Fiat Ducato 2006 User Manual

Fiat Auto S.p.A.

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SECOND PHASE

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DOCUMENTATION MODIFICATIONS / UPDATES

Date Referent File Name Description of modification

All rights reserved. No part of this publication may be reproduced or disclosed in any form or by any means. Processing the material below may not involve specific responsibilities for unintentional errors or omissions. The information given in this publication is continuously updated; Fiat Auto S.p.A. disclaims all responsibilities for any errors, omissions, damage or loss that might result from the use of outdated information. This publication is issued for training purposes only. Exhaustive, updated technical information for servicing purposes can be found in the service manual and any other service information for the vehicle model concerned.

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CONTENTS

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INDICE................................................................................................................................................................... 2

1. BRIEFING ........................................................................................................................................................ 2

2. DATI TECNICI................................................................................................................................................... 2

2.1 MOTORE......................................................................................................................................................... 2

2.1.1 Dati caratteristici ....................................................................................................................................... 2

2.2 FRIZIONE........................................................................................................................................................ 2

2.3 CAMBIO DI VELOCITA’................................................................................................................................. 2

2.4 DIFFERENZIALE............................................................................................................................................ 2

2.5 PIANO DI MANUTENZIONE PROGRAMMATA........................................................................................... 2

3. MOTORE.......................................................................................................................................................... 2

3.1 MOTORE 3.0................................................................................................................................................... 2

3.1.1 Caratteristiche ........................................................................................................................................... 2

3.1.2 Supporti motore.......................................................................................................................................... 2

3.1.3 Basamento e sottobasamento.................................................................................................................. 2

3.1.4 Testa cilindri ............................................................................................................................................... 2

3.1.5 Alberi della distribuzione.......................................................................................................................... 2

3.1.6 Albero motore........................................................................................................................................... 2

3.1.7 Volano......................................................................................................................................................... 2

3.1.8 Pistoni e bielle .......................................................................................................................................... 2

3.1.9 Comando della distribuzione................................................................................................................... 2

3.1.10 Impianto alimentazione aria................................................................................................................... 2

3.1.11 Impianto alimentazione combustibile .................................................................................................. 2

3.1.12 Impianto di scarico.................................................................................................................................. 2

3.1.13 Impianto EGR.......................................................................................................................................... 2

3.1.14 Impianto recupero vapori olio dal basamento .................................................................................... 2

3.1.15 Impianto lubrificazione motore.............................................................................................................. 2

3.1.16 Circuito raffreddamento motore.......................................................................................................... 2

3.2 GESTIONE ELETTRONICA MOTORE ......................................................................................................... 2

3.2.1 Controllo motore EDC 16 C 39................................................................................................................. 2

3.2.2 Pin out centralina controllo motore...................................................................................................... 2

3.2.3 Schema elettrico gestione motore.......................................................................................................... 2

3.2.4 Componenti dell’impianto di iniezione/accensione.............................................................................. 2

3.3 DIAGNOSI...................................................................................................................................................... 2

3.3.1 Sezione parametri...................................................................................................................................... 2

3.3..2 Sezione Errori........................................................................................................................................... 2

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3.3.3 Diagnosi attive visualizzabili con l’examiner......................................................................................... 2

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3.3.4 Configurazioni visualizzabili con examiner.............................................................................................2

3.4 PROCEDURE.................................................................................................................................................2

3.4.1 Motore staccato- stacco testa/e cilindri e coppa olio per ispezione comprende posa su cavalletto e

rimozione............................................................................................................................................................2

3.4.2 Motore - Ricomposizione. Lavaggio e controllo parti smontate - Riattacco testa cilindri e coppa

olio - Non comprende interventi su testa cilindri e gruppo organi ausiliari................................................2

3.4.3 Attrezzi per la revisione motore.............................................................................................................. 2

4 TRASMISSIONE .............................................................................................................................................2

4.1 - CAMBIO DI VELOCITA E DIFFERENZIALE TIPO C 546 ( M40 )............................................................2

4.1.1 Caratteristiche costruttive.......................................................................................................................2

4.2 -PROCEDURE.................................................................................................................................................2

4.2.1 CAMBIO MECCANICO (6 VELOCITA') CON DIFFERENZIALE - SCOMPOSIZIONE E RICOMPOSIZIONE - LAVAGGIO, VERIFICA PARTICOLARI - EV. SOST. SINCRONIZZATORI, COMANDI

INTERNI, RUOTISMI, ALBERI E CUSCINETTI................................................................................................. 2

4.2.2 Attrezzi per la revisione del cambio ........................................................................................................2

5. SOSPENSIONI pneumatiche autolivellanti posteriori..................................................................................2

6. CRONOTACHIGRAFO DIGITALE .................................................................................................................2

6.1. Diagnosi con Examiner................................................................................................................................ 2

7. TELECAMERA POSTERIORE........................................................................................................................2

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1. BRIEFING

After the sales launch in June 2006, the new Fiat Ducato range is complemented by new features for improved versatility and efficiency. The range of engine versions is complemented by the 157 bhp 3.0 Multijet engine combined with the new M40 gearbox.

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The new self-levelling rear air suspension offers great comfort and consistent chassis attitude under all loading conditions (vehicle laden or unladen, load distributed evenly or unevenly). In addition, the rear loading sill can be lowered to facilitate loading and unloading and the rear end can be raised to improve ramp breakover angle and/or increase ground clearance when driving over an obstacle.

The new rear-view parking camera system with in-cab display provides better rear visibility when manoeuvring.

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Lastly, the new Ducato can be equipped with a digital tachograph to monitor vehicle usage, a convenient feature for companies that operate large fleets of vehicles

2. TECHNICAL DATA

2.1 ENGINE

2.1.1 Characteristic data

Type code

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SofimF1CE048ID

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Cycle

Number and arrangement of cylinders

Piston diameter and stroke (mm) Total displacement

(cm3)

Compression ratio

Maximum power output EEC(kW)

Maximum power output

EEC(bhp)

At

(rpm)

Maximum torque (EEC) (Nm)

At

(rpm)

Diesel

4 in-line

95.8x104

2999

19:1

117

157

3500

400

1600

Fuel

Fuel system

Diesel fuel (ENS 590 Specification)

Multijet” Common Rail” direct injection

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2.2 CLUTCH

Type Dry single-plate, pressure plate with automatic play take-

Drive

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up device

Push-type

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Outer diameter of driven plate (mm)

Inner diameter of driven plate (mm)

2.3 GEARBOX

Type

Gear ratios

(*) Different versions

2.4 DIFFERENTIAL

Axle ratio

258±1

160±5

C546 (M40)

I

II

III

IV

V

VI

RM

3.950 - 4.222 - 4.563 (*)

4.167

2.350

1.462

1.047

0.955(*)

0.786

0.659(*)

0.652

0.552(*)

4.083

(*) Different versions

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2.5 SCHEDULED MAINTENANCE PLAN

Description

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Check tyre condition / check for wear, adjust tyre pressure (if needed).

Check operation of lighting system (headlamps, indicators, emergency lights, luggage compartment/passenger & driver compartment lights; instrument panel warning lights, etc.). Check operation of windscreen wiper & washer; adjust nozzles if necessary.

Check positioning/wear of windscreen wipers

Check brake pads for wear; check front and rear disk pad wear indicator for proper operation (if fitted) Visually inspect the conditions and soundness of body outside, underbody protection, rigid and flexible pipe lengths (exhaust, fuel feed and brake pipes and hoses), rubber parts (boots, sleeves, bushes, etc.) Visually inspect the accessory drive belts

45 90 135 180 225

+ + + + +

+ +

Check the fluid levels (engine cooling, brakes, windscreen washer, battery, etc.) and top up, if necessary Check the handbrake lever travel and adjust as required

Check that the locks are clean and the levers clean/lubricated

Measure exhaust emissions/smoke

Check operation of engine control systems (via the diagnostic connector)

Replace the accessory drive belt

Change fuel filter

Change air filter cartridge

+ + + + +

+

+ + + + +

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Change engine oil and engine oil filter

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+ + + + +

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Change brake fluid (or every 24 months)

Change pollen filter (or every 24 months)

Service must be performed every 30000 km if the vehicle is chiefly used in any of the following particularly harsh conditions:

 Towing trailer or caravan;  Dusty roads;  Frequent short trips (less than 7-8 km) with outside temperatures below freezing;  Engine frequently left idling or running long distances at low speed (door-to-door delivery for example),

or if not used for a long time;

 City traffic.

+ +

+ + + + +

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3. ENGINE

3.1 3.0 ENGINE

3.1.1 Features

The main features of the 3.0 Multijet engine are as follows:

130

120

110

100

90

80

70

60

Power [kW]

50

40

30

20

10

0

1000 1500 2000 2500 3000 3500 4000 4500

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F1C 107 kW [145 HP] - 400 Nm

WG

[rpm]

650

600

550

500

450

400

350

300

250

200

150

100

50

0

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- turbocharged Diesel engine with fixed geometry turbocharger;

- Euro 4 emissions compliant

- power output: 160 bhp;

- four cylinders in line;

- 2998 cc displacement;

- bore: 95.8 mm;

- stroke: 104 mm;

- compression ratio: 19:1

- firing order: 1 – 3 – 4 - 2

- double overhead camshaft, 16 valves;

- aluminium alloy cylinder head;

- camshaft bearing housings incorporated in

Torque [Nm]

upper head section;

- chain-driven timing system;

- rocker arms with hydraulic tappets;

- centrifugal water pump incorporated in crankcase;

- engine control unit: Bosch EDC16C39;

- high-pressure pump: Bosch CP3.2 (no transfer gear pump);

- nodular cast iron engine block;

- pressed sheet metal oil sump.

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3.1.2 Engine mounts

GENERAL

The engine mounts connect engine and body. They are designed to withstand engine weight and torque loads. Engine mounts feature blocks made of metal and rubber that dampen engine vibration so as to significantly reduce the amount of vibration transmitted to the body.

TYPE

The engine support system is a special baricentre system. The engine is retained by two mounts (one on gearbox side and one on timing gear side) and a torque

linkage

.

3.1.3 Crankcase and lower block

The crankcase is made of cast iron. There are five main bearing housings. Suitable coolant and oil galleries are provided in the crankcase walls. Spray jets installed in crankcase bottom use engine oil to cool the pistons and lubricate the piston pins. Crankcase and lower block are sealed with sealant.

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1 – Flexible mount, gearbox side 2 – Mounting bracket, gearbox side 3 – Rear mounting bracket 4 – Flexible mount, timing gear side 5 – Mounting bracket, timing gear side

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1 - Crankcase

2 – Lower block 3 – Centring pin 4 – Piston cooling jet 5 – Jet connector

3.1.4 Cylinder head

The one-piece cylinder head is made from aluminium-silicon alloy.

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Valve opening is controlled by two chain-driven hollow-section overhead camshafts; cams are fitted onto the shafts; camshafts are installed in the upper head section. The four valves per cylinder are located in their respective guides and operated by rocker arms actuated by the cams of the camshafts; hydraulic tappets keep the rocker arms in contact with the valves.

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The valve guides are an interference fit in the seats in the cylinder head. The inner bore is bored to specification after installation using a special boring tool. Unlike cylinder heads with a prechamber, the whole combustion process occurs inside the combustion chamber in the piston.

The cylinder head is made up of the following components:

- camshaft housing,

- hydraulic tappets, 1 – Upper head section

- rocker arms, 2 – Gasket

- camshafts, 3 – Cylinder head

- exhaust and intake valves, 4 – Centring bushes

- valve guides,

- valve seats.

1 – Cylinder head

2 – Gasket 3 – Centring bush 4 – Engine block

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The head accommodates: intake ports; exhaust ports; valve passages; coolant galleries; oil galleries; injector holes, glow plug holes, bolt holes for fastening to the engine block.

The head is installed on top of the cylinders; the aluminium alloy construction combines such advantages as ligthweight, compression strength and high heat conduction. Two centring bushes ensure correct location of the upper head section.

Head gasket

The gasket between cylinder head and crankcase is composed of three layers of stainless steel coated with special heat-resistant rubber material. While head gaskets of three different thicknesses are used at the factory, replacement gaskets come in one standard thickness only. Factory gaskets are differentiated by notches as follows

- 1 notch : thickness class 1

- 2 notches: thickness class 2

- 3 notches: thickness class 3

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1 – Head gasket 2 – Thickness class notches

3.1.5 Camshafts

The timing sensor detects the position of the intake camshaft drive gear to determine the current phase of engine operation. The timing sensor is located on the engine oil filler cover on the upper head section.

The camshafts are made from steel and feature a hollow design

1 – Exhaust camshaft 2 – Intake camshaft

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Hydraulic tappets

1

. Tappet retaining spring

2. Hydraulic tappet

3. Rocker arm with spring

4. Cam

3.1.6 Crankshaft

The crankshaft is made of carbon steel and rests on five main bearing housings with plain bearings in-between. Crankshaft end float is determined by the half bearing housed at the central main bearing housing. Eight counterweights set at 180° balance the rotating masses to provide perfect engine balance.

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1 – Crankshaft 2 – Central main bearing (incorporates end float adjustment) 3 – Main bearings 4 – Oilway hole

5. Phonic wheel

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3.1.7 Flywheel

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The dual-mass flywheel is secured to the crankshaft by 8 screws. The flywheel has 3 centring pins for the clutch mechanism

The flywheel is an energy storage device that stores energy during the power stroke and gives up energy during the combustion stroke to smooth out engine rotation.

Flywheel size is designed to enable engine idling and overcome friction developed during idling.The DVA dual-mass flywheel (or clutch flywheel) consists of two separate masses for crankshaft and gearbox main shaft with a torsional damping system in-between. Resonance points, normally found in the 800 to 2200 rpm range with conventional flywheels, occur at lower rpms, namely outside the operating range. This flywheel design offers the following advantages over conventional flywheels:

- pulsing engine power is dampened resulting in less transmission noise;

- less overall noise translates into less in-cab noise. The clutch disk (with springs) located between the dual-mass flywheel and the gearbox has lower inertia to enable smoother gearshifts.

3.1.8 Pistons and connecting rods

CONSTRUCTION

The pistons are obtained from aluminium alloy castings; the connecting rods are forged from hardened and tempered steel and split to obtain the con rod caps by the fracture splitting method. The pistons have a recess for the combustion chamber. The pistons and con rod small ends are joined by floating piston pins. Piston pins are restrained by two circlips fitted in grooves in the piston pin sleeves.

1 – Mass integral with crankshaft. 2 – Mass integral with gearbox main shaft.

3 – Centring pin for clutch mechanism 4 – Hub 5 – Ball bearing 6 – Gearwheel

7 – Torsional damping system.

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To ensure correct piston position, the mark on the piston must be pointing to the timing gear side

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1 – Piston 2 – Piston pin 3 – Circlips 4 – Connecting rod 5 – Con rod bearings 6 – Piston mark for correct installation

1 – Connecting rod 2 – Con rod cap

The aluminium alloy pistons are grouped into two size classes and have a mark on the crown to indicate correct mounting

position

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1 – Engine type 2 – Piston class 3 – Supplier 4 – Mounting position of piston inside the cylinder barrel

The piston is made up of two main components:- head, or area where the piston rings sit; its diameter is slightly smaller than the cylinder bore to accommodate heat expansion; the piston crown features the valve pockets and recessed combustion chambers,

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- the skirt, which acts as a guide for the con rod small end which withstands its axial thrust. The skirt accommodates two sleeves for the piston pin and a groove matching the piston cooling jet in the crankcase.

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Piston (1) and connecting rod (2) with con rod cap must be assembled with piston mark, connecting rod and con rod positioned as shown in the figure.

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3.1.9 Camshaft drive

The timing system is a double overhead camshaft system with four valves per cylinder and hydraulic tappets. Drive is transmitted by two drive chains:

- a double 3/8” chain transmits drive from the crankshaft to the oil pump/vacuum pump and high pressure pump shafts;

- a single chain transmits drive from the high pressure pump shaft to the camshafts. The camshaft drive gears are interchangeable and feature slots for the sensor.

Each rocker arm is kept in contact with its valve by a cam and hydraulic tappet to eliminate the need for periodic adjustments

.

1 – Rocker arm 2 – Hydraulic tappet 3 – Valve 4 – Exhaust camshaft 5 – Intake camshaft 6 – Cam chain

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The figure below shows how timing system and auxiliary drive system are operated

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1 – Camshaft drive gears 2 – Single chain 3 – Hydraulic tensioner with backstop 4 – Chain tensioner mobile sliding shoes 5 – Hydraulic chain tensioner 6 – Drive gear on crankshaft 7 – Fixed sliding shoe 8 – Oil pump/vacuum pump and power steering pump drive shaft gear 9 – Double chain 10 – High pressure pump drive shaft gear

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Chain hydraulic tensioner

Timing chain tension is controlled by an automatic hydraulic tensioner with backstop that eliminates the need for tension adjustments.

A = Fully extended: 76.9 ± 0.4 mm B = With piston engaged: 53.6 mm C = Minimum travel to disengage piston:

2.3 mm D = Useful stroke: 24.5 mm

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3.1.10 Air supply system

The intake air is filtered and conveyed to the exhaust gas turbocharger; before reaching the engine, the compressed air is cooled in the air-air heat exchanger (Intercooler).

The following figure schematically illustrates the main elements comprising the air supply circuit.

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1 – Air filter 2 – Oil vapour recovery fitting 3 – Turbocharger 4 – Intake manifold 5 – Throttle body actuator 6 – Air intake connector 7 – Resonator 8 – Intercooler heat exchanger 9 – Exhaust manifold

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Turbocharger

The turbocharger is of the fixed geometry type with waste-gate valve

1 – Compressor 2 – Turbine 3 – Air-operated exhaust gas bypass actuator 4 – Pressure pipe to control WASTE – GATE valve A – Air enters compressor B – Air exits compressor

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3.1.11 Fuel system

GENERAL

The fuel feed system is divided into a low pressure circuit and a high pressure circuit.

The low pressure circuit is composed of:

- tank

- submerged auxiliary motor pump;

- Diesel fuel filter;

- return manifold.

The high pressure circuit is composed of:

- pressure pump;

- distribution manifold.

Low pressure circuit

Fuel tank

The plastic fuel tank features a flexible filler neck and incorporates a seat for electric fuel pump and fuel level meter.

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A – 90-litre tank B – 125-litre tank 1 – Fuel tank 2 – Fuel filler neck 3 – Breather pipe

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Submerged pump assembly complete with level indicator control system

- electric fuel pump

- float level indicator

- diaphragm pressure regulator

- screen prefilter

Main components:

- fuel filter

Pump characteristic data:

- safety valve setting: 600 - 800 KPa,

- pump nominal delivery: 134 l/h (23°C),

- power supply: 12.5V.

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A – Float level sensor B – Delivery fitting B – Return fitting D – Electric connector

1 – Fuel level sensor power supply 2 – Fuel level sensor ground 3 – Fuel pump ground 4 – Fuel pump power supply

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Fuel filter

The fuel filter is fitted in the engine compartment near the fireproof bulkhead. The filter is made of a plastic shell that contains a depth partition cartridge made of synthetic material, which ensures high efficiency, long service life and effective water separation.

1 – Fuel inlet 2 – Fuel outlet 3 – Eectric connector for water presence sensor 4 – Water drain screw 5 – Filter body 6 – Fuel temperature sensor connector 7 – Filter cartridge (sealing O-ring supplied) 8 – Cover gasket

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9 – Cover fixing ring nut 10 – Cover 11 – Spacer 12 – Rubber seal 13 – Ferromagnetic ring 14 – Gasket 15 – Float 16 – Water sensor

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OPERATION

Diesel fuel is drawn from the tank by a 12 V electric pre-feed pump that provides adequate delivery to lubricate and cool the Radialjet pump as well. The Diesel fuel filter is installed between the electric pump and the Radialjet pump. High-pressure hydraulic lines are steel pipes with 2 mm inner diameter and 6 mm outer diameter. The fuel recirculated from pump and injectors is collected in a single pipe and delivered to the tank.

1 – Fuel tank 2 – Submerged pump assembly 3 – Pipe connecting tank with fuel filter 4 – Fuel filter 5 – Pipe connecting fuel filter with fuel pressure control valve 6 – Fuel pipe fitting 7 – Pipe connecting fuel pressure control valve with high pressure pump

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High pressure circuit

1 – Pressure pump

2 – Pressure regulator

3 – Fuel pipe fitting

4 – Pipe connecting high pressure pump with fuel manifold (Rail)

5 – Fuel pressure sensor

6 – Pipe connecting fuel manifold (Rail) with electro-injectors

7 – Fuel manifold (Rail)

8 – Return pipe from electro-injectors

9 – Plug

10 – Electro-injector

11 – Fuel pipe from filter

12 – Return to tank

High pressure pump

GENERAL’

The CP3.2 fuel pump of the Common Rail system is called Radialjet pump because pumping action is accomplished by three pumping elements (pistons) arranged radially in relation to the axis of rotation of the pump shaft. The three pistons are spaced 120° apart. The quantity of fuel sent to the pumping pistons is controlled by a pressure regulator governed by the engine control unit

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RADIALJET PUMP CHARACTERISTICS

Pump pistons are operated by a rotating triangular cam integral with pump shaft. The rotating cam moves a mechanical element (tappet) linking it to piston foot. Cam to tappet contact is ensured by a spring. Each pumping unit has an intake valve and delivery ball valve. Fuel from the three delivery valves is collected in a single point inside the pump and conveyed to a common manifold through a single duct. A peculiar feature of this pump is that it is lubricated and cooled by the fuel circulating inside it or through suitable ports. Delivery pressure is controlled by a low-pressure solenoid valve installed at the pump inlet end so as to compress just the amount of fuel needed to achieve required pressure according to ECU mapping. The main features of the Radialjet pump are outlined below:

- type: Radialjet radial piston pump

- number of pistons: 3

- maximum operating pressure: 1600 bar

- feeding: Diesel fuel at 3.5 ÷ 5.0 bar

- lubrication: by Diesel fuel fed to pump

- cooling: by Diesel fuel fed to pump

Note: The high pressure pump cannot be serviced; do not remove or disturb the retaining screws.

OPERATION

The pump is driven by the crankshaft via a double chain and turns at the same speed as the engine. In this injection system, valve timing and injection duration are controlled by the electroni c control system

and the pump simply maintains the fuel in the manifold at the required pressure. The figure below shows the layout of pump hydraulic feeding system.

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(Relative) pressures in the circuit:

(a) 4.15 bar < p < 5.35 bar ; (b) 3.5 bar < p < 5.0 bar ; (c) p < 0.8 bar (d) 0.3 bar < p < 0.8 bar

1 – High pressure pump 2 – High pressure delivery pipe 3 – Return pipe from electro-injectors 4 – Electro-injectors 5 – Common Rail 6 – Fuel pressure sensor 7 – Filter with water separator 8 – Electric fuel pump check valve

Fuel regulator

The fuel pressure regulator is installed in the low-pressure circuit of the CP3.2 pump. The pressure regulator meters the amount of fuel delivered to the high-pressure circuit according to the commands it receives directly from the engine control unit The main components of the pressure regulator are listed below:

- connector,

- body,

- solenoid,

- preload spring,

- shutter cylinder.

The pressure regulator is normally open unless it is receiving any input signals; in this condition, the pump will be delivering its maximum flow rate. The engine control unit varies fuel delivery in the high-pressure circuit by partially closing or opening the fuel pipe sections in the low pressure circuit via a PWM (Pulse Width Modulation) signal

1 – Connector 2 – Fuel outlet holes 3 – Fuel inlet hole

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9 – Line pressure relief valve 10 – Tank 11 – Electric fuel pump

12 – Filter at electric fuel pump intake end

13 – Electric fuel pump overpressure valve

14 – Pressure relief valve 15 – Proportional pressure regulating valve.

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OPERATION

When the engine control unit governs the flow regulator (via PWM signal), the solenoid (1) is energised and displaces the magnetic core (2). The core causes the shutter cylinder (3) to move in an axial direction and fuel flow is restricted.

1 – Solenoid 2 – Magnetic core 3 – Shutter cylinder 4 – Fuel inlet 5 – Fuel outlet

When the solenoid (1) is de-energized, the magnetic core is pushed into its rest position by the preload spring (3). In this condition, the shutter cylinder (4) is in the position that provides a fully unrestricted fuel flow.

1 – Solenoid 2 – Magnetic core 3 – Preload spring 4 – Shutter cylinder

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Inertia switch

The inertia switch is located under the dashboard on passenger side. In the event of a collision, it cuts off the fuel pump ground connection to shut off fuel delivery to the injection system.

It contains a ferromagnetic ball held in place in its tapered seat by a permanent magnet. When vehicle deceleration exceeds a certain threshold due to a collision, the ball breaks free from its seat and hits a switch, so that fuel pump relay ground is switched to the body computer. This cuts off pump supply, releases the door locks and turns on the interior lighting. The switch features a flexible cover to enable resetting.

NOTE: If you notice a burning smell or any leaks after an impact (including a minor collision), do no reset the switch until you have located and repaired the trouble, or a fire may result. If there are no leaks and the vehicle is capable of restarting, press the button to activate the fuel pump.

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3.1.12 Exhaust system

The engine exhaust gases flow through the manifold to the three-way catalytic converter

1 – Pre-catalyst bracket 2 – Clamp 3 – Gasket 4 – Pre-catalyst 5 – Pre-catalyst bracket 6 – Gasket

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7 – Exhaust pipe middle section 8 – Catalyst 9 – Catalyst bracket (on body) 10 – Flexible mounts 11 – Silencer bracket (on body) 12 – Silencer

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3.1.13 EGR system

GENERAL

This system recirculates part of the exhaust gases to the intake under certain particular operating conditions. This lowers peak temperature in the combustion chamber so as to reduce nitrogen oxide (NOx) formation. The engine control unit recirculates a portion of the exhaust gases taken from the exhaust manifold back to the engine intake. To this end, the engine control unit processes the inputs from:

- atmospheric pressure sensor,

- water pressure sensor,

- engine rpm sensor,

- accelerator pedal potentiometer and pilots both the vacuum control solenoid valve and the throttle valve via a PWM signal according to the mapping stored in its memory.

Each time the engine control unit signals it to do so, the vacuum control solenoid valve opens a connection between the servo brake vacuum circuit and the EGR circuit. This creates a certain amount of vacuum in the EGR circuit according to the command signal. Vacuum operates the E.G.R. pneumatic valve that retracts and lifts a shutter to open an exhaust gas passage to the intake. This creates a connection between the exhaust and intake manifolds, so that part of the exhaust gases flow into the intake manifold. Exhaust gases are cooled while flowing through the heat exchanger and then conveyed into the throttle valve chamber where they are mixed with the air from the intercooler and delivered to the intake manifold; in the meantime, the engine control unit adjusts the amount of fuel injected into the cylinders depending on the amount of exhaust gas recirculated.

When engine operating conditions are such that no gas recirculation is required (start-up, cold engine, idle speed, load request, high altitude), the ECU sends no control signal to the vacuum control solenoid valve. The solenoid valve closes the connection between the servo brake vacuum circuit and the E.G.R. circuit and lets filtered air from the dedicated filter enter the E.G.R. circuit to restore atmospheric pressure.

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a – Servo brake vacuum circuit

b – E.G.R. controlled vacuum circuit 1 – Engine control unit 2 – Throttle valve assembly 3 – Vacuum take-up point 4 – Water temperature sensor

E.G.R. valve

The E.G.R. valve is mounted at the end of the heat exchanger. The valve is cooled by the engine coolant coming out of the heat exchanger to ensure improved efficiency and long life. The amount of recirculated exhaust gas is determined by a poppet valve operated by the vacuum let in by a calibrated connector; vacuum is taken from the pipe connecting vacuum pump to servo brake. The vacuum let in by the solenoid valve overcomes the pressure exerted by the spring (1) and raises a diaphragm (2); the shutter (3) connected to it rises and lets burnt exhaust gases flow back into the intake

manifold

.

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5 – Engine rpm sensor 6 – E.G.R. pneumatic valve 7 – Air flow meter 8 – Intake air filter 9 – EGR vacuum control valve 10 – Vacuum-operated servo brake

1 – Vacuum duct,

2 – Spring 3 – Diaphragm. 4 – Shutter.

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E.G.R. solenoid valve

The E.G.R. solenoid valve operates the E.G.R. valve to determine the amount of exhaust gases to be delivered to the intake duct. The duty-cycle-controlled solenoid valve determines the amount of servo brake pump vacuum to be connected to the E.G.R. valve so as to recirculate a certain amount of exhaust gas. The figure below shows the layout of the EGR circuit.

1 – Servo brake vacuum pump 2 – Engine control unit 3 – E.G.R. solenoid valve 4 – Filter for connection to the atmosphere 5 – E.G.R. valve on engine

A – Exhaust gas from exhaust manifold B – Exhaust gas recirculated to the intake manifold

The figure below shows a detail diagram of the E.G.R. solenoid valve

1 – Connection to the atmosphere 2 – Electrical connector 3 – Connection to vacuum source

3a – White identification dot 4 – Connection to E.G.R. valve 4a – Yellow identification dot

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Solenoid valve characteristic data

Pilot frequency: 140 ± 7Hz. Minimum duty cycle value: 6%. Maximum duty cycle value: 6%. Maximum feed vacuum: 930 mbar. Winding resistance: 5.5 ±5 Ohm at 20 ± 5°C

The following graph shows the solenoid valve characteristic curve

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Heat exchanger

The heat exchanger installed between turbocharger and throttle valve assembly cools down exhaust gas to reduce its volume. Its body accommodates a set of corrugated pipes. The recirculated exhaust gas passing through the pipes is cooled down by the engine coolant flowing inside the body.

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3.1.14 Crankcase oil vapour recovery system

General

A portion of combustion gases escapes past the end gaps of the piston rings into the sump; the oil fumes in the sump become mixed with the exhaust gases. From the chain compartment, this mixture is conveyed upwards, and oil is partly extracted by a device located on top of the timing cover and conveyed into the air intake circuit. This device consists of a rotary filter (3) splined to the shaft (1) of the high pressure/camshaft pump and a cover (2) that accommodates two normally closed valves (4 and 5). The diaphragm valve (4) controls the release of the partially filtered mixture to keep pressure inside the chain compartment at ~ 10 ÷ 15 mbar. The umbrella valve (5) releases part of the remaining oil contained in the mixture exiting the filter (3) into the chain compartment and oil condenses inside chamber (6).

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A – Gas with an oil content greater than 10 g/h B – Gas with an oil content ~ 0.2 g/h C – Condensed oil returning to oil sump

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OPERATION

As the mixture passes through the rotary filter (3), oil particles are extracted by centrifugal force, hit the cover walls, condense and are conveyed back into the lubrication circuit.

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The filtered mixture is made to pass through the shaft holes (1) and the diaphragm valve (4) lets it flow into the air conveyor upstream of the turbocharger. The valve (4) is opened or closed by the combined action of the pressure acting on the diaphragm (4) and the vacuum underneath it. Any oil left in the mixture exiting the rotary filter (3) condenses inside chamber (6) and is released into the chain compartment by the umbrella valve (5) when the engine is stopped and the vacuum keeping the valve closed is removed

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3.1.15 Engine lubrication system

GENERAL

The forced lubrication system consists of the following components:

- gear oil pump incorporated in the same assembly as the vacuum pump;

- pressure regulator incorporated in the oil pump;

- five-element heat exchanger;

- duel-filtration oil filter with incorporated safety valve.

OPERATION

Engine oil is drawn from the sump through the suction rose by the oil pump, pressurised and delivered to the heat exchanger for cooling. Oil flows through the oil filter and is conveyed to all lubrication points through galleries or pipes. After the lubrication cycle, the oil drips back into the sump. The safety valve incorporated in the oil filter cuts off the filter from the circuit when it becomes clogged. In addition, the lubricating oil feeds the hydraulic tensioners of the auxiliary drive shafts and camshafts as well as the hydraulic tappets.

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A – Pressure regulator closed B – Pressure regulator open C – Oil pressure switch D – Pressurised oil E – Dripping oil E – Coolant

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Oil pump/vacuum pump assembly

The oil pump/vacuum pump assembly is mounted on the crankcase on timing gear side. The oil pump drive gear is driven by the crankshaft via a chain and transmits motion to the vacuum pump.

Note: this assembly cannot be serviced and must be replaced when faulty.

The figure below shows a cross-section view of the oil pump

1 – Oil pump 2 – Oil pressure regulator 3 – Vacuum pump

The oil pump is a gear pump; the vacuum pump is a radial vane pump.

1 – Inlet duct for crankcase oil 2 – Oil intake duct 3 – Oil pressure regulator 4 – Oil delivery duct

5 – Vacuum pump air intake duct 6 – Vacuum pump oil intake duct

Oil pressure regulator

The oil pressure regulator is housed inside the pump. The figure below shows its components.

1 – Circlip 2 – Valve 3 – Spring 4 – Valve body.

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Oil pressure regulator valve closed

Oil pressure regulator valve open

Oil filter

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When oil pressure in duct C drops below

4.4 bar, the valve (1) shuts holes D and E and the pressurised oil is delivered to the crankcase.

1 – Valve 2 – Spring A – Sump oil intake duct B – Oil delivery duct to crankcase C – Oil return duct from crankcase D – Oil drain hole E – Oil drain hole

When pressure in duct C is 4.4 bar or higher, it helps the valve (1) overcome the spring (2); the valve lowers and opens the drain holes D-E that connect delivery duct A and intake duct B, so that pressure drops. As soon as pressure drops below 4.4 bar, the spring (2) pushes the valve (1) back into the closed position.

The oil filter is of the simple filtration type with incorporated by-pass valve and opens at a differential pressure of 2.5 ± 0.2 bar.

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Heat exchanger

The figure below shows the heat exchanger.

The amount of oil in the circuit and oil pressure are continually monitored by:

- oil pressure sensor,

- oil level sensor,

- engine oil level control unit.

Engine oil pressure sensor

The engine oil pressure sensor is located near the oil filter on the water-oil heat exchanger.

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1 – Five-element heat exchanger 2 – Gasket 3 – Case 4 – Fitting 5 – Screw 6 – Oil filter mount 7 – Oil pressure switch 8 – Screw 9 – Heat exchanger case

10 – Gasket

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1 – Engine oil pressure sensor

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The figure below shows the engine oil pressure sensor.

A – Detail of connector 1 – Connector 2 – Engine oil pressure sensor body 3 – Gasket

Engine oil level sensor

The engine oil level sensor is located near the alternator, on the crankcase exhaust side.

1 – Engine oil level sensor

The engine oil level sensor is a hot-wire sensor.

The figure below shows the engine oil level sensor.

1 – Connector 2 – Engine oil level sensor body 3 – Gasket

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Engine oil level measurement

The system consists of an electronic control unit located near the engine control unit in the engine compartment and a hot-wire sensor.

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A – Engine oil level control unit B – Detail of connector 1 – +12 Volt 2 – Output signal level 3 – Oil level sensor + 4 – Ground 5 – Ground signal 6 – Oil level sensor ground

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Engine oil level is checked when the ignition key is turned to On to start the engine. The system uses the heat dissipating properties of oil. The current flowing through the hot wire causes its temperature and resistance to rise, while voltage drops. When the hot wire is submerged in oil, the oil will take up part of the heat; as a result, temperature, resistance and voltage drop will be lower. When the key is turned to On, the control unit feeds 210.5mA to the hot wire of the sensor. After a time delay to allow for power supply to stabilise (t0 ÷ t1 = 150 mSec), the control unit takes a first voltage reading (t1 ÷ t2 = 10 mSec ). After another time delay (t0 ÷ t1 = 865 mSec), the control unit takes a second voltage reading and compares it to the first reading. At this point, one of the following may occur:

1) if the difference between the two readings is less than 125mV, it means that oil level is correct;

2) a difference greater than 445mV indicates minimum oil level;

3) if the second reading is greater than 3.5mV, it means that the sensor is interrupted;

4) if voltage is less than 1mV, it means that the sensor is shorted.

The oil control unit converts the reading into a PWM signal and sends it to the engine control unit. The engine control unit sends the corresponding parameter over the C-CAN network to trigger the necessary indications on the instrument panel.

PWM frequency : 125 ± 10Hz Tolerance at ambient temperature PWM ± 3.5% Oil level PWM signal represented by duty cycle TA / TP. At the minimum level the PWM will be at 30% (440mV) whereas at the max level it will be 90% (125mV). Between 10% and 15%, data acquisition is in progress. Between 3% and 7%, an error has occurred.

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3.1.16 Engine cooling circuit

The engine forced cooling system is a closed circuit and consists of the following components:

- expansion tank with an inlet and outlet valve incorporated in the plug to regulate circuit pressure;

- engine cooling module to dissipate the heat removed from the engine by the coolant;

- heat exchanger that cools lubricating oil;

- heat exchanger for exhaust gas (EGR) cooling;

- centrifugal water pump incorporated in crankcase;

- thermostat controlling coolant circulation

Diagram showing engine cooling system operation

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1. Coolant pump

2. Coolant tank

3. Radiator

4. Thermostat

5. Oil/coolant heat exchanger

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6. Exhaust gas/coolant heat exchanger

7. Bleed screw

8. In-cab heater

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Engine coolant pump

The engine coolant pump is driven by the crankshaft via a poli-V belt; the pump delivers coolant to the crankcase and - with greater pressure head - to the cylinder head. The engine coolant pump is located on the crankcase on timing gear side.

When coolant temperature reaches or exceeds operating temperature, the thermostat trips and conveys coolant to radiator and cooling fan. Pressure in the circuit varies with temperature and is controlled by the inlet and outlet valves incorporated in the expansion tank filler plug.

Supplemental engine coolant tank

The tank feeds coolant to the circuit and takes up excess coolant when it expands from heat as engine temperature rises.

A calibrated valve in the sealed plug

- lets air exit the circuit; this is the air drawn from the pipe coming from the coolant outlet fitting on the head; or

- lets air in when the engine has cooled down and vacuum is created in the circuit.

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1 – Engine coolant pump 2 – Seal 3 – Pipe connecting pump to expansion tank

1 – Expansion tank 2 – Engine coolant level sensor connector 3 – Fitting for coolant delivery to engine cooling circuit 4 – Engine breather fitting 5 – Radiator breather fitting 6 – Expansion tank plug

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Expansion tank plug

The expansion tank plug maintains pressure in the cooling circuit within the specified range. The plug accommodates two valves:

- one is set at 0.02÷0.07 kg/cm² and lets air at atmospheric pressure into the circuit to prevent vacuum (inlet valve);

- the other valve is set at 1.4±0,1 kg/ cm² and releases exceeding pressure (outlet valve).

The outlet valve serves two purposes:

- it maintains a slight pressure in the circuit so as to increase coolant boiling point;

- it releases excess pressure to the atmosphere when coolant temperature rises. The inlet valve lets air into the circuit when coolant cools down and shrinks in volume, creating vacuum in the circuit.

Thermostat

The thermostat is housed inside the outlet manifold for the engine coolant exiting the head on the intake side, and its purpose is to maintain ideal engine temperature:

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1

– Threaded cover 2 – Cover 3 – Outlet valve spring 4 – Inlet valve 5 – Outlet valve 6 – Inlet valve spring 7 – Outlet valve 8 – Lower cover 9 – Sealing O-ring

The by-pass thermostat requires no adjustment. If you suspect a malfunction, replace it. The water temperature sensor is mounted on thermostat body. Valve travel at 79°C ± 2°C = 0.1 mm Valve travel at 94°C ± °C = 7 mm Valve travels 7 mm in less than 60”.

A – Thermostatic valve closed B – Thermostatic valve open

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3.2 ELECTRONIC ENGINE MANAGEMENT

FEATURES

The EDC16C39 Common Rail system is a high-pressure electronic injection system for fast directinjection diesel engines.

Its main features comprise:

- high injection pressures (1600 bar);

- pressure control range from 150 bar up to maximum operating pressure (1600 bar), regardless of engine speed and loading;

- operation at high engine rpm (up to 6000 rpm under full loading);

- high pressure pump with three pumping elements;

- accurate injection (advance and duration) control;

- less consumption;

- less emissions.

The main features of the system are outlined below:

- fuel temperature control;

- engine coolant temperature control;

- injected fuel control;

- idle speed control;

- fuel cut-off during deceleration;

- cylinder balance control at idle speed;

- surge control;

- exhaust smoke control under acceleration;

- exhaust recirculation control (E.G.R.)

- torque limitation control;

- rpm limitation control;

- glow plug control;

- air conditioner control (where fitted);

- electric fuel pump control;

- cylinder position control;

- main and pilot injection advance control;

- closed-loop injection pressure control;

- electrical balance control;

- turbocharging pressure control;

- self-diagnosis;

- connection to Fiat CODE (Immobilizer) control unit.

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1 – Auxiliary fuel pump

2 – Fuel filter 3 – Fuel return manifold 4 – CP3.2 pressure pump 5 – Pressure regulator on pump 6 – Supercharging sensor 7 – Injection control unit 8 – Pressure sensor 9 – Rail 10 – Throttle body 11 – E.G.R. solenoid valve 12 – Oil level sensor 13 – E.G.R. actuator

14 – Glow plug 15 – Glow plug control unit 16 – Air flow meter 17 – Rpm sensor 18 – Timing sensor 19 – Oil minimum pressure switch 20 – Lambda sensor on pre-catalyst 21 – Main catalyst 22 – Engine wiring harness 23 – Pedal unit 24 – Vehicle wiring harness 25 – Water temperature sensor

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3.2.1 EDC 16 C 39 engine control

FEATURES In this Common Rail fuel injection system equipped with CP3.2 pump, the flow regulator located at the high pressure pump inlet controls the fuel flow required by the low pressure circuit. The high pump pressure then feeds the Rail as appropriate. This way, only the necessary amount of fuel is pressurised, there is less need to heat fuel in the system and overall energy efficiency is improved The CP3.2 pump maintains fuel at high pressure regardless of the current stroke of the cylinder that is expecting the fuel and stores the fuel in a common duct for all electro-injectors (Rail). As a result, fuel at the injection pressure determined by the ECU is constantly available at injector inlets. When the ECU energises the solenoid valve of an injector, fuel is drawn from the rail and injected into the corresponding cylinder. The hydraulic system is comprised of a low pressure and high pressure circuit. The high pressure circuit consists of the following pipes:

- pipe connecting high pressure pump outlet to Rail;

- Common Rail;

- feed pipes from Rail to injectors. The low pressure circuit consists of the following pipes:

- suction pipe from tank to prefilter

- pipes feeding the mechanical supply pump and prefilter;

- pipes feeding the high pressure pump through the fuel filter;

- return pipe from high pressure pump;

- return pipe from electro-injectors;

- return pipe to tank. Because of the high pressures in this hydraulic circuit, the following safety precautions must be strictly observed:

- make sure to tighten the high pressure pipe fittings to the correct torque;

- do not disconnect high pressure pipes while the engine is running (DO NOT attempt to bleed the circuit, this would be useless and dangerous!) A low pressure circuit in good running order is critical to proper operation of the system, so do not make changes to the circuit and repair any leaks without delay.

INJECTED FUEL CONTROL

The control unit controls fuel pressure regulator and electro-injectors based on the inputs from accelerator pedal potentiometer, air flow meter or air pressure sensor in intake manifold and engine rpm sensor. When the engine is started, injection timing and firing order are determined using the inputs from the engine rpm sensor and the timing sensor (synchronisation); afterwards, injection timing is dependant on the engine rpm sensor inputs only and the standard firing order of the 3000 JTD engine (1 – 3 – 4 – 2) is resumed. The control unit inhibits the injection when:

- fuel pressure exceeds 1700 bar;

- fuel pressure drops below 100 bar;

- engine rpm exceeds 5000 rpm.

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INJECTION ADVANCE CONTROL

The electronic control unit basically relies on two factors to calculate injection advance: the amount of fuel to be injected and engine rpm. Injection advance is adjusted according to engine coolant temperature so as to compensate for the increasing injection delay during warm-up, while the combustion chambers are still cold.

INJECTION PRESSURE CONTROL

This is a critical feature, as injection pressure affects the following parameters:

- amount of fuel fed into the cylinders (injection duration being equal);

- fuel atomisation;

- injection depth;

- time delay after command signal before fuel is actually injected;

- duration of fuel injection into combustion chamber.

These parameters significantly affect engine operation and performance in terms of power output, exhaust emissions, noise and driveability. The engine control unit uses engine rpm and load inputs to control the pressure regulator at the high pressure pump inlet so as to achieve and maintain optimal line pressure. When the engine is cold, injection pressure is adjusted based on engine coolant temperature to meet varying engine demand as operating temperature changes. Fuel pressure is adjusted to instantaneous engine operating conditions (rpm, load, etc.). The lower the pressure, the longer the injection times (and vice versa), also depending on load requirements. Up to 2800 rpm, a pre-injection feature reduces the noise typically associated with direct injection systems. Pre-injection advance angles, intervals between pre-injection and main injection and main injection advance angles vary according to the instantaneous operating conditions of the engine.

ELECTRIC FUEL PRE-FEED PUMP CONTROL

The auxiliary fuel pump submerged in the tank is powered by the engine control unit through a contactor when the ignition key is set to RUN. Power supply to the electric pump is removed when:

- the engine has not started after the ignition key has been in the RUN position for 10 seconds;

- the inertia switch has tripped.

FUEL CUT-OFF DURING DECELERATION

Fuel cut-off occurs when the engine control unit receives an input from the potentiometer indicating that the accelerator has been released. In this condition, the control unit cuts off power supply to electro-injectors and restores it before idle rpm is reached; the ECU also controls the fuel pressure regulator accordingly.

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IDLE SPEED CONTROL

The control unit controls fuel pressure regulator and electro-injector timing based on the inputs from the engine rpm and coolant sensors so as to keep idle rpm stable. Under certain conditions, the ECU will also use battery voltage to control idle speed.

MAXIMUM RPM LIMITATION CONTROL

The engine control unit achieves rpm limitation in two ways:

- it lowers line pressure to reduce the amount of fuel injected as the engine is approaching the maximum rpm limit (4500 rpm);

- it shuts down the electro-injectors in the event the engine exceeds 5000 rpm.

MAXIMUM TORQUE LIMITATION CONTROL

The injection control unit uses rpm to calculate maximum torque parameters and maximum smoke rate allowed based on the mapping stored in its memory. The control unit adjusts these parameters based on engine coolant temperature and vehicle speed, and uses the resulting corrected parameters to meter out the correct amount of fuel through the pressure regulators and the electro-injectors.

FUEL TEMPERATURE CONTROL

The injection control unit continually monitors fuel temperature through the sensor in the fuel filter. When fuel reaches a predetermined temperature (80°C), the engine control unit begins to gradually decrease maximum power and keeps cutting power up to 90°C, until achieving a minimum value of 60% of rated power.

ENGINE COOLANT TEMPERATURE CONTROL

The injection control unit continually monitors engine coolant temperature through the sensor on the thermostat. If engine coolant temperature exceeds certain predetermined values, the control unit will:

- signal the fuel pressure regulator and the electro-injectors to reduce the amount of fuel injected (power reduction starting from 106°C).

- actuate the engine cooling fan (switch-on/off temperatures: 95 / 91°C for first speed, 99 / 95°C for second speed). When the ignition key is turned to STOP (and temperature is higher than the cooling system switch-on threshold), the fan will keep running for up to 20 sec., so that temperature drops below the switch-on threshold. When the ignition key is turned to RUN (and coolant temperature is higher than the cooling system switch-on threshold), the fans will not switch on until engine speed rises above 770 rpm (rpm with a warm engine is 800 rpm).

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EXHAUST SMOKE RATE CONTROL

The injection control unit also provides smoke limitation, for event smoke emissions are produced under sharp acceleration To meet this requirement, the control unit processes the signals sent by accelerator pedal potentiometer, engine rpm sensor and intake air sensor (air flow meter or pressure/temperature sensor); the injection control unit controls the fuel pressure regulator and the electro-injectors so that the right amount of fuel to reduce exhaust smoke is injected into the combustion chamber .

EXHAUST RECIRCULATION CONTROL (E.G.R.)

To ensure compliance with EURO 4 emissions standard, the control unit reduces the amount of fresh air taken in according to engine load and accelerator pedal potentiometer inputs, and signals the pneumatic EGR valve to open so as to draw a portion of the exhaust gas.

AIR CONDITIONER CONTROL

The engine control unit controls the air conditioner compressor clutch so as to preserve engine performance when the air conditioner is on. When the air conditioner is switched on, the engine control unit provides more fuel at idle speed to meet the increased demand from the engine and shuts down the air conditioner in the event of:

- exceeding engine coolant temperature (AC is shut down at 105°C and re-enabled at 100°C).

ENGINE IMMOBILIZER

The system offers an engine immobilizer feature. This is achieved thanks to a Fiat CODE control unit that communicates with the engine control unit and an electronic key that incorporates a code transponder. Each time the key is turned to STOP, the Fiat CODE system shuts down the engine control unit completely. When the key is turned to RUN, the following occurs in the order:

- the engine control unit (which has the secret code stored in its memory) asks the Fiat CODE control unit to transmit the secret code required to cancel the inhibit condition;

- the Fiat CODE control unit will only send the secret code after receiving the identification code from the key transponder;

- when the secret code is recognised, the engine control unit inhibit is disabled and the unit is restored to normal operation.

SELF-DIAGNOSIS

The injection system can be fully diagnosed by connecting the EXAMINER equipment to the diagnostic connector located in the engine compartment. The system includes a self-diagnosis feature to recognise, store and warn of possible malfunctions. In the event a sensor or actuator is found to be malfunctioning, preset signal recovery strategies ensure acceptable engine operation. This way, the vehicle can be driven to nearest service centre for the necessary repairs.

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FIXED GEOMETRY TURBINE CONTROL (VGT)

The control unit processes the supercharging sensor inputs at varying engine rpm and determines the amount of fuel to be injected:

- the ECU adjusts injection duration;

- it adjusts the amount of exhaust gas flowing through the turbocharger so as to ensure optimal performance under all operating conditions.

LAMBDA SENSOR CONTROL

The control unit uses the inputs from the Lambda sensor to prepare “correction maps” for the main injection and compensate for injection component decay (EGR, injectors, pressure rail, air flow meter, Lambda sensor)

SOLENOID VALVE CONTROL The control unit switches on the cooling fans at the first or second speed depending on engine coolant temperature and coolant pressure in the air conditioning system.

CRUISE CONTROL (WHERE FITTED)

The control unit directly adjusts the amount of fuel injected depending on the position of the cruise control lever so as to control and maintain the vehicle speed stored in the memory. It also controls a status light on the instrument panel to indicate whether the system is on or off. The cruise control system is temporarily disabled:

- when the brake is operated,

- when the clutch is operated;

- pressing the "resume" button brings the vehicle back to the stored speed. The cruise control is not disabled when the accelerator pedal is depressed (for instance, when overtaking) and automatically brings the vehicle back to stored speed as soon as the accelerator is released. For safety reasons, the ASR (antispin) feature overrides the cruise control.

3.2.2 Engine Control unit pinout

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M010A connector

1 – Key-on power source from main contactor 2 – Control unit ground 1 3 – NC 4 – Control unit ground 2 5 – Key-on power source from main contactor 6 – Control unit ground 3 7 – NC 8 – Accelerator pedal potentiometer 2 ground 9 – Accelerator pedal potentiometer 1 signal 10 – Fuel temperature signal (ground) 11 – Fuel temperature signal (signal) 12 – Air conditioner linear pressure sensor (ground) 13 – Air conditioner linear pressure sensor (signal) 14 – NC 15 – NC 16 – NC 17 – Brake pedal switch (signal) 18 – NC 19 – NC 20 – Fuel pump contactor power supply (positive) 21 – NC 22 – Air conditioner linear pressure sensor (power supply) 23 – NC 24 – NC 25 – K line for diagnosis 26 – NC 27 – NC 28 – Direct power supply from switch +15 29 – Compressor cut-in contactor control 30 – Accelerator pedal potentiometer 1 ground 31 – Accelerator pedal potentiometer 2 signal 32 – DPF exhaust gas temperature signal (where fitted) 33 – DPF exhaust gas temperature ground (where fitted) 34 – Exhaust gas temperature sensor 1 signal (where fitted) 35 – Exhaust gas temperature sensor 1 ground (where fitted) 36 – Particulate filter differential sensor signal (where fitted)

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37 – Particulate filter differential sensor negative power supply (where fitted) 38 – Resume from cruise control command 39 – NC 40 – NC 41 – NC 42 – NC 43 – NC 44 – Particulate filter differential sensor power supply (where fitted) 45 – Accelerator pedal potentiometer 1 power supply 46 – Accelerator pedal potentiometer 2 power supply 47 – NC 48 – NC 49 – NC 50 – NC 51 – Lambda sensor heating (negative) 52 – Glow plug preheating time/fault detection feedback input 53 – NC 54 – Compressor cut-in request from pushbutton positive signal 55 – NC 56 – Cruise control for “set / acc.” 57 – NC 58 – NC 59 – NC 60 – NC 61 – NC 62 – NC 63 – NC 64 – Lambda sensor Nerst cell reference voltage signal 65 – Lambda sensor pumping current 66 – NC 67 – NC 68 – (Provision for) Diesel filter heater contactor command 69 – Engine cooling fan speed contactor 2 cut-in command 70 – NC 71 – Malfunction indicator light (EOBD/MIL) 72 – Direct power supply from battery 73 – NC 74 – Water in fuel sensor (signal) 75 – NC 76 – NC 77 – Cruise control on/off control lever positive 78 – Cruise control “set/dec.” command positive 79 – Clutch pedal pressed positive signal (NC switch)

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80 – Clutch pedal pressed redundant signal (positive), normally closed. 81 – NC 82 – NC 83 – Can line from NBC – (Can low) 84 – Can line from NBC – (Can High) 85 – NC 86 – Ground for Lambda sensor signal 87 – Lambda sensor reference current 88 – NC 89 – NC 90 – Engine cooling fan speed contactor 1 cut-in command 91 – NC 92 – NC 93 – Glow plug preheating contactor 94 – Engine cooling fan speed contactor 3 cut-in command

M010B Connector

1 – Injector no. 3, supply 2 – Injector no. 2, supply 3 – NC 4 – NC 5 – NC 6 – NC 7 – NC 8 – Fuel pressure sensor (ground) 9 – NC 10 – NC 11 – Timing sensor (power supply) 12 – Rpm sensor (negative input) 13 – Absolute pressure sensor (power supply) 14 – NC 15 – NC 16 – Injector no. 1, supply 17 – Injector no. 4, supply 18 – NC 19 – Fuel flow regulator (power supply) 20 – Timing sensor (negative) 21 – NC 22 – Oil level sensor (ground)

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23 – Absolute pressure sensor (negative) 24 – NC 25 – NC 26 – NC 27 – Rpm sensor (positive input) 28 – Rail pressure sensor (positive) 29 – NC 30 – NC 31 – Injector 2 (negative command) 32 – NC 33 – Injector 4 (negative command) 34 – NC 35 – NC 36 – NC 37 – Air temperature sensor (signal) inside air flow meter 38 – NC 39 – NC 40 – Absolute pressure sensor (signal) 41 – Water temperature sensor (ground) 42 – Air mass quantity in flow meter signal 43 – Fuel pressure sensor on rail (signal) 44 – Air flow meter (ground) 45 – NC 46 – Injector 3 (negative command) 47 – Injector 1 (negative command) 48 – NC 49 – Flow regulator control (negative) 50 – Timing sensor (signal) 51 – NC 52 – Oil level sensor (signal) 53 – Air temperature signal of absolute pressure sensor 54 – NC 55 – NC 56 – Signal oil pressure sensor (normally closed) 57 – NC 58 – Water temperature sensor (signal) 59 – Powered throttle actuator command 60 – EGR negative command

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3.2.3 Engine management wiring diagram

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Key to engine management wiring diagram components

A040. Preheating glow plugs B001. Engine compartment connector box B002. Connector box under dashboard B099. Pmaxi-fuse box on battery C010. Front left ground C022. Central dashboard ground C100. Cab ground D001. Dashboard/front junction D004. Engine/front junction E050. Instrument panel H001. Ignition switch I030. Brake pedal switch I031. Clutch pedal switch I050. Inertia switch K030. Engine oil pressure sensor K031. Water in diesel filter sensor K032. Engine oil level sensor K036. Engine water temperature sensor K040. Lambda sensor K041. Air flow meter K044. Intake air pressure and temperature sensor K046. Rpm sensor K047. Timing sensor K055. Accelerator pedal potentiometer K081. Fuel temperature sensor K083. Fuel pressure sensor L030. EGR solenoid valve L062. Throttle body M001. Body computer M010. Engine control unit M015. Glow plug preheating control unit M186. Engine oil level control unit N040. Electric fuel pump and fuel level meter N070. Electro-injectors N193. Fuel flow regulator O007. Oil vapour heating resistor

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3.2.4 Injection/ignition system components

ENGINE CONTROL UNIT

It is fitted in the engine compartment on the right-hand side panel.The control unit is of the "flash e.p.r.o.m." type, i.e. it can be reprogrammed from outside without removing the hardware. The injection control unit incorporates the absolute pressure sensor. The figure below shows the control unit.

RPM SENSOR

Features

TIMING SENSOR

Features

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The rpm sensor is fitted on the crankcase with its sensing surface facing the phonic wheel on the engine flywheel. It is an inductive sensor that changes its output as it senses the changes in the magnetic field caused by the phonic wheel teeth (60 - 2 teeth) passing across it. The injection control unit uses the rpm sensor signal to:

- determine the rotation speed;

- determine the angular position of the crankshaft.

The timing sensor is a Hall sensor fitted on engine oil filler cover on the upper cylinder head section. It determines engine timing by sensing the position of intake camshaft drive gear. The injection control unit uses the signal of the timing sensor to determine T.D.C. at the end of the compression stroke. 1 –Timing sensor

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INTAKE AIR TEMPERATURE AND OVERPRESSURE SENSOR

Features

The intake air overpressure and temperature sensor is an integrated component used to measure the pressure and temperature of the air inside the intake manifold. The sensor is fitted on the intake manifold and its output is used by the engine control unit:

- to adjust turbocharger pressure

- to protect the engine from overheating

- to diagnose air flow meter operation

Sensor pinout:

1 – Ground 2 – Air temperature signal

Sensor output voltage changes with absolute pressure according to the following law:

Ua=(c1*pabs+c0)*Us

where:

- Ua = signal output voltage in V

- Us = power supply voltage in V

- pabs = absolute pressure in kPa

- c0 = 5.4/280

- c1 = 0.85/280 kPa-1

3 – 5 V power supply (from engine control unit) 4 – Turbocharging pressure output signal

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The graph below shows output signal tolerance in relation to pressure

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.

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The following table lists temperature sensor resistance values in relation to air

temperature

Temperature

(°C)

Minimum Rated Maximum

-40 45301 48153 51006

-35 33703 35763 37823

-30 25350 26854 28359

-25 19265 20376 21487

-20 14785 15614 16443

-15 11453 12078 12702

-10 8951 9426 9901

-5 7055 7419 7783 0 5605 5887 6168 5 4487 4707 4926

10 3618.7 3791.1 3693.5 15 2938.5 3074.9 3211.3 20 2401.9 2510.6 2619.3 25 1975.8 2062.9 2150.1 30 1644.7 1715.4 1786.2 35 1374.2 1431.8 1489.5 40 1152.4 1199.6 1246.7 45 969.9 1008.6 1047.4 50 819.1 851.1 883.0 55 694.2 720.7 747.1 60 590.3 612.3 634.2 65 503.6 521.9 540.2 70 431.0 446.3 461.6 75 370.1 382.89 395.7 80 318.68 329.48 340.27 85 275.25 284.37 293.48 90 238.43 246.15 253.86

95 207.12 213.67 220.23 100 180.42 186.00 191.58 105 157.37 162.35 167.32 110 137.63 142.08 146.52 115 120.68 124.66 128.63 120 106.09 109.65 113.21 125 93.48 96.68 99.88 130 82.58 85.45 88.32

Resistance in Ohm

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ENGINE COOLANT TEMPERATURE SENSOR

The engine coolant temperature sensor is mounted on a thermostatic plate and detects coolant temperature by means of a double NTC (negative temperature coefficient) thermistor.

One NTC thermistor sends a signal to the injection control unit, while the other sends a signal to temperature indicator and light on the instrument panel. The sensor uses semiconductor technology; as sensor temperature increases with coolant temperature, sensor resistance drops. The change in resistance is not linear; temperature increase being equal, resistance will drop faster in the low temperature range than at higher temperatures.

AIR FLOW METER WITH INCORPORATED AIR TEMPERATURE SENSOR

Features

The hot-film air flow meter is located on the air intake sleeve. It incorporates the intake air temperature sensor.

Air flow meter pinout:

1 – Power supply 2 – Ground 3 – Air temperature sensor signal 4 – Air mass quantity signal

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ACCELERATOR PEDAL POTENTIOMETER

Features

The sensor casing is secured to the accelerator pedal and accommodates two (main and safety) potentiometers connected by an axial shaft. The shaft is fitted with two springs: a coil spring provides the correct resistance when pressure is applied to the pedal, the second is the return spring for when the pedal is released.

Sensor output voltage changes with accelerator pedal position and is sent to the injection control unit. The accelerator pedal position signal is processed together with the rpm input to calculate injection times and pressure.

MOTOR-DRIVEN THROTTLE BODY

Double potentiometer = factor 2 Power supply voltage (U1, U2) = 5 V ± 0.3 V Series and contact resistance (Rs + Rc) = 1 kOhm ±0.4 kOhm Maximum load on sliding contact = 0.5 micro Ampere Potentiometer resistance Rn1 = 1.2 kOhm ±0.5 kOhm Potentiometer resistance Rn2 + Rv2 = 1.7 kOhm ±0.8 kOhm Linearity = ±0.02 u/U

P1/P2 synchronisation = absolute value(u1/(U1/2)-u2/U2) ≤ 0.014 u

1 – Accelerator pedal potentiometer 2 power supply 2 – Accelerator pedal potentiometer 1 power supply 3 – Accelerator pedal potentiometer 1 ground 4 – Accelerator pedal potentiometer 1 signal 5 – Accelerator pedal potentiometer 2 ground 6 – Accelerator pedal potentiometer 2

signal

The (normally open) throttle valve assembly fitted on the intake manifold controls the flow rate of intercooler air to be mixed with the exhaust gases recirculated by the E.G.R. valve, according to a programmed percentage. Recirculated exhaust gas is mixed with intercooler air in a duct inside the cylinder head. The throttle valve is operated by an electric actuator controlled by a PWM signal from the EDC 16 control unit. If the throttle valve jams, the control unit will reduce engine performance to prevent engine damage.

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The motor-driven throttle body performs two functions:

- shut-off management

- it controls exhaust gas temperature by restricting the cross-section area of the intake duct.

Connector pinout

1 – PWM (Pulse Width Modulate) command 2 – Power supply 3 – Ground 4 – Position signal

A– Throttle valve B – Electrical actuator

CLUTCH PEDAL POSITION SWITCH

The clutch pedal position switch is mounted on the pedal assembly and generates a positive signal for the electronic control unit when the clutch is engaged (pedal released). Whenever the clutch is disengaged to shift gears, the control unit senses that the switch signal is missing and disables the Cruise Control (where fitted).

BRAKE PEDAL POSITION SWITCH

The brake pedal position switch is mounted on the pedal assembly. When the brake pedal is released, the switch generates a positive signal. The control unit uses this signal to determine when the brake is operated so as to disable the Cruise Control (where fitted) and cut off fuel. The switch also operates the brake lights.

A – Power supply positive B – Electrical load C – Wiring diagram (pedal depressed)

A – Power supply positive B – Electrical load C – Not connected D – Not connected

E – Wiring diagram (pedal depressed) F – Diagram showing operation 0 – Brake pedal released 1 – Brake pedal depressed

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3.3 DIAGNOSIS

3.3.1 Parameter section

Exhaustive system information can be viewed in the parameter screen, starting with typical engine operation parameters (rpm, water temperature, etc.). The system is derived from the EDC16C39 SYSTEM developed for Fiat Croma and Alfa 159, so the following parameters should be noted: SPEED LIM FUNCTION: Possible states are:LEARNT: After proxi alignment, when the vehicle did not exceed the speed limit set in the ECU SPEED LIMITATION: Displays vehicle speed limitation set in the ECU

WARNING: The following OPTIONAL parameters:

- AC cut-in request

- AC control relay

- Air conditioner pressure

- Cruise control switch

- Request from Cruise control lever

- Irrev. Cruise control error state

will be labelled 'Not available' unless the teach-in procedure for that function has been performed

Parameter description can be viewed by pressing the HELP button in the PARAMETER SELECTION screen

DESCRIPTION HELP Engine rpm ENGINE RPM: Shows engine rotation speed Accelerator pedal Accelerator pos. 1 AD/C Accelerator pos. 2 AD/C

Fuel COR CYL 1 FUEL CORRECTION CYL 1/2/3/4: Amount of fuel added/subtracted for

Fuel COR CYL 2 FUEL CORRECTION CYL 1/2/3/4: Amount of fuel added/subtracted for

Fuel COR CYL 3 FUEL CORRECTION CYL 1/2/3/4: Amount of fuel added/subtracted for

Fuel COR CYL 4 FUEL CORRECTION CYL 1/2/3/4: Amount of fuel added/subtracted for

TOTAL FUEL QTY Target fuel

PRESS Measured fuel PRESS Fuel pressure AD/C Press reg opng (MPROP) Meas TURBO PRESS Turbo PRESS TURBOCHARGING PRESSURE AD/C: Voltage reading at sensor

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ACCELERATOR POSITION 1 AD/C: Voltage reading of accelerator potentiometer channel 1

ACCELERATOR POSITION 2 AD/C: Voltage reading of accelerator potentiometer channel 2.

each injector to obtain the same performance from all cylinders and correct possible engine malfunctions.

each injector to obtain the same performance from all cylinders and correct possible engine malfunctions. TOTAL FUEL QTY: Total overall quantity of Diesel fuel injected

TARGET FUEL PRESSURE: This is the pressure calculated by the control unit and estimated to occur in the high pressure fuel circuit. MEASURED FUEL PRESSURE: This is the pressure reading taken in the high pressure fuel circuit. FUEL PRESSURE AD/C: Voltage reading at sensor output.

PRESS REG OPNG (MPROP): Opening rate of pressure regulator fitted on the high pressure pump at the low pressure circuit end MEASURED TURBOCHARGING PRESSURE: This is the pressure reading taken in the turbocharging circuit.

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AD/C output. Engine oil pressure Target air mass TARGET AIR MASS: Air quantity calculated by control unit according to

Measured air mass EGR control EGR valve opening Atmospheric pressure

Air Temp (air flow meter) Air Temp (Turbo)

Air Temp AD/C (Turbo)

Water temperature Water Temp AD/C WATER TEMPERATURE AD/C: Voltage reading at water temperature

Fuel temperature Fuel temperature AD/C Battery voltage BATTERY VOLTAGE: Power supply voltage fed to control unit Lambda sensor voltage Lambda oxygen conc

Vehicle speed

Preheat ECU Diag Fuel pump relay command

Fan speed Throttle SV opening Throttle state AC cut-in request AC relay command

AC PRESS

Brake pedal state

Brake contact 2

Clutch pedal

Water in diesel

filter

Cruise control

switch

Request from

Cruise lever

FUEL TEMPERATURE AD/C: Voltage reading at Diesel fuel temperature sensor output

LAMBDA OXYGEN CONC: Concentration rate . . of Lambda sensor, range is 0% to 21%.

sensor inputs. MEASURED AIR MASS: Quantity of air measured by air flow meter.

EGR VALVE OPENING: EGR valve opening rate dictated by ECU signal ATMOSPHERIC PRESSURE: Pressure reading taken by sensor housed inside control unit

AIR TEMP (AIR FLOW METER): Air temperature measurement taken by digital air flow meter

AIR TEMPERATURE (TURBO): Air temperature reading taken inside turbo sensor. AIR TEMPERATURE AD/C: Voltage reading at air temperature sensor output. WATER TEMPERATURE: Engine coolant temperature

sensor output FUEL TEMPERATURE: Fuel temperature inside Diesel fuel pump.

LAMBDA SENSOR VOLTAGE: Voltage at sensor expressed in milliVolts.

VEHICLE SPEED: Vehicle speed. PREHEATING CONTROL UNIT DIAG: 'ON' means that the glow plug preheating control unit has cut in

FUEL PUMP RELAY COMMAND: State of Diesel fuel low pressure pump relay command

THROTTLE SV OPENING: Opening rate of throttle in intake duct (5% = throttle wide open, 95% = throttle closed)

AC CUT-IN REQUEST: Request to switch on air condition compressor AC RELAY COMMAND: State of air conditioner relay command from

control unit.

BRAKE PEDAL STATE: Indicates whether brake pedal is 'Pressed or 'Released'. BRAKE CONTACT 2: Brake pedal position detected by secondary contact of brake pedal. CLUTCH PEDAL: Clutch pedal position.

CRUISE SWITCH: Possible states are 'On' and 'Off'; when set to 'On', it

automatically maintains the cruising speed set by the driver.

REQUEST FROM CRUISE LEVER: Request triggered by cruise lever (None, Cruise Resume Button (RCL), Set Cruise deceler (-),Set Cruise

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Target cruise speed Irrev. Cruise error state

Current gear CURRENT GEAR: Gear currently in use Fuel consumption FUEL CONSUMPTION: Fuel consumption expressed in L/100KM Fuel level indicator Gearbox type fitted

Injection control unit Engine start

Universal code

Max engine rpm Max rpm time counter Overrev events Programming sessions Speed limitation

Speed LIM function

Odometer Odo count last time prog

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deceler (+) TARGET CRUISE SPEED: Reference speed used by cruise control for vehicle cruising speed IRREV. CRUISE ERROR STATE: Covers all events leading to cruise control inhibition. To re-enable the cruise control, perform a 'Key Off' (STOP)-'Key On' (RUN) sequence and proceed to re-enable the cruise control.

FUEL LEVEL INDICATOR : Quantity of fuel in the tank.

GEARBOX TYPE FITTED: Type of gearbox used in the vehicle. A 'Not plausible' state indication may only occur when the engine control units of vehicles with different transmission types (manual/automatic) have been swapped INJECTION CONTROL UNIT: Indicates whether the injection control unit has been programmed

ENGINE START: Indicates whether the injection control unit enables engine starting UNIVERSAL CODE: Indicates whether the injection control unit is receiving a universal code from the Electronic Key Control Unit/Body Computer MAX ENGINE RPM: Maximum rpm reached by engine

MAX RPM TIME COUNTER: Indicates how long engine kept running at maximum rpm

OVERREV EVENTS: Indicates how many times the engine overrevved. PROGRAMMING SESSIONS: Indicates how many times the control

unit has been programmed. SPEED LIMITATION: Displays the vehicle speed limitation set in the

control unit. SPEED LIM FUNCTION: State 'LEARNT' indicates that proxi alignment was performed and the vehicle did not exceed the speed limit set in the Engine Control Unit. ODOMETER: Distance travelled by vehicle in km. ODOMETER COUNT LAST TIME PROGRAMMED: Odometer count when control unit was last programmed.

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3.3..2 Error Section

Errors are divided into the following classes: TRANSIENT: Error detected for a short time, namely too short to be classified as present INTERMITTENT: Error no longer detected by the control unit but stored in the error memory. PRESENT: Error is still detected by the control unit.

Pressing the 'Del. Errors' key deletes errors in the non-volatile memory.

In this system, the trouble code is displayed before the description in the ERROR environment.

P0016 - Timing/rpm synchronisation P0053 - Lambda sensor resistance P0090 - Fuel Press (regulator at HI press pump inlet) P0091 - Fuel Press (regulator at HI press pump inlet) P0092 - Fuel Press (regulator at HI press pump inlet) P0093 - Fuel Press (regulator at HI press pump inlet) P0094 - Fuel Press (regulator at HI press pump inlet) P0095 - Air Temp sensor (inside turbo) P0100 - Air flow meter

P0101 - Air flow meter signal P010F - Air mass/air flow meter mismatch P0110 - Air flow meter air temp signal P0111 - Air flow meter air temp signal P0115 - Water temperature sensor P0116 - Water temperature sensor P0120 - Accelerator pedal sensor 1 P0122 - Accelerator pedal connector P0130 - Lambda sensor electrical diagnosis P0135 - Lambda sensor electrical diagnosis P0168 - Limit for high fuel temp P0180 - Fuel temperature sensor P0190 - Fuel high pressure sensor

P0191 - Fuel pressure signal P0201 - Cylinder 1 injector P0202 - Cylinder 2 injector P0203 - Cylinder 3 injector P0204 - Cylinder 4 injector P0216 - Injection time P0219 - High engine rpm P0220 - Accelerator pedal sensor 2 P0230 - Fuel pump relay command P0234 - Turbocharging pressure P0235 - Turbocharging pressure sensor P0262 - Cylinder 1 injector P0265 - Cylinder 2 injector P0268 - Cylinder 3 injector

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P0271 - Cylinder 4 injector P0335 - Engine rpm sensor P0340 - Timing sensor P0380 - Preheating unit command P0401 - EGR valve P0402 - EGR valve P0403 - EGR valve P0480 - Fan 1 or PWM P0481 - Cooling fan command 2 P0482 - Cooling fan command 3 P0500 - Vehicle speed signal (CAN) P0504 - Brake switch P0520 - Oil pressure switch P0530 - Air conditioner pressure sensor P0560 - Battery voltage P0564 - Cruise control (irreversible cut-off) P0579 - Cruise cut-in commands P0601 - ECU faulty (EEPROM) P0606 - ECU faulty (Microprocessor) P060A - Monitoring interrupted during initialisation P060B - Adc control P0611 - Injection control P061B - ECU calibration P061C - Shut-off control P062D - ECU faulty (injector control) P062E - ECU faulty (injector control) P0638 - Throttle valve command P0641 - Sensor power supply 1 P0645 - AC relay command P0651 - Sensor power supply 2 P0683 - Preheating control unit (feedback) P0685 - Main relay P0697 - Sensor power supply 3 P0700 - Request to turn on MIL from AT P0704 - Clutch switch P0748 - Fuel Press reg (at HI press pump inlet) P1131 - Upstream Lambda 1 signal (plausibility) P1132 - Upstream Lambda 1 signal (plausibility)

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P1140 - Lambda sensor P1205 - Particulate filter P1206 - Particulate filter P1218 - ECU faulty (HW recovery) P1219 - Regeneration time too long P1301 - Injector registration P1605 - ECU faulty (HW CY310) P1606 - ECU faulty (communication) P1607 - Lambda sensor control circuit P1611 - Lambda sensor control circuit P1618 - ECU faulty (HW CY940) P1619 - ECU faulty (HW CY940) P1623 - ECU faulty (BUS com) P2084 - Temp snsr at particulate filter inlet P2085 - Temp snsr at particulate filter inlet P2135 - Accelerator pedal power (plausibility) P2146 - Group 1 injector command P2148 - Group 1 injector command P2149 - Group 2 injector command P2151 - Group 2 injector command P2226 - Atmospheric press sensor P2231 - Lambda sensor resistance P2243 - Lambda sensor electrical diagnosis P2264 - Water in fuel filter sensor P1304 - Speed limitation

P2299 - Accelerator brake plausibility P2452 - Differential pressure sensor P2453 - Differential pressure sensor signal P2455 - Differential pressure sensor P2505 - Key input 2626 - Lambda sensor electrical diagnosis P2A00 - Lambda sensor U1601 - C-CAN line error U1700 - CAN network (NCM - NBC) U1706 - CAN network (NCM - NFR) U1711 - CAN network (NCM - NCA) U0426 - Electronic key P0102 - Air flow meter adapt offset presetting P0103 - Air flow meter adapt offset P0104 - Air flow meter adapt offset (engine idling) P0105 - Air flow meter adapt offset (engine under loading) P011A - Water temperature sensor P0336 - Rpm sensor (phonic wheel) P250A - Engine oil level sensor P0089 - Fuel Press (regulator at HI press pump inlet) P1303 - Speed limitation

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3.3.3 Active diagnosis displayed with the examiner

DESCRIPTION HELP

CODE CARD START

If the key is turned to STOP, the Code Card starting

FUEL PUMP RELAY

EGR VALVE ACTUATION

FAN LOW SPEED ACTUATION

FAN HIGH SPEED ACTUATION

PREHEATING RELAY

AC RELAY ACTUATION

Lets you start the engine using the vehicle's Code Card in the event the Key or the Electronic Key Control Unit/Body computer (if fitted) is faulty.

procedure will have to be repeated The Diesel fuel pump is operated for a few seconds. You should hear a hissing sound coming from the fuel fittings.

You should hear a clicking sound from the valve

You should hear the fan running . The cooling fan is operated at high speed for a few seconds The relay should keep clicking for a few seconds

You should hear the compressor clutch engage repeatedly for about 10 seconds.

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FUEL PRESS REG (HIGH PRESS

PUMP INLET)

MALFUNCTION LAMP

ACTUATION

PREHEATING LAMP

ACTUATION

CRUISE LAMP

Operates the Diesel fuel pressure regulator several times NOTE: The Diesel fuel pressure regulator is installed on the high pressure pump (low pressure circuit end)

The lamp flashes for a few seconds WARNING: In vehicles equipped with Body Computer, lamp actuation command is sent to the Body Computer, that physically actuates the lamp. However, the lamp not turning on DOES NOT indicate a Body Computer malfunction.

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WATER TEMPERATURE LAMP

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The lamp flashes for a few seconds WARNING: In vehicles equipped with Body Computer, lamp actuation command is sent to the Body Computer, that physically actuates the lamp. However, the lamp not turning on DOES NOT indicate a Body Computer malfunction.

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WATER IN FUEL FILTER LAMP

OIL PRESSURE LAMP

ACTUATION

THROTTLE SOLENOID VALVE You should hear a clicking sound from the valve

TEACH-IN RESET

Check that the indicator light is flashing WARNING: In vehicles equipped with Body Computer, lamp actuation command is sent to the Body Computer, that physically actuates the lamp. However, the lamp not turning on DOES NOT indicate a Body Computer malfunction. Check that the indicator light is flashing WARNING: In vehicles equipped with Body Computer, lamp actuation command is sent to the Body Computer, that physically actuates the lamp. However, the lamp not turning on DOES NOT indicate a Body Computer malfunction.

This command resets the teach-in parameters (air conditioner and cruise control) stored in the control unit When the teach-in functions are reset, the state of parameters (available in the selection list) is updated as follows:

WARNING: Teach-in reset should only be used after swapping the ECUs of vehicles featuring different functions

3.3.4 Configurations displayed with the examiner

VIEW INJECTOR

CODES

WARNING: On 4-cylinder vehicles (1.9 engine), parameter 'CYL 5

This command lets you view the injector codes stored in the control unit

injector code' will read 'Not available'

- air conditioner presence is stored automatically

upon switch-on

- cruise control presence is stored automatically

upon switch-on

This command lets you store the code of a new injector into the control

unit

CYL 1…..4

REPLACEMENT

If you replaced an injector, you must perform the 'Injector registration' procedure, i.e. enter the code stamped on the magnet of the new injector

INJECTOR

REPLACEMENT (BANK)

This command lets you store the code of a new injector into the control unit

The 'Injector replacement (bank)' procedure must be used when you

replace all injectors.

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REPLACEMENT (ONLY

FOR VERSIONS WITH

REPLACEMENT (ONLY

FOR VERSIONS WITH

CONTROL UNIT REPLACEMENT

CONTROL UNIT AND

INJECTOR(S)

REPLACEMENT

RAIL PRESSURE

SENSOR

REPLACEMENT

RAIL PRESSURE

SENSOR AND

INJECTOR(S)

REPLACEMENT

LAMBDA SENSOR

LAMBDA SENSOR)

AIR FLOW METER

LAMBDA SENSOR)

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WARNING: This procedure should be carried out:

- when the control unit has been replaced This procedure is aimed at reducing engine noise and enhancing compliance with emission regulations. This command stores the injector codes (when the injectors were not replaced) into the control unit and resets the following parameters:

- Pilot injection fuel amount correction (to compensate for injector ageing)

- Main injection fuel amount correction (dependant on Lambda sensor reading) WARNING: This procedure should be carried out:

- when the control unit and one or more injectors have been replaced This procedure is aimed at reducing engine noise and enhancing compliance with emission regulations. This command stores the code of the new injector(s) into the control unit and resets the following parameters:

- Pilot injection fuel amount correction (to compensate for injector ageing)

- Main injection fuel amount correction (dependant on Lambda sensor reading) WARNING: This procedure should be carried out:

- when the rail pressure sensor has been replaced This procedure is aimed at reducing engine noise and enhancing compliance with emission regulations. This command resets the following parameters stored in the control unit:

- Pilot injection fuel amount correction (to compensate for injector ageing)

- Main injection fuel amount correction (dependant on Lambda sensor reading) WARNING: This procedure should be carried out:

- when the rail pressure sensor has been replaced This procedure is aimed at reducing engine noise and enhancing compliance with emission regulations. This command stores the code of the new injector(s) into the control unit and resets the following parameters:

- Pilot injection fuel amount correction (to compensate for injector ageing)

- Main injection fuel amount correction (dependant on Lambda sensor reading) WARNING: This procedure should be carried out:

- when the Lambda sensor has been replaced This procedure is aimed at enhancing compliance with emission regulations. This command resets all fuel correction values for the main injection stored in the control unit for the different Lambda sensor readings. WARNING: This procedure should be carried out:

- when the air flow meter has been replaced This procedure is aimed at enhancing compliance with emission regulations. This command resets all fuel correction values for the main injection stored in the control unit for the different Lambda sensor readings.

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3.4 PROCEDURES

3.4.1 Engine removed - removal of head/and cylinders and oil sump for inspection, includes placement on stand and removal

1. Disconnect the wiring connections of engine rpm sensor (1a), engine oil level sensor (1b) and alternator (1c).

2. Disconnect the wiring connections of electro-injectors (1a) and timing sensor (1b).

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4. Disconnect the wiring connections of throttle body actuator (1a) and fuel pressure sensor (1b).

5. Release wiring harness from its retainers and remove.

3. Disconnect the wiring connections of engine oil pressure sensor (1a), fuel pressure regulator (1b), air temperature / pressure sensor (1c), engine coolant temperature sensor (1d) and preheating glow plugs (1e).

6. Unscrew the retaining screws (1a), remove the clamp (1b), disconnect and remove the oil vapour recovery pipe (1c).

7. Unscrew the retaining screw (2a) and remove the engine oil dipstick (2b).

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8. Press the retaining clips (1a) in the

direction shown by the arrow and

disconnect the fuel recovery pipes (1b) from

the electro-injectors (1c).

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9. Detach the fuel recovery pipe (1) from

the fitting and remove it.

10 Loosen the retaining screws of the fuel

collector pipe and of the electro-injector

retaining brackets.

11. Unscrew the fittings on the fuel collector

pipe (1a) and on the electro-injectors (1b);

remove the fuel pipes (1c).

12. Install tool 99342153 (1a) and extract the electro-injectors (1b).

13. Unscrew the retaining screw of the fuel delivery pipe.

14. Unscrew fittings (2a) on the fuel collector pipe and (2b) on the high pressure pump and remove the fuel delivery pipe (2c).

15. Remove the screws (3a) and the fuel collector pipe (3b).

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16. Remove the screws (1a) and the retaining brackets (1b) of the electroinjectors (1c).

17. Use a suitable tool to unscrew and remove the engine oil filter (1).

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20. Unscrew the retaining screws of the retaining bracket for the fuel low pressure pipes.

21. Unscrew the retaining screws (2a), remove the spacers and the high pressure fuel pump (2b) along with the low pressure pipes (2c); collect the coupling (2d) and remove the seal (2e).

18. Unscrew the retaining screws (1a) and remove the water-oil heat exchanger (1b) along with its gasket.

19. Unscrew the retaining screw (1a) at the intake manifold end and the fitting (1b), and then remove the vacuum pipe (1c).

22. Unscrew the retaining screws (1a) and remove spacers (1b) and power steering pump (1c).

23. Collect the coupling (2a) and remove the seal (2b).

24. Unscrew the retaining screws (1a) and remove the guard (1b).

25. Unscrew the screws retaining EGR valve pipe to exhaust manifold.

26. Unscrew the retaining screw and loosen collar (3a), disconnect the pipe (3b) and collect the gasket.

27. Remove the clamp (4a) and disconnect the water pipe (4b).

28. Unscrew the retaining screws (5a) and remove the EGR heat exchanger (5b) along with valve and pipes.

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NOTE: Collect the gasket at the exhaust

manifold end.

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34. Unscrew the retaining screws (1a) and nuts (1b) and remove the upper timing cover (1c).

29. Unscrew the oil delivery fitting (delivery

from cylinder head to turbocharger).

30. Unscrew the oil return fitting (return

from crankcase to turbocharger).

31. Unscrew the retaining nuts and collect

the spacers.

32. Remove the exhaust manifold-and-

turbocharger assembly and collect the

gasket.

33. Unscrew the retaining screws (5a) and

remove the bracket (5b).

35. Work the automatic belt tensioner (1a) with a suitable key so as to slacken the auxiliary drive belt (1b) and remove the belt.

36. Fit tool 1.860.815.000 to the crankshaft (1).

37. Unscrew the retaining screw (2a) and remove the auxiliary drive belt pulley (2b).

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38. Unscrew the retaining screws (1a) and remove the oil vapour separator (1b).

39. Remove the circlip (2a) and extract the centrifugal filter (2b).

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42. Rotate the crankshaft and install the crankshaft timing tools 99360615 (1a) and the camshaft timing tool 99360614 (1b)

40. Unscrew the retaining screws (1a) and remove the lower timing cover (1b) along with its gasket.

41. Remove the front crankshaft oil seal.

43. Unscrew the retaining screws (1a) and remove water pump/rigid engine mount (1b).

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44. Unscrew the retaining screws (1a) and

remove the oil pump–vacuum pump

assembly (1b).

45. Remove the key (2).

46. Unscrew and remove the upper (1a)

and lower (1b) hydraulic chain tensioners.

47. Unscrew the retaining pin (2a) and

remove the lower (2b) and upper sliding

shoe (2c).

NOTE: The upper hydraulic chain tensioner

is equipped with a backstop and must be

replaced after each removal

Training Academy

50. Unscrew and remove the plug (1).

51. Unscrew the retaining screws (2a) and remove the fixed upper sliding shoe (2b).

52. Unscrew the retaining screws (1a) and remove the fixed sliding shoes (1b).

48. Unscrew the retaining screw (1a),

collect the washer (1b) and remove the

gear (1c).

49. Unscrew the retaining screw (2a),

collect the washer (2b) and remove gear

(2c) and upper timing chain (2d).

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53. Lock out rotation of the high pressure pump drive shaft (1) using a suitable key.

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56. Unscrew the retaining screws (1a) and remove the upper head section (1b).

54. Unscrew the retaining screw (1a) and separate the shaft along with the drive gear of the oil pump-vacuum pump assembly (1b) from the high pressure drive shaft (1c).

55. Remove gear (1b) and lower timing chain (1c) from the high pressure pump drive shaft (1a).

57. Remove the upper head gasket (1).

58. Unscrew the retaining screws (1a) and remove the cylinder head (1b).

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59. Remove the cylinder head gasket.

60. Unscrew the retaining screws (1a) and remove the engine oil suction funnel (1b).

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3.4.2

inspecting removed parts - Cylinder head and oil sump installation - Does not include procedures for cylinder head and auxiliary drive assembly

Engine - Reassembly. Washing and

1. Unscrew the retaining screw (1a) and remove the automatic tensioner (1b) of the auxiliary drive belt pulley.

2. Unscrew the screw (2a) and the retaining bolt (2b) and remove the alternator (2c).

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4. Unscrew the retaining screw (1a) and remove the rpm sensor (1b).

5. Unscrew and remove the engine oil level sensor (2).

3. Unscrew the retaining screws (1a) and remove the alternator / intermediate shaft mount (1b).

6. Remove the fuel high pressure pump drive shaft (1).

7. Unscrew the retaining nuts (2a) and remove the fuel high pressure pump mount (2b).

8. Secure tool 99360187 (1b) to the power steering pump mount (1c) to lock out rotation of the power steering drive shaft (1a).

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9. Unscrew the retaining screw (1a) and remove the power steering pump shaft gear (1b).

10. Unscrew the retaining screw and remove the tool you used to lock the power steering pump shaft.

11. Remove the power steering pump drive shaft (1).

12. Unscrew the retaining nuts (2a) and remove the power steering pump mount (2b).

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13. Rotate the crankshaft until bringing pistons no. 1 and 4 close to BDC.

14. Unscrew the retaining screws (1a) and remove the con rod caps (1b) of pistons 1 and 4 and their bearings.

15. Withdraw pistons no. 1 and 4 (2) along with the connecting rods and bearings.

- Follow the same procedure to remove pistons no. 2 and 3 and their con rod caps, connecting rods and con rod bearings.

NOTE: Mark connecting rods and con rod caps with the number of the cylinder they were removed from and their relative mounting positions; keep the con rod bearings in their housings. If reused, all components must be refitted in their original positions.

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16. Rotate the service stand.

17. Unscrew the screws retaining the rear engine mount (1) to the lower engine block.

18. Unscrew the nut retaining the rear engine mount (2) to the service stand.

19. Remove the rear engine mount (3).

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23. Unscrew the retaining screws (1a) and (1b) and remove the lower block.

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24. Remove the lower main bearings (1).

NOTE: Mark the main bearings with their mounting positions; if reused, all bearings

20. Unscrew the screws retaining the front engine mount (1) to the lower engine block.

21. Unscrew the nut (2) retaining the front engine mount to the service stand.

22. Remove the front engine mount (3).

must be refitted in their original positions.

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25. Remove the crankshaft (1) from the lower block. You will need a hydraulic hoist or an assistant.

26. Remove the upper main bearing (2) and the thrust half-rings.

27. Remove the upper main bearings (3).

NOTE: Mark the main bearings with their mounting positions; if reused, all bearings must be refitted in their original positions.

28. Unscrew the fittings (1a) and remove the piston cooling jets (1b).

- Remove the water/oil sealing plugs from the engine crankcase using suitable tools.

- Unscrew the retaining screws and remove the crankcase from the service stand.

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Installation

- Thoroughly clean all parts you have removed and inspect their condition.

- Fit the water/oil sealing plugs - smeared with LOCTITE 270 sealant - to the engine crankcase using suitable tools.

- Lubricate all mechanical mating parts with engine oil.

WARNING: On refitting, always renew the following components: snap rings and circlips, seals and gaskets, and the screws with the threads coated with sealant.

1. Inspect the head mating face of the cylinder assembly for distortion; you may use a calibrated ruler (1b) and a feeler gauge (1c) (remove the centring dowels (1a) first).

- If you find any distortion, grind the mating face.

NOTE: Before grinding the crankcase, make sure that piston height over cylinder barrel and the difference in height among the four pistons will not exceed the specified values after grinding.

Piston height over crankcase (mm): 0.3 ÷ 0.6 Difference in height over crankcase among the four pistons (mm) ≤ 0.15

Training Academy

2. Inspect the cylinders: check barrel surface for signs of seizure, scoring, oval and exceeding wear.

3. To check cylinder barrel inner diameter and measure oval, taper and wear, use a bore gauge (1) with a dial gauge you will have set to zero on the ring gauge of the cylinder barrel bore or on a micrometer.

4. Check the inside diameter of each individual cylinder at three different heights (1a), (1b) and (1c) on two planes at right angles to each other: one plane should be parallel to engine longitudinal axis (1d), the other should be at right angles to it (1e); the worst wear is normally found on the latter plane and in the first measurement.

- If you find any oval, taper or wear, bore/grind and plateau hone the barrels.

NOTE: When regrinding the cylinder barrels, ensure to obtain the specified fit and clearance to the replacement pistons; spare pistons come with a 0.4 mm oversize with respect to nominal value.

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- The figure below shows the planes and reference axes for bore diameter measurements.

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NOTE: Planes and reference axes are also shown in the figure above.

* Surface roughness parameters:

R1 = 4 ÷ 10 µm Rz = 3 ÷ 8 µm Ra = 0.3 ÷ 0.6 µm W1 < 2 µm

- Carefully check surface porosity after regrinding:

AREA B1= Area subjected to maximum mechanical stress (piston rings contact barrel), maximum porosity allowed: 2 noncontinuous items max. 0.5 x 0.5

AREA B2= Area where piston rings rub against barrel, maximum porosity allowed: 2 non-continuous items max. 1 x 0.8

1. Unscrew the retaining screws (1a) and remove the phonic wheel (1b).

2. Remove the timing drive gear (2b) from the crankshaft (2a) using a

- Check main journals and crank pins and grind them if you find any signs of seizure, scoring or exceeding oval.

suitable extractor.

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1. Before grinding the crank pins (1a), measure the main journals (1b) with a micrometer to determine to what diameter the crank pins should be ground.

Training Academy

- Measure crank pin and main journal oval.

Main journal oval (mm) 0.006

Crank pin oval (mm) 0.006

1. We recommend noting your measurements in a table as shown below:

- nominal diameter of main journals no. 1-23-4 (1a);

- nominal diameter of main journal no. 5 (1b);

- main journal diameter measurements (minmax) (1c);

- nominal diameter of crank pins (1d);

- crank pin diameter measurements (minmax) (1e).

Diameter of main journals

no. 1-2-3-4 (mm)

Diameter of main journal

no. 5 (mm)

Diameter of crank pins

(mm)

NOTE: Main journals and crank pins must always be ground to the same undersize class. Main journal or crank pin undersize must be marked on the side of the crank pin no. 1:

- Use letter M for undersize crank pins.

- Use letter B for undersize main journals.

- Use letters MB for undersize crank pins and main journals.

Main journal undersize (mm) 0,254 - 0,508

Crank pin undersize (mm) 0,254 - 0,508

76.182 ÷ 76.208

83.182 ÷ 83.208

64.015 ÷ 64.038

Flywheel mounting flange oval

(mm)

- Measure crank pin and main journal taper.

Main journal taper (mm)

Crank pin taper (mm)

Flywheel mounting flange

taper (mm)

- Check the parallelism of crank pin surfaces.

Crank pin parallelism 0.017

NOTE: If crankshaft journals need grinding, check the following tolerances after grinding.

1. Check that the crank pins (1a) and main journals (1b) are symmetrical with respect to the nominal position (1c) of the main journals.

Crank pin symmetry (deviation

from nominal position of main

journal) (mm)

Crank pin symmetry (distance

between centres allowed) (mm)

Crank pin symmetry (angle

allowed)

0.01

0.00 7

0.04

Max

0.35

104 ±

0.125

180° ±

15

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WARNING: Round off the edges of main journal and crank pin lubrication holes.

Training Academy

- Install the phonic wheel and tighten the

retaining screw to 1.5 daN m

1. Install the piston cooling jets (1a) and tighten the

fittings (1b) to 2.5 daN m.

- Grinding the crank pins and main journals to an undersize may damage the rolled areas of their side grooves. Turn and roll the grooves to the following specifications:

- Rolling force: main journal no. 1 925 ±25 daN, main journals no. 2-3-4-5 1850 ±50 daN, crank pins 1850 ±50 daN.

- Rolling turns: 3 approach turns, 12 rolling turns, 3 exit turns.

- Rolling speed: 56 rpm.

- Reduction of crank pin groove diameter after rolling:

0.15 ÷ 0.30 mm.

- Reduction of main journal grooves after rolling 0.15 ÷ 0.30 mm.

Relief radius for crank

pins and main journals

(mm)

,

- Heat the timing drive gear up to 180ºC for 15 minutes maximum and install it on the crankshaft.

- Wait for the timing drive gear to cool down and perform a slip strength test.

1.6 ÷ 1.7

1. Clean the upper main bearings (1a) and (1b) thoroughly and place them in their original positions in the crankcase.

NOTE: Replacement main bearings (1a) come with an undersize inner diameter.

Main bearing undersize (mm) 0.254 - 0.508

NOTE: The central main bearing (1b) has thrust rings.

NOTE: Do not attempt to adapt the bearings.

15.0

Slip strength testing of timing

drive gear on crankshaft

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1. Refit the crankshaft into place in the crankcase.

an assistant

You will need a hydraulic hoist or

.

Training Academy

1. Clean the lower main bearings (1a) thoroughly and place them in their original positions in the lower block (1b).

- Position the calibrated wire (filagage) to measure clearances between main bearings and main journals.

1. Install the lower block (1a) and tighten the retaining screws (1b) to the specified torque.

5.0 + 60° + 60°

2.6

Scre

w

Scre

w

Inside lower block

Outside lower block

- Unscrew the retaining screws and remove the lower block.

1. To determine the clearance between main bearing and main journal, compare the width of the squeezed calibrated wire at the position where it is thinnest with the scale included in the package. The marks on the calibrated scale indicate clearance (in millimetres). If clearance is not as specified, change the bearings and repeat the inspection.

Main bearings to main

journal clearance (mm)

1. Measure crankshaft end float using a dial gauge with a magnetic base (1a) positioned on the crankshaft (1b) as shown in the figure.

Crankshaft end float

(mm)

- If end float is greater than specified, change the thrust main bearings and check clearance between main journals and main bearings again. If end float is still outside the specified range, replace the crankshaft.

0.032 ÷ 0.102

0.060 ÷

0.310

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NOTE: The thrust rings are integral with the central main bearing. The bearing comes in one standard size

(including replacements)

central main

.

5.0 + 60° + 60°

Scre

w

Training Academy

Inside lower block

-

Clean the mating faces of crankcase and

lower block thoroughly

1. Apply LOCTITE 510 sealant to the crankcase as shown in the diagram, taking care to spread it evenly over the whole mating face.

NOTE: Install the lower block within 10 minutes of applying the sealant.

1. Install the lower block (1a) and tighten the retaining screws (1b) to the specified torque and in the specified order.

.

1. Tighten the outer retaining screws of the lower block to

2.6 daN m.

1. Install the rear engine mount and its centring pins.

2. Tighten the screws retaining the rear engine mount to the lower engine block to the specified torque.

3. Tighten the nut retaining the rear engine mount to the service stand.

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1. Install the front engine mount and its centring pins.

2. Tighten the screws retaining the front engine mount to the lower engine block to the specified torque.

3. Tighten the nut retaining the front engine mount to the service stand.

Training Academy

1. Using a piston ring compressor (1a), fit the connecting rod-and-piston assemblies (1b) into the cylinder barrels and ensure that:

• connecting rod number matches con rod cap number;

• piston ring end gaps are spaced 120° apart from one another;

• pistons are all the same weight;

• the symbol stamped on piston crown is

pointing to engine flywheel; or the recess in piston skirt is located at the position of the oil squirts.

- Install the con rod caps of pistons no. 1 and 4 in the same order noted during removal and install the retaining screw, but do not tighten yet.

- Follow the same procedure to install pistons no. 2 and 3 and their con rod caps, connecting rods and con rod bearings.

NOTE: If the con rod bearings do not need replacing, refit them in the same order and in their original positions noted during removal.

1. Remove the con rod cap and clean

- Lubricate pistons, circlips and the inner bore of the cylinder barrels properly.

- Rotate the crankshaft until bringing the crank pins of pistons no. 1 and 4 close to BDC.

crankshaft journal and con rod bearing thoroughly so as to remove any trace of oil.

2. Place a length of calibrated wire (2b) (filagage) on the crankshaft journal (2a).

- Fit the con rod cap and tighten the retaining

screws to 50 daN m + 70°.

- Repeat the procedure for the other con rod caps.

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Training Academy

- Unscrew the retaining screws and remove the con rod cap.

- To determine the clearance between con rod bearing and connecting rod, compare the width of the squeezed calibrated wire at the position where it is thinnest with the scale included in the package. The marks on the calibrated scale indicate clearance (in millimetres). Clearance should be 30.035 ÷ 0.08 mm; if clearance is not as specified, change the bearings and repeat the inspection.

- Repeat the procedure for the other con rod caps.

- Fit the con rod caps and install new

retaining screws; tighten to 5.0 daN m + 70°.

1. After installing the connecting rod-andpiston assemblies, check piston height over crankcase face (1a) with the pistons at TDC using a dial gauge with a magnetic base (1b).

Piston height over

crankcase (mm)

Difference in height

over crankcase among the four

pistons (mm)

0.3 ÷ 0.6

0.15

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1. Install the engine oil suction funnel (1a) with a new seal and tighten the retaining screws (1b) to

1.0 daN m.

Training Academy

1. Install the power steering pump mount (1a) and tighten the retaining nuts (1b) to

2.5 daN m.

2. Refit the power steering pump drive shaft

.

1. Install oil sump (1a), gasket (1b) and trim (1c).

2. Tighten the retaining screws to 2.5

daN m.

3. Tighten the oil drain plug to 5.0 ± 1 daN m

1. Lubricate new seals (1a) and (1b) with engine oil and fit them on the power steering pump mount (1c).

1. Insert tool 9936017 (1b) into to the power steering pump drive shaft (1a) to lock out shaft rotation and secure the tool to mount (1c) using the screws (1d).

1. Fit the gear (1a) to the power steering pump drive shaft (1b).

2. Install the retaining screw but do not tighten yet.

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1. Lubricate new seals (1a) and (1b) with engine oil and fit them on the high pressure pump mount (1c).

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1. Fit the shaft with drive gear (1a) on the high pressure pump shaft (1b) and tighten the retaining screw (1c).

1. Install the high pressure pump mount (1a) and tighten the retaining nuts (1b) to

2.5 daN m.

2. Refit the high pressure pump drive shaft.

1. Wrap a new chain (1a) around gears (1b), (1c) and (1d) and install the gear (1c) on the shaft (1e) so as to tension up portions A and B of the chain.

- Inspect the fixed sliding shoes and replace them if worn.

1. Position the fixed sliding shoe (1a) and

tighten the retaining screws (1b) to 2.5 daN m.

2. Position the fixed sliding shoe (2a) and

tighten the retaining screws (2b) to 2.5 daN m.

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- Ensure that the mating faces of cylinder head and crankcase are clean.

1. If you had removed the cylinder head centring dowels, refit them into place on the crankcase.

2. Position the cylinder head gasket with the work “ALTO” (UP) facing the cylinder head.

NOTE: Keep the head gasket sealed in its package until shortly before installation and avoid contact with dirt.

1. With the aid of an assistant, install the cylinder head.

2. Install the retaining screws but do not tighten yet.

1. Tighten the cylinder head retaining screws to the specified torque in 3 steps; follow the order shown in the figure and observe the following procedure:

1st STEP (torque)

Scre

13.0

Screw Cylinder head 7-

6.5

2nd STEP (angle)

Scre

90°

Cylinder head 1-

w

2-3-4-5-6 (1st

8-9-10 (1st step)

Cylinder head 1-

2-3-4-5-6 (2nd

step)

M15x1.5

L193

M12x1.5

L165

M15x1.5

L193

Training Academy

NOTE: Head gaskets come in one standard thickness.

Screw Cylinder head 7-

90°

3rd STEP (angle)

Scre

90°

Screw Cylinder head 7-

60°

2. - Tighten the cylinder head retaining screws on timing chain compartment side

to 2.5 daN m

1. If you had removed the upper head section centring dowels, refit them into place on the cylinder head.

2. Clean the hydraulic tappets (2a) thoroughly, lubricate them and install into the cylinder head (2b), making sure to fit the rocker arms (2c) in their correct positions on the valves.

8-9-10 (2nd step)

Cylinder head 1-

w

2-3-4-5-6 (3rd

8-9-10 (3rd step)

step)

M12x1.5

L165

M15x1.5

L193

M12x1.5

L165

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3. Install the upper head gasket.

1. Position the upper head section (1a) complete with the camshaft timing templates 99360614 (1b).

2. Tighten the retaining screws to

2.5 daN m.

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1. Wrap a new chain (1a) around gear (1b) and gear (1c).

NOTE: Install the gear so that when it engages the centring dowel on the intake camshaft, slots A are in the position shown in the figure.

NOTE: The portion of chain between the two gears must be taut.

2. Fit the washer (2a) and install the retaining screw (2b), but do not tighten yet.

1. Position the fixed upper sliding shoe (1a) and tighten the retaining screws (1b)

to 1.0 daN m.

2. Fit the plug into place with a new gasket and tighten to the specified torque.

1. Wrap the chain (1a) around gear (1b) and mount the gear on the exhaust camshaft.

2. Fit the washer (2a) and install the retaining screw (2b), but do not tighten yet.

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- Inspect the mobile sliding shoes and replace them if worn.

1. Position the mobile sliding shoes (1a)

and tighten the retaining pin (1b) to 4.0

daN m.

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1. Rotate the crankshaft into the appropriate position that will permit installation of the crankshaft timing tool 99360615 in the correct position.

1. Fit the lower hydraulic chain tensioner

into place and tighten to 5.0 daN m.

1. Tighten the screw retaining the gear to

power steering pump shaft to 13.0 daN m.

1. Fit a new upper hydraulic chain tensioner (with backstop) (1a) and tighten

to 5.0 daN m.

WARNING: Never reuse the upper hydraulic chain tensioner (with backstop). If the piston (1b) slips off the new chain tensioner accidentally, another new chain tensioner must be used.

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2. Insert a suitable screwdriver through the opening in the upper head section and push down on the mobile sliding shoe (2b) tab (2a) until pushing the piston (2c) of the upper hydraulic chain tensioner (2d) to end of travel position. Release the mobile sliding shoe (2b) and ensure that the piston (2c) pulls the chain (2e) taut as it slides out of its housing.

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1. Ensure that the portion of chain between the camshaft drive gears is taut.

2. Tighten the retaining screw of the

exhaust camshaft drive gear to 11.0 daN m.

3. Remove the camshaft timing tools

99360614.

1. Tighten the retaining screw of the

intake camshaft drive gear to 1.0 daN m.

1. Lock out rotation of the high pressure pump drive shaft using a suitable key.

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1. Ensure that the portion of chain (1a) between the high pressure pump drive gear (1b) and the power steering pump drive gear (1c) is taut.

2. Tighten the retaining screw of the shaft

with drive gear to 11.0 daN m.

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4. Remove the crankshaft timing tool

99360615.

1. Fit a new gasket to the upper timing cover.

2. Install the upper timing cover (2a) and tighten retaining screws (2b) and nuts

(2c) to 1.0 daN m.

3. If you had removed the timing sensor (3a), refit it and tighten the retaining

screw (3b) to 1.0 daN m.

1. Fit the coupling (1a) into the power steering pump drive gear (1b).

2. Position the oil pump–vacuum pump assembly (2a); use a new gasket (2b).

3. Tighten the retaining screws to 2.5

daN m.

- Unscrew the retaining screw and remove the tool 99360187 you used to lock the power steering pump shaft.

1. Fit the lower timing cover (1a) with a new gasket and install the retaining screws (1b), but do not tighten yet.

1. Clean the seat for the front crankshaft seal thoroughly.

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Fiat Ducato 2006 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual