Diesel Engine Repair Guide
Diesel Engine Repair Guide
                  Repair in Central
                      DIESEL
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                                  Mercedes Benz
                                     OM904
                                   System PLD
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                                  08-Transistor Main At the. 46N06        Circuit Common of Units Cylinders 1 and two
                                  (NPN)
                                  09-Transistor Main At the. 46N06        Circuit Common of Units Cylinders 3 and 4
                                  (NPN)
                                  10-Transistor Main At the. N439AC       Circuit Relay in Match
                                  11-Integrated Circuit At the. 29030     To convert A / D and Reverse in Signal From sensors in
                                                                          rotation and phase of the engine
                                  12-Integrated Circuit At the. XC9572    Main Manager gives Units Injection Molding, commands
                                                                          the action in each unity of system PLD
                                  14-Processor At the. SAK-C167CR-        Responsible per commend all system functions, well at
                                  LM                                      run calculations and operation fundamental
                                  15-SOIC Integrated Circuit 16 At the.   Decoder protocol Can have the occupation in send and
                                  B10011S                                 receive packages in Dice for Network Can
                                  16-Component At the. MPXA4115A          Sensor in pressure Atmospheric
                                                                                   Pin 2 Feed 24
                                                                                   volts
Pin 3 Grounding.
                                       With at information of pages previous on The description From pins From components watch
                                  with O oscilloscope at next shapes in waves below:
                                       With at information of pages previous on The description From pins From components watch
                                  with O oscilloscope at next shapes in waves below:
                             Component fundamental of printed circuit because It is he what feed The part logic of system. In
                           case in short circuit this component is susceptible The burn, for run O diagnosis feed The plate
                           using scheme electric and certify US next pins at feeds.
                                                                                                    Pin 4 Grounding
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                                    Very important circuit for system, because if not there is the occurrence of signal in rotation arriving at
                                  processor not there is operation. Possible defectsin that circuit can to be diagnosed with the use of
                                  oscilloscope. Below Follow O circuit of these sensors.
                                      One particularity of this circuit and the presence in rectifier diodes making A paper important at
                                  the treatment of that sign as well with oa presence of c.is with functions in converters A / D. See
                                  the pins Where you signals electrical if locate:
                                  Mercedes Benz
                                   OM906 / 457
                                   PLD System
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01
                                  19
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                                  04
                                                                           07
                                  03
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                                  05
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13
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17
                                              18         16   15   14
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                                  12-Integrated Circuit At the. XC9572   Main Manager gives Units Injection Molding, commands
                                                                         the action in each unity of system PLD
                                  13-Integrated Circuit At the. 29030    To convert A / D and Reverse in Signal From sensors in
                                                                         rotation and phase of the engine
                                  16-Processor At the. SAK-C167CR-       Responsible per commend all functions of the system,
                                  LM                                     well at run calculations and operation fundamental
                                  17-Component At the. MPXA4115A         Sensor in pressure Atmospheric
                                  18- SOIC Integrated Circuit 16 At      Decoder protocol Can have the occupation in send and
                                  the. B10011S                           receive packages in Dice for Network Can
                                  19- Filter At the. B82790              Filter in line gives Network Can
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                                                                                     Pin 2 Feed 24
                                                                                     volts
Pin 3 Grounding
                                  With at information of pages previous on The description From pins From components watch
                                  with O oscilloscope at next shapes in waves below:
                                       With at information of pages previous on The description From pins From components watch
                                  with O oscilloscope at next shapes in waves below:
                                     Component fundamental of printed circuit because It is he what feed The logical part of system.
                                  In case in short circuit this component it is susceptible The burn, for run O diagnosis feed The plate
                                   using scheme electric and certify US following pins at feeds.
                                    Very important circuit for system, because if not there is the occurrence of signal in rotation
                                  arriving at processor not there is operation. Possible defectsin that circuit can to be diagnosed with
                                  the use of oscilloscope. Below Follow O circuit of these sensors.
                                      A particularity of this circuit is the presence of rectifier diodes playing an important role in the
                                  treatment of this signal, as well as the presence of c.is with functions of A / D converters. See the
                                  pins where the electrical signals are located:
                                      Electric signals from this circuit are brief durations of 2 to 3 seconds, but they are fundamental
                                  for the starting release of this injection system. Observe the time base of the signals with the
                                  oscilloscope and check if they are plausible.
                                     In the Transistors highlighted, we find the signals that are from the starter relay system, in this
                                  case around 1.5 sec. of duration
                                  Mercedes Benz
                                     OM 457
                                   System MR
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13
                                  18
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                                  03
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11 10
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                                                                            1
                                                                            6
                                                   17        15   14
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                                  12-Integrated Circuit nº 1120 AMV   Main Manager of Injection Units, commands the action of
                                                                      each unit of the PLD system
                                  13-Integrated Circuit nº 1160D      A / D Converter and Signal Inverter for motor speed and
                                                                      phase sensors
                                  15-Processor No. SAK-XC2080         Responsible for managing all system functions, as well as
                                                                      performing fundamental calculations and operation
                                  16-Component No. MPXA4115A          Atmospheric pressure sensor
                                  17- SOIC Integrated Circuit 16 nº   Can protocol decoder has the function of sending and
                                  B10011S                             receiving data packets to Can Network
                                  18- Filter No. B82790               Can Network line filter
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                                                                               Pin 2 Power
                                                                               24 volts
                                       Transistor nº
                                    439AG with Source
                                    and Gate connected
                                    in short serves as
                                    protection against
                                    current return
                                                                Pin 2 switches negative
                                                                potential of IU 1, 2 and 3
Pin 3 Grounding
                                With at information of pages previous on The description From pins From components watch
                           with O oscilloscope at next shapes in waves below:
                                    Very important circuit for system, because if not there is the occurrence of signal in rotation
                                  arriving at processor not there is operation. Possible defectsin that circuit can be diagnosed with the
                                  use of oscilloscope. Below Follow O circuit of these sensors.
                                      One particularity of this circuit and the presence in rectifier diodes making A paper important at
                                  the treatment of that sign as well with oa presence of c.is with functions in converters A / D. See
                                  the pins Where you signals electrical if locate:
                                  Scania
                                  MS 6.2
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                                  09
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                                  2-Piezoelectric Crystal          Send a signal (clock) for what O processor start The operate, and
                                                                   it suits as a counter of processor for determined occupation
                                  3-Memory PSOP No.                Contains all at information in management of motor and all
                                  AM29F400BT                       strategies in operation.
                                  7-Integrated Circuit No. 30296   Interface of sensor in rotation, sensor in pressure and
                                                                   temperature of air and pressure of turbo
                                  8-Integrated Circuit No. 30377   Pedal of accelerator, light switch gives clutch
                                  16-Integrated Circuit nº         CAN protocol decoder, located on the back of the board
                                  3043322
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                                     They follow the same operating logic as the Mercedes, with the central unit being primarily
                                  responsible for the drive. The circuit of the injection units has an individual drive by cylinder, and a
                                  common switching for the six units of the system. Now see some particularities of the circuit.
                                     The electrical signals the U.I are all the same as those shown below, so in the diagnosis to be
                                  made, stick to this model presented
                                    In this circuit we observe the presence of diodes, resistors and a C.I (30296) acting as an analog to
                                  digital signal converter, this circuit is fundamental for the operation of the motor, so be aware of
                                  some characteristics of this circuit for later diagnostics.
Ford EDC 07
Cummins 4 and 6
Cylinders
                                  * Obs. : The difference between modules 4 and 6 cylinders is only in the programming of the
                                  Micro controller Flash.
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                                   03
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04 01
Nozzle B
                                                                                                      0
                             05                                                                       6
07
09
                           16                           Nozzle                       Nozzle A
                                                        C
                                       14
                                                         13             12
                                                   15              10              11
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                                  02-Integrated Circuit nº 30439   Responsible for activating the maintenance lamp, warning, stop
                                                                   start lamp and start lock relay, according to the pins:
                                  03-Integrated Circuit No.        Activates fuel heater and air inlet heater 1 by the following pins;
                                  BTS721L                          17-Air inlet heater 1 18-Fuel heater
                                  04-Integrated Circuit No.        Activates air inlet heater 2 and motor brake by pins:
                                  BTS721L                          14-Air inlet heater 2
                                                                   18-Signal output for motor brake valve
06-Line filter nº 70504 J1939 data link communication protocol line filter
03
04
01
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Injector Individual:
                                  An important detail is that in the visualization of the signals we realize that although different in their
                                  amplitude, the timing of the signals and their characteristics are identical
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                                     The electrical signals observed with the oscilloscope are very similar to those of other power
                                  stations, see how important these signals are.
                                      It has the characteristic of being mirrored in relation to each other and they work with a speed
                                  rate of 1,000 kbit / s, remembering that, as in the case of the CAN network, this protocol works with
                                  the sending and receiving of data packets with a priority identifier. , indicating the urgency of the
                                  signal, divide it into high traffic priority or low priority. Now see the electrical signal that this circuit
                                  contains.
                                  Volvo D12C
                                     TEA
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Components Overview
                                                     11                   09
                                                               10
                                        13
14
15
                                                                               08
                                                                07
                                  16                 12
                                                                               06
                                  17
                                                                               05
                                                          04         03   01
                                                02
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                                  2-Memory PLCC Am29F400          Contains all engine management information and operating
                                                                  strategies.
                                  3-Integrated Circuit No.        Oil temperature sensor interface (left), Air temperature sensor
                                  HC4951A                         interface (right)
                                  4-Integrated Circuit nº         Injection Unit Manager
                                  G1020KF9
                                  5-Component No. SPXS 4010A      Atmospheric pressure sensor
                                                                                                                       Página | 76
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                                  Volvo D12D
                                    TEA v.2
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Components Overview
                                                      13               12        11
                                              16
                                                             1
                                                             5
17
18
10
                                                                 14                         0
                                  19                                                        9
                                                                            08
                                  20
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                                  05
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                                              04                      01
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                                  4-Integrated Circuit nº
                                  G1020KF9
                                     This circuit is also similar to the other circuits of other diesel injection systems where we have
                                  one transistor switching three IUs at a time.
As is typical of the common circuits of the units, we will have characteristic signals.
                                     VW
                                   EDC 16C8
                                    System
                                  Common Rail
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Components Overview
                                            01
                                                        02
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05
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                                                              0
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                                      09         08
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Components Overview
04 05 06
01
                                                                         07
                                                  03           02
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                                  3-Integrated Circuit nº 30505   Discharge Injector Manager (CRIN), responsible for the
                                                                  activation of the injectors by the following pins:
Common Injectors
6-Integrated Circuit nº 30618 Operates on the fuel pressure valve and turbo control actuator
                                  7-Integrated Circuit nº 30616   Activates main relay, feed pump relay, rotation interface and
                                                                  voltage regulator.
                                                                  Rotation sensor analog signal input pin 2 and digital output pin
                                                                  26.
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                                      We noticed in this circuit as well as others the presence of resistors and diodes because the
                                  characteristic signal of this system is analog and alternating, because of this present in this circuit
                                  there is also an integrated circuit with its own functions of a digital analog converter.
No difference with respect to the EDC 07 system, observe the electrical signals.
                                     Ford
                                  Siemens SID
                                   901 System
                                    Common
                                      Rail
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                                        01
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Roteiro de diagnóstico
                                      To make an accurate diagnosis at the Centers as well as in any job, it is important to follow
                                  some work routines and execute them to be successful. We will now observe some work routines
                                  based on symptoms claimed by customers and what procedure is important to do in order to obtain
                                  an eventual repair diagnosis of the ECU.
                                              3-Power supply for logic part (processor, memories, C.I) 4-Broken track
                                              5- Oxidized terminal
                                              6- Rotation sensor circuit 7-Grounding
                                              8- Cold weld
                                              9- Corrupt injection file 10-Processor
                                              11-Crystal
5-Cold welding
                                              SENSOR FAILURE
                                              1-Broken trail
2-Filter capacitor
Initials Meaning
Initials Meaning
                                  IGN Ignition
                                  IMMO Immobilizer System
                                  INJ Injector Fuel
                                  KS Knock Sensor
                                  LSFC Low Speed Fan Control
                                  LTFT LONG TIME FUEL TRIM
                                  MAF Mass Air Flow
                                  MAP Manifold Absolute Pressure
                                  MPFI Multipoint Fuel Injection
                                  NOx Nitrogen Oxide
                                  NTC Negative Temperature Coeficient
                                  OCT Octane Adjust
                                  PAT Pressure and Air Temperature
                                  PATS Passive Anti-Thieft System
                                  PCM Powertrain Control Module
                                  PIP Profile Ignition Pickup
                                  PWM Pulse Wave Modulation
                                  PWR Power Relay
                                  RAM Random Acess Memory
                                  ROM Read Only Memory
                                  RSH Rollen Shepp Hebel
                                  SPOUT Spark Output Signal
                                  STFT Short Time Fuel Trim
                                  TDC Top Dead Center
                                  TFI Tick Film Ignition Top-Feed
                                  TPS Throttle Position Sensor
                                  TWC Three Way Catalytic Converter
                                  VAF Vane Air Flow
                                  VSS Vehicle Speed Sensor
                                  WAC Wide Open Throttle Air Conditioner
                                  WOT Wide Open Throttle