Testing the electronic diesel system (EDS) - ra07016021128x(1120)
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Engine 602.96, 603.96 TURBO - H. Engine 603.971 - Model 140 (USA) model year 1992 - a.-b. Tests, c. Trouble-shooting, d.-f. Test programs, g. Test key-operated engine-stop
Preceding work:
Operation no. of operation texts and work units or standard texts and flat rates: 07-1120
- Engine 602.96, Model 201
Federal Model Year 1987
- Engine 603.96, Models 124 and 126
- Engine 603.96,
Model 124 Model Year 1988
- Engines 602.96 and 603.96, Models 124 and 201
- Engines 602.96 and 603.96
Model Year 1990 and
Model Year 1991
- Engines 602.962 and 603.970,
- Engines 602.96 and 603.96, Models 124 and 201 Basic Version Code 62/0,
- Engine 603.971, Model 140
Test conditions
- Coolant temperature approx. 80 °C
- Air conditioner: OFF
- Selector lever position "P"
- Fuse at overvoltage protection relay or base module (engine 603.971) in order
- Battery voltage approx. 12 volts at overvoltage protection between contacts 1 and 5 or engine 603.971 battery voltage approx. 12 V at EDS control unit between contact 1 and contact 14.
Note engine 603.971
Before reading the stored faults by means of the pulse output, the battery must on no account be disconnected, base module and EDS control unit (N39) must on no account be unplugged.
Special tools
COMMERCIALLY AVAILABLE TOOLS
| Designation | e. g. make, order no. |
|---|---|
| Multimeter | Sun, DMM-5 |
| Digital testers | Sun, EMT-1019/Master 3 Sun, DIT 9000, DMA1000 Sun, MEA 1500 All-Test, 3610-MB Hermann 421, MO941, D960 Bosch, MOT 002.01, MOT 103, 301/401 |
| Y distributor | 117 078 01 45 |
| Lambda control tester | Bosch KDJE-P600 Hermann L 115 |
Test cable shop-made
Test cable (X11)
Pin assignment of test socket
SCOPE OF PARTS
| Position | Designation | Part no. | Quantity/dimension |
|---|---|---|---|
| 1 | Test socket | 123 545 00 26 | 1 |
| 2 | Jacks | 001 545 28 26 | 3 |
| - | Cable | Commercial | Length as per drawing |
| 3 | Terminal, red | Commercial | 1 |
| 4 | Terminal, black | Commercial | 1 |
| 5 | Connector | Commercial | Ø 4.8 mm |
| 6 | Connector | Commercial | Ø 4 mm |
H. Engine 603.971, Model 140 Model Year 1992
- Short-test
- Testing with pulse counter
- Troubleshooting schedule
- Test program with contact box
- Test program for components not covered with pulse output
- Function test ELR, ARF, P2 control
- Testing key-operated engine stop
- Short-test
Digital tester (001) and pulse counter (021) connect, disconnect. Pulse counter (013) connect with adapter (075) to test coupling (X11/4), disconnect. Contact box (004) with test cable (002) connect to EDS control unit (N39), disconnect. Digital multimeter (003) connect to contact box (004), disconnect. Vacuum tester (019) connect with Y distributor to ARF valve or to boost pressure control vacuum unit, disconnect. Fuse at overvoltage protection (K1/1) check. Selector lever move into position "P". Air conditioner/automatic climate control switch off. Engine warm up to operating temperature (coolant temperature approx. 80 °C) Fuse of base module check (read pulse output base module contact 8), see Diagnosis Manual Chassis Volume 1. NOTE: Before reading the stored faults via the pulse output, the battery must on no account be disconnected, base module and EDS control unit (N39) must on no account be unplugged.Start button of pulse counter (013) press for 2-4 seconds. Display read and note. Start button once again press. If no new display appears, no further fault in system. The number which appears in the display of the pulse readout indicates whether and which component is faulty or whether components in the control loop are faulty. See fault table C). - Testing with pulse counter
Connection diagram
Contact assignment of pulse counter adapter
- Ground, terminal 31
- Terminal 87
- Terminal 30
- EDS pulse readout
Notes regarding pulse readout
If a complaint is received but no fault is displayed via the pulse readout, perform the function test, "E".
The figure 1 indicates no fault detected in the electronic system. All further figures are assigned to a particular component/fault group.
The figures from 1 to 15 appear in the display field of the pulse counter.
If the U-Batt LED lights up after connecting the pulse counter, pulse counter and pulse counter power supply are in order.
- Connect pulse counter as stated in the connection diagram.NOTE: The U-Batt LED in the display field must light up; if not:
- Check fuse of pulse counter.
- Test contact 1 of test coupling (X11/4) to battery positive (11-14 V).
- Test contact 4 of test coupling (X11/4) to contact 1 (6-12 V).
- Engine idling.
If the fault counter is read with the pulse counter with ignition "ON" , the pulse readout "7" (engine speed sensor) appears.
- Press start button for between 2 and 4 seconds.
- Read off pulse output and note.
Readout "1" = no fault stored.
Greater than "1" = fault in system.
- Fault table
- 5. Once again press start button for between 2 and 4 seconds. The previous figure re-appears if no further fault is stored in the system. If a further fault is present in the system, its fault code is displayed.
- 6. Repeat this procedure until the first fault is again displayed.
- 7. Rectify noted faults (pulse readout) according to troubleshooting schedule.
- 8. Perform components test.
Erasing fault memory
After a fault has been erased, the pulse displayed must be erased as follows:
- 9. Press start button and read the rectified fault, then press start button for 6-8 seconds.NOTE: Each fault displayed must be erased individually .
Once the fault has been rectified and erased, the fault code no longer appears in the fault output.
If a figure greater than 1 is displayed, further fault in the system.
The figure in the display field of the pulse readout indicates whether and which component is faulty or whether components in the control loop are faulty.
Pulse readout Component/fault loop 1(1) All functions "in order" 2 Control rod travel sensor (L7) 3 Air flow sensor potentiometer (B2/1) 4 EDS control unit (N39), altitude sensor 5 Vacuum transducer (Y31/1), switchover valve (Y31/6) or fault in exhaust control loop (4) 6 EDS control unit (N39), internal power supply 7 Engine speed sensor (L3) (is not stored) 8 Coolant temperature sensor (B11/4) 9 Intake air temperature sensor (B2/1a) 10 Power supply 11(3) ELR actuator (2), vacuum transducer (Y31/1), vacuum transducer (Y31/4) or boost pressure cutoff switchover valve (Y31/6) 12 not assigned 13 EDS control unit (N39) faulty (internal memory) 14 EDS pressure sensor (B5/1) faulty (electric) 15 Fault in boost pressure control circuit (overpressure) (1) If complaints received, perform function test ELR, ARF, P2 control or "test program for components not covered with pulse output". (2) Fault is not stored, readout if short-circuit and open circuit. (3) Readout only if open circuit. (4) Readout if interruption in pneumatic supply, e. g. vacuum line faulty. - Test program with contact box
Connection diagram of contact box
SYMBOLS FOR TEST INSTRUMENTSContact box Multimeter Contact Pin Voltage measurement (volts, DC voltage) Resistance measurement (ohms) Test program
Contact assignment of plug connection, air flow sensor potentiometer (B2/1)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
- Test program for components not covered with pulse output COOLANT AND INTAKE AIR TEMPERATURE SENSORS
Temperature in °C Resistance (± 10 %) Voltage in V (± 10 %) 20 2.5 kΩ 3.85 30 1.7 kΩ 3.47 40 1.18 kΩ 3.05 50 833Ω 2.63 60 600Ω 2.22 70 440Ω 1.85 80 327Ω 1.5 90 243Ω 1.22 100 185Ω 0.99 - Function test ELR, ARF, P2 control NOTE: This test should only be performed if a complaint is received but no fault is indicated with the pulse readout.
Test step/test scope Test instrument/test connection Operation/requirement Specification Possible cause/remedy 1.0 Idle speed control Tachometer with TDC sensor Engine idling Coolant temperature approx. 80 °C 610 rpm ± 20 Actuator, injection pump, engine speed sensor (L3), EDS control unit (N39), see test steps 7 and 11 Connector unplugged from actuator 560 rpm ± 40 Set speed at injection pump. Injection pump 2.0 Exhaust control loop Connect vacuum tester with Y distributor to ARF valve Engine at 900 rpm ± 50 and > 300 mbar Briefly full throttle Vacuum drops Perform mechanical test of vacuum transducer (Y31/1), air flow sensor (B2/1).
EDS control unit (N39) ARF valve3.0 ARF valve Connect vacuum tester directly to ARF valve Engine off Pressurize ARF valve with 300 mbar Detach vacuum line ARF valve closes audibly Replace ARF valve 4.0 Boost pressure control Connect vacuum tester (020) with Y distributor to outlet (OUT) of vacuum transducer (Y31/4). Engine idling >300 mbar Vacuum supply
Vacuum line
Vacuum transducer (Y31/4)
EDS control unit (N39)Boost pressure control valve vacuum unit Slowly increase engine speed to approx. 2000 rpm Vacuum drops - Testing key-operated engine stop
Test step/test scope Test instrument/test connection Operation/requirement Specification Possible cause/remedy 1.0 Key-operated engine stop Connect vacuum tester with Y distributor to Stop vacuum unit Engine idling
Stop engine0 mbar
5-6 sec.
> 300 mbarKey-operated engine stop relay Key-operated engine stop switchover valve Vacuum lines Stop vacuum unit Fuses 17, 24 faulty 2.0 Key-operated engine stop relay 2-pin coupling at switchover valve (Y9/1) Connect multimeter in parallel Engine idling
Stop engine>12 V for 5-6 sec. Fuses 17, 24 faulty Key-operated engine stop relay (N17/3) faulty 3.0 Key-operated engine stop switchover valve Connect vacuum tester with Y distributor to connection 2 of switchover valve (Y9/1) Engine idling >500 mbar Vacuum pump Supply line colour: tr