -T01906◆ Cable ties

1.1

Removing engine WARNING

When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: ◆ Install all lines (e.g. for fuel, coolant, vacuum) as well as electric cables in such a way that the original routing is restored. ◆ Ensure that there is sufficient clearance to all moving or hot components.

Note Before carrying out further work, disconnect battery earth strap.

– With the ignition switched off, disconnect battery earth strap.

90

Repair Group 10 - Removing and installing engine

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

– All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.

Note ◆ Before carrying out repair work, we recommend that the engine be secured on the engine and gearbox support -VAS 6095- using universal mounting -VAS 6095/1- and brackets -6095/1-3- ⇒ Page 93. ◆ The subsequently described procedure for the removal and installation of the engine may deviate slightly, depending on the equipment of the boat. ◆ The engine oil must pumped out first before starting repairs on the engine ⇒ Page 202. ◆ The engine can be removed out upwards, with or without the gearbox, depending on the equipment of the boat.

◆ Use an appropiate engine crane when removing or installing the engine.

The figure on the right shows an example for the removal of the engine using an engine crane.

– Disconnect battery earth cable at engine earth connection -1 - next to flywheel cover.

1 Removing and installing engine

91

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

– Disconnect positive cable from battery main wiring harness battery -2- on starter motor -1-.

– Turn union nut -A- on multipin connection, below the central electrics, in -direction of arrow- using wiring harness key -T01905- and pull connector off forwards.

– Move wiring harness to side.

Note ◆ Before removing fuel supply line, clamp with hose clamp -VAS 3094-. ◆ Observe environmental regulations for disposal.

WARNING Before loosening fuel line connections, wrap a cloth around the connection.

Then carefully pull off line and collect leaking fuel.

– Disconnect fuel supply line -1- on fuel filter -2-.

– Seal line so that fuel system is not contaminated by dirt.

– Disconnect fuel return line -1- at union -2- on high-pressure accumulator (fuel rail) for cylinder bank 1.

– Seal union with a plug so that no dirt can enter the highpressure accumulator (fuel rail) for cylinder bank 1.

– Observe rules for cleanliness ⇒ Page 4.

– Close seawater shut-off valve (sea cock).

92

Repair Group 10 - Removing and installing engine

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

3

– Open drain plug -2- on heat exchanger approx. one turn and drain seawater.

Note ◆ Do not completely remove the drain plug! ◆ If possible, slide a suitable hose over the drain plug union and collect the seawater in a container.

– Loosen clamp -1- and pull coolant hose -2- off seawater pump -3-.

– Collect escaping seawater.

Engine with connection for external heater – On boats with an external warm water heater, mark both connecting lines and disconnect from engine.

Continuation – Open and close expansion tank cap to release pressure in cooling system.

– Remove exhaust hoses from exhaust pipe unions.

– Unscrew assembly mountings/engine mountings from boat hull.

– Unscrew nuts -arrow- on assembly mountings/engine mountings for this.

– Pull off or disconnect all other necessary connection/unions on engine.

– Carefully lift engine out of boat using an appropiate crane.

1.2

Securing engine on engine and gearbox support

Before carrying out repair work, secure engine on assembly stand with engine and gearbox support -VAS 6095/1- using universal mounting -VAS 6095/1-3- and bracket for V6 TDI engine -VAS 6095-.

1 Removing and installing engine

93

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

Procedure – Secure engine to a workshop crane and lift engine slightly.

– Before removal of gearbox, disconnect hydraulic hoses and seal unions against ingress of dirt.

Note Before installing engine on engine and gearbox support -VAS 6095-, remove all additional components on engine.

– Now disconnect gearbox.

– Remove exhaust manifold, with attachments, on both sides of engine.

– Bolt bracket -VAS 6095/1-3- to cylinder block.

– Attach engine to universal mounting -VAS 6095/1-3- with bracket -VAS 6095/1- as shown.

1.3

Installing engine Note

◆ The tightening torques listed on this page apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts. ◆ Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant. ◆ Do not use de-greased parts. ◆ Tolerance for specified torques is ± 15%. ◆ Torque settings for assembly mountings ⇒ Page 96. ◆ Renew all bolts tightened with specified tightening angle. ◆ To secure torque converter on drive plate, use only new bolts of the correct type (same as original equipment) as specified in ⇒ Parts catalogue. ◆ Renew self-locking nuts and bolts when performing assembly work. ◆ Renew bolts which are tightened to a specified angle as well as oil seals and gaskets. ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly. ◆ Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Parts catalogue. ◆ Fit all cable ties in the original position when installing.

Install in reverse order.

94

Repair Group 10 - Removing and installing engine

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

1.4

3

Securing gearbox bell housing to engine (reverse gear gearbox)

– Secure gearbox bell housing to engine.

1 - Gearbox bell housing 2 - Hexagon head collar bolt M12x70 (qty 2) 40 Nm ± 10% Note Bolts are screwed into the intermediate housing from the back.

1 - Gearbox bell housing 3 - Multi-point socket head bolt M12x60 (qty 4) 60 Nm ± 10% Note Bolts are screwed into the intermediate housing from the front.

1 Removing and installing engine

95

3

Marine Boat Engine 2011 ▶ 8-cylinder diesel engine (4.2 l engine, common rail) 05.2011

1.5

Assembly mountings

1.5.1 Assembly overview - assembly mountings 1 - M10 hexagon collared nut q 105 ± 5 Nm 2 - Washer 3 - Nut for adjustment of height 4 - Assembly mounting with base plate q To secure base plate to boat hull: use bolts with a Ø of min. 10 mm and suitable washers.

5 - Left engine mounting 6 - Right engine mounting 7 - M8 x12 hexagon head collar bolt 8 - Gearbox support 9 - Gearbox 10 - Gearbox support

96

Repair Group 10 - Removing and installing engine

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