Aftersales Training -

Participant's Workbook.
Diesel engine.

BMW Service
The information contained in this Workbook is intended solely for the participants of this
seminar run by BMW Aftersales Training.

Refer to the latest relevant BMW Service information for any changes/supplements to the
Technical Data.

Information status: December 2007

Contact: conceptinfo@bmw.de

© 2007 BMW AG
München, Germany
Reprints of this publication or its parts require the written approval of
BMW AG, München
VS-12 Aftersales Training
Participant's Workbook.
Diesel engine.
Notes on this Workbook

Symbols used
The following symbols are used in this Workbook to facilitate better
comprehension and to draw attention to important information.

3 contains information for better understanding of the described

systems and their functions.

1 identifies the end of a note.

Information status:
BMW vehicles conform to the highest safety and quality standards.
Changes in terms of environmental protection, customer benefits and
design render necessary continuous development of systems and
components. Consequently, this may result in deviations between this
Product Information and the vehicles available during the training course.
This documentation relates exclusively to left-hand drive vehicles with
European specifications. Some controls or components are in part
arranged differently in right-hand drive vehicles than shown on the
graphics in the Product Information. Further differences may arise as the
result of the equipment variants used in specific markets or countries.

Additional sources of information

Further information on the individual topics can be found in the following
sources of information:
- Product Information
- Owner's Handbook
- BMW diagnosis system
- Workshop systems documentation
- SBT BMW Service Technology
Contents.
Diesel engine.

Training 1
Information on how to use this workbook 1
Fuel-and-air mixing 2
Intake air and exhaust system 10
Fuel system 23
Engine electrics 37
Diagnostics 42
 9
Training.
Diesel engine.

Information on how to use this workbook

This workbook helps trainers and participants to achieve the learning objectives of this module.
The focal points of the basic modules are:
• the ability to process customer orders in a professional manner and with appreciation of the
process as a whole
• the building of specialist, diagnostics and repair competencies
• the development of a feeling of responsibility for continuously checking the quality of one's
own work and improving it.
The workbook offers a means of working independently through tasks similar to customer
orders. However, the workbook is also designed to lend support to, and provide a framework
for, tasks led by the trainer. Additionally, there is space to make your own notes and write down
important information.
Unlike the Basic Information document, which contains a great deal of background information,
the workbook is intended to record experiences and impressions from training.

1
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Fuel-and-air mixing
Diesel engines can be driven on various fuels.
• Diesel
• Bio-diesel
• SunDiesel = BtL fuel (biomass to liquid)
• Natural diesel = vegetable oil.
They have to be adapted for the type of fuel in
each case. This documentation exclusively
addresses diesel engines driven on diesel.
In a diesel engine, air is compressed and
injected directly into the combustion chamber
at the end of the compression stroke. "Internal
fuel/air mixing" occurs in which the injected
fuel is mixed with air and ignites as a result of
the high temperature caused by compression.
For this to occur, the injected fuel must be
supplied in the correct quantity and quality
(optimum atomized form). That is necessary in
order that the engine produces the required
power output and that complete combustion
takes place.

Chemical conditions
Chemical conditions include those chemical • Complete combustion
properties of the diesel fuel that have an effect
• Ignitability
on the combustion process.
• Flashpoint
• Density
• Sulphur.

These include:
Notes:

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1. Indicate the special characteristics and properties that you think belong to the
different chemical conditions listed.
Complete combustion:
4 Each fuel requires a specific amount of air to achieve complete combustion.
4 Diesel fuel consists of carbon atoms and hydrogen atoms that are converted into carbon
dioxide (CO2) and water (H2O) during combustion.
4 Optimum fuel combustion is achieved in the presence of an air surplus.
4 Diesel fuel evaporates at approximately 55 °C.
Ignitability:
4 Ignitability is a measure of when the fuel begins to evaporate.
4 The higher the cetane number, the more ignitable the fuel.
4 The lower the cetane number, the more ignitable the fuel.
Flashpoint:
4 The flashpoint is a measure of when the fuel spontaneously ignites.
4 Diesel fuel has a flashpoint above 55 °C.
Density:
4 The density of the fuel has a bearing on engine output.
4 Cold fuel has a lower density.
Sulphur:
4 The sulphur in the fuel reduces particle emissions.
4 A higher sulphur content in the fuel results in higher particle emission levels.
4 The sulphur content of the fuel is controlled by legislation.

Fuel-Air Ratio
The fuel-air ratio indicates the composition of Practical fuel-air ratio
the fuel-and-air mixture. It specifies how many
The practical fuel-air ratio indicates how many
parts of fuel are mixed with how many parts of
kg of air are actually supplied to the engine per
air.
kg of fuel.
The power output, fuel consumption and the
If the proportion of fuel is smaller, e.g. 1 : 13,
exhaust emissions all depend largely on the
there is a shortage of air. This is referred to as
fuel-air ratio. Complete combustion takes
a "rich" mixture.
place at a precisely defined calculated fuel-air
ratio, the theoretical fuel-air ratio.

Theoretical fuel-air ratio (stoichiometric

ratio)
This defines the air mass required for
complete combustion of 1 kg of fuel. That is
why it is also called the theoretical air
requirement. For diesel, the theoretical fuel-air
ratio is 1 : 14.5. That means that complete
combustion of 1 kg of diesel requires 14.5 kg
of air.

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Air ratio λ (lambda)

The air ratio λ is the ratio between the mass of air actually supplied and the theoretical air
requirement.

2. Construct the formula for calculating the air ratio.

Air ratio λ =

If the engine is supplied with precisely 14.5 kg of air, i.e. exactly the theoretical air requirement,
then λ = 1. That is demonstrated by the formula:

14.5 kg
λ= =1
14.5 kg

Now let's return to the earlier examples:

With a rich mixture of 1 : 13, i.e. 13 kg of air to 1 kg of diesel, the lambda value is as follows:

13.0 kg
λ= = 0.9
14.5 kg

With a lean mixture of 1 : 16, i.e. 16 kg of air per kg of diesel, the resulting lambda value is:

16.0 kg
λ= = 1.1
14.5 kg

3. Which statements are correct?

4 If the proportion of fuel is greater, e.g. 1 : 16, there is a surplus of air. The mixture is then
"lean".
4 A "rich" mixture is where the fuel is characterized by a surplus of air.
4 The practical fuel-air ratio indicates the actual air mass supplied.

4. Write the air ratio in the following table.

Air content Lambda

Air deficiency λ 1
Air surplus λ 1

Notes:

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Effect of air ratio

The air ratio has a direct effect on an engine's
power output/torque, its fuel consumption and
the composition of the exhaust.
The following graphics show the relationship
between λ, the exhaust gas recirculation rate
and the pollutant emissions.

1 - Exhaust gas recirculation rate and air ratio

Index Explanation
A Air ratio λ =
B Exhaust gas recirculation rate

2 - Exhaust gas recirculation rate and pollutant emissions

Index Explanation
A Pollutant emission
B Exhaust gas recirculation rate
CO Carbon monoxide
HC Hydrocarbon
NOx Nitrogen oxides

5. What information can you deduce from the graphs above?

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Operating conditions
Different engine operating conditions require Therefore, fuel-and-air mixing adjusts to the
certain mixture compositions (quality). particular operating conditions.

6. Name the various operating conditions and explain what needs to be taken into
consideration for each one of them.

Operating condition Particularities

Cold starting

Warming up

Medium power

Full power

Transition/acceleration

Idling

Overrunning

6
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Exhaust composition
The fuel-and-air mixture undergoes chemical
changes in the course of combustion. In the
process its composition is altered.
The following graphic shows the composition
of the exhaust gas of a diesel engine operated
on diesel fuel directly after combustion
(without exhaust re-treatment).

7. Assign the item numbers to the correct descriptions in the table.

Index Explanation Index Explanation

Carbon dioxide (CO2) Sulphur dioxide (SO2)
Nitrogen (N2) Oxygen (O2)
Water (H2O) Hydrocarbon (HC)
Particles Nitrogen oxides (NOx)
Carbon monoxide (CO)

Notes:

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8. What are the particularities of the listed constituent elements of the emissions?

Constituent element Particularities

of emissions

Nitrogen (N2)

Carbon dioxide (CO2)

Carbon monoxide (CO)

Sulphur dioxide (SO2)

Particles

Hydrocarbon (HC)

Nitrogen oxides (NOx)

Oxygen (O2)

8
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How mixture preparation works

At least three subsystems are essential to the
mixture preparation process:
• Air intake and exhaust system
• Fuel system
• Engine electronics.
With direct fuel injection, the fuel has to be
atomized in the correct amount and at the
right time and then injected into the
combustion chamber in the correct mixture
ratio.
The interaction of the three systems above is
designed to ensure that these conditions are
fulfilled

3 - Direct injection

9. What are the tasks of each of these systems?

System Tasks

Air intake and exhaust system

Fuel system

Fuel system

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Intake air and exhaust system

10. Assign the item numbers to the correct components.

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Index Explanation
Boost-pressure sensor
Diesel particulate filter (DPF)
Throttle valve
Intake silencer (air cleaner)
Centre silencer
EGR (exhaust gas recirculation) -
valve and distance sensor
Exhaust back pressure sensor
N47D20O0 engine
EGR bypass valve
Oxidation catalytic converter
Air intake system
The unfiltered air is referred to as raw air. The
intake air system is divided into an area in
which the air is not yet filtered, known as the
unfiltered air duct. Downstream of the filter
11. On the vehicle and dismantled engine, trace the route of the intake air from the
intake snorkel to the cylinder head. In the relevant order, note down the
components through which the intake air flows.
Index Explanation
Exhaust turbocharger with VNT
Charge-air temperature sensor
Exhaust temperature sensor
Digital Diesel Electronics (DDE)
Charge-air cooler
Hot-film air mass meter (HFM)
EGR cooler
Rear silencer
Oxygen sensor
element, the raw air is cleaned and is,
therefore, now referred to as purified air. From
the filter element onwards, the system is
called a purified air system.
11
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Intake silencer

12. What are the functions and tasks of the intake silencer?

13. Carry out a filter replacement on the vehicle and make notes detailing your
procedure.

Notes:

Exhaust turbocharger

14. What are the benefits of turbocharging?

4 Lower fuel consumption by comparison with a naturally aspirated engine of equivalent
capacity
4 The otherwise unused exhaust gas energy is used for turbocharging
4 The turbocharged engine consumes less fuel than an equally powerful naturally aspirated
engine
4 The exhaust turbocharger is subject to a replacement interval
4 The torque curve can be plotted more favourably
4 Engines can operate with a greater air surplus than a naturally aspirated engine
4 The exhaust turbocharger comprises a turbine and a compressor, both located on the one
shaft.

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15. Assign the item numbers to the correct components.

Index Explanation Index Explanation

16 Oil return flange Oil supply
Turbine wheel Impeller
Outlet to catalytic converter Compressor housing
8 Sealing plate Wastegate valve
Partial-vacuum canister Turbine housing
13 Piston ring seal 3 Heat shield
7 Safety plate Input from exhaust manifold
14 Main bearing 4 Bearing housing
Outlet to charge air cooler 15 Bearing bushing
Input from intake silencer

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Charge-air cooler

16. Why is a charge-air cooler used?

4 So that the engine is cooled by the intake air
4 Because air is heated both during compression and by the exhaust turbocharger
4 To increase the density of the intake air
4 Because it means the exhaust turbocharger does not have to work as hard
4 Because it means engine output can be increased.

Notes:

Throttle valve ensures that the elevated exhaust gas

temperatures required for diesel particle filter
A throttle valve is required in all diesel engines
regeneration are achieved.
equipped with a diesel particle filter. By
throttling the intake air, the throttle valve

17. What other tasks does the throttle valve have?

Notes:

14
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Intake manifold cylinders. In addition, the ducts to each

individual cylinder branch off further into swirl
The intake manifold is usually made of plastic.
ducts and tangential ducts.
Inside it, the air is branched off the individual

18. Remove the intake manifold in accordance with the Repair Instructions. Note
down your procedure (work sequence).

Notes:

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Swirl flaps Engine/s Electric Pneumatic

The swirl flap closes the tangential port in M67D44O1 X -
order to generate a stronger swirl of air via the
swirl port in the combustion chamber at lower M57D30T2 - X
engine speeds. With increasing engine speed, M57TU2 - X
they open to ensure cylinder charging through N47D20T0 X -
the tangential port.
N47 X -
The following table shows which type of
M47TU2 - X
actuation is used for the different engines.

19. Assign the item numbers to the correct components.

Index Explanation Index Explanation

Tangential port Swirl flap
Swirl port Exhaust duct

Notes:

16
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Exhaust system
The exhaust system takes care of removal of
the burned gases. It also incorporates exhaust
treatment systems that remove harmful
emissions from the exhaust. The type of
exhaust re-treatment depends on the engine
model.
One aim of the exhaust system is to reduce
flow resistance to a minimum so as to achieve
optimum engine performance.

20. On the vehicle and dismantled engine, trace the route of the exhaust gas from the
cylinder head to the tailpipe. In the relevant order, note down the components
through which the exhaust gas flows.

Notes:

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Exhaust gas recirculation

21. As you have surely noticed by now, there is another duct that branches off from
the exhaust manifold. This duct returns the exhaust gas to the intake air system.
What reason could there be for this?

Notes:

Oxidation catalytic converter The catalytic converter can reduce the

The purpose of exhaust cleaning is to reduce
the harmful constituents of the exhaust,
carbon monoxide (CO), hydrocarbons (HC)
and nitrogen oxide (NOx) to a statutory
minimum. CO, HC and NOx together make up
about 1 - 2 % of the total exhaust quantity. In
vehicles with a diesel engine, the oxidation
catalytic converter is used for this purpose.
exhaust components CO, HC and NOx.
The oxidation catalytic converter is encased in
a stainless steel housing and is firmly
embedded in a damping mat.
Index Explanation
1 Exhaust gas back-pressure
connection
2 Oxygen sensor
3 Exhaust temperature sensor
4 Exhaust temperature sensor
5 Oxidation catalytic converter
6 Diesel particle filter

4 - Catalytic converter and DPF with sensors in M67D44O1 engine

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The catalytic converter consists of three main

components:
• Ceramic substrate
• Intermediate layer
• Catalytically active layer
The ceramic substrate is made up of
thousands of tiny channels through which the
exhaust flows.

6 - Design of catalytic converter

5 - Ceramic substrate
Those channels are covered in an extremely
porous intermediate layer. It has the effect of
substantially increasing the surface area.
The intermediate layer carries the catalytically
active layer. The catalytically active layer
consists of platinum (Pt) and palladium (Pd).
Index Explanation
1 Ceramic substrate
2 Intermediate layer
3 Catalytically active layer
The name, oxidizing catalytic converter,
means that a conversion takes place in the
presence of oxygen. The catalytically active
layer makes those conversions possible.
The exhaust constituents remain for only a
very short time inside the catalytic converter.
But that time is long enough for the harmful
exhaust constituents to react with the surface
of the channels, the catalytically active layer.

22. Note down how the constituent elements of the exhaust gas are converted in the
oxidizing catalytic converter.

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Diesel particle filter the diesel particulate filter. These are closed at
their ends. Each inlet duct is surrounded by
The diesel particle filter is encased in a
four exhaust ducts.
stainless steel housing and is firmly
embedded in a damping mat.
The assembly of this diesel particle filter is
very similar to that of the oxidation catalytic
converter. A so-called monolith (ceramic
body) serves as a core.
Like the oxidation catalytic converter, the
diesel particle filter has many thousand
channels running through it, through which
the exhaust flows. The difference, however, is
that the walls are porous and allow gaseous
materials to flow through them.
As with the oxidation catalytic converter, the
surface is coated with the precious metals 8 - Cross section of the diesel particulate filter
platinum and palladium.
The soot particles deposit on the coating of
the inlet ducts and remain there until they are
combusted as a result of an increase in the
exhaust temperature. The cleaned exhaust
gas flows out of the exhaust ducts through the
coated, porous filter walls.
The soot particles that are deposited on the
filter walls would eventually cause damage to
the diesel particulate filter. The soot particles
therefore need to be burnt off. This happens
when the exhaust temperature rises above the
soot ignition temperature. This process is
known as filter regeneration. The carbon
particles are converted to gaseous carbon
7 - E60 diesel particle filter in M57TU2 TOP engine
dioxide (CO2).
The coating helps to achieve a reduction in the If the sulphur content in the diesel fuel is > 50
soot ignition temperature and thus to - 100 ppm, there is a possibility of heavy white
guarantee good regeneration characteristics smoke development and a sulphur odour from
of the diesel particulate filter. the exhaust tailpipe.
The exhaust gases flow out of the oxidation
catalytic converter and into the inlet ducts of

Notes:

20
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23. Note down how the constituent elements of the exhaust gas are converted in the
diesel particulate filter.

24. What is the effect on the diesel particulate filter if solid particles such as oil ash,
swarf and additive residues are allowed to enter it?

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Silencers distinguished by their position within the

exhaust system, i.e. forward, centre or rear
The purpose of silencers is to reduce the
silencer. Frequently, the catalytic converter
deafening noise of combustion to a
acts as the forward silencer.
comfortable level. Several silencers may be
used in combination. They are then

25. Note down the different silencing techniques that can be used in the exhaust
system.

Technique Function

Absorption

Reflection

Superposition

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Fuel system

Fuel supply system

Diesel fuel situations, paraffin separation may begin from
approximately 0 °C. For this reason, diesel
The engine generates the force to propel the
fuels are specially prepared for winter use and
vehicle from the energy stored in the fuel.
provided with flow improvers. This makes
Diesel alone is the fuel most commonly used
winter-grade diesel fuel cold-resistant to
for operating diesel engines in passenger
temperatures of at least -22 °C. Mixing
vehicles.
gasoline is no longer permissible in modern
Diesel is made up of a mixture of various engines, since this may damage the fuel
hydrocarbons (HC). system. Gasoline has very low cetane
numbers, which significantly downrates
Since diesel fuel deposits paraffin crystals at
ignitability.
low temperatures, this may cause
obstructions in the fuel filter. In unfavourable

26. What does the cetane number of a diesel fuel indicate?

4 Power density
4 Boiling point
4 Viscosity
4 Knock resistance
4 Ignitability
4 Density
4 Sulphur content.

27. On the vehicle and dismantled engine, trace the route of the fuel from the fuel
tank to the injectors. In the relevant order, note down the components through
which the fuel flows.

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Fuel tank The fuel tank is shaped to fit the bodywork so

as to save space. For safety reasons, it is
The fuel tanks in modern vehicles are made of
placed forward of the rear axle. This makes the
plastic.
risk of rupture in an accident relatively low.
Plastic tanks have the advantage of being
To a large extent, the fuel tank contains the
lighter, easier to manufacture in the required
fuel supply system.
shape and very safe in the event of an
accident.

28. Note down the various tasks of the fuel tank.

Notes:

24
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9 - E70 fuel tank with diesel engine

Index Explanation Index Explanation

A Fuel cap
B Pressure relief valve
C Non-return valve
D Surge chamber
E Fuel tank
F Service cap
G Lever-type sensor
H Filler breather valve
I Connection
J Maximum fill level
K Non-return valve
L Filter
1 Initial fill valve
2 Filter screen
3 Fuel pump
4 Pressure relief valve
5 Non-return valve
6 Feed line
7 Return line
8 Non-return valve
9 Suction jet pump
10 Run-out protection valve
11 Suction jet pump
12 Pressure limiting valve

29. Which components are responsible for tank venting?

25
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30. Explain the tasks of the following components:

Component Task

Initial fill valve

Suction jet pump

Pressure limiting valve

Run-out protection valve

Non-return valve

Pressure relief valve

26
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Surge chamber the tank is close to empty or when the vehicle

motion is causing the fuel to move around a lot
Inside the surge chamber is the electric fuel
inside the tank, the surge chamber ensures
pump (EKP) and a venturi pump. The surge
there are no air bubbles in the fuel delivered by
chamber is open at the top. It makes sure that
the pump.
the fuel pump is always immersed in fuel and
thus does not draw in any air. Especially when

31. Assign the item numbers to the correct components.

Index Explanation Index Explanation

Initial fill valve Suction jet pump
Surge chamber Fuel return
Pressure limiting valve

Notes:

27
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32. Makes notes about the various components in the surge chamber.

Initial fill valve Notes

Suction jet pump Notes

Pressure relief valve Notes

28
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Fuel conditioning system

The fuel conditioning system is the system
that delivers and meters the correct amount of
fuel for combustion.
The tasks include:
• Supplying the required pressure
• Injecting the required volume of fuel
(injection-rate control)
• Adjusting the required injection start
(injection start control).
In order to comply with the stricter emission
limits for diesel engines, modern fuel injection
systems use more precise injection and higher
pressures.
The Common Rail System perfectly fulfils
these requirements. With the Common Rail
System, the fuel in the rail is stored at high
pressure and injected into the combustion
chambers in a map-controlled manner.

Notes:

29
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33. Assign the item numbers to the correct components.

Index Explanation Index Explanation

Rail-pressure sensor High-pressure pump
Fuel return Fuel feed from the fuel tank
Leakage oil line High-pressure line from the high-
pressure pump to the rail
Rail-pressure regulating valve Solenoid valve injector
Fuel return to the tank Fuel feed (low pressure)
Rail (high-pressure accumulator) High-pressure line from the rail to
the injector
Fuel pressure temperature sensor Fuel high pressure
Volume control valve

34. Explain the tasks of the following components:

30
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Component Task

High-pressure pump

Volume control valve

Rail

Rail-pressure sensor

Rail-pressure regulating
valve

Fuel injector

31
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Fuel injector common rail system. The upper power class is

equipped with the piezo injectors that have
The injectors are high-precision components
been used in the M67TU/M57TU2 since
that are able to inject the finest and precisely
2005.
defined fuel volumes into the combustion
chamber at precisely determined times. The nozzle needles are opened hydraulically in
both types of injector. The piezo injector
Different injectors are used for the upper and
differs from the solenoid valve injector by how
lower power class. The lower power class
the switch valve that controls the hydraulics in
uses the solenoid valve injectors that have
the injector is activated.
been used since BMW introduced the

35. Remove an injector from the dismantled engine. Proceed in accordance with the
Repair Instructions.

Notes:

32
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Solenoid valve injector Index Explanation

8 Supply duct to the nozzle
9 Nozzle needle
10 Control chamber
11 Valve ball

Notes:

10 - Sectional view of the solenoid valve injector

Index Explanation
1 Fuel return
2 Electrical connection
3 High-pressure connection
4 Coil
5 Outlet restrictor
6 Inlet restrictor
7 Valve control piston

33
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Piezo injector

11 - Sectional view of the piezo injector

Index Explanation Index Explanation

1 Control chamber 5 Actor module
2 Piezo element 6 Coupler module
3 High-pressure supply 7 Switch valve
4 Fuel feed 8 Nozzle needle

34
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12 - Piezo injector closed 13 - Piezo injector, injection start

Index Explanation Notes:

1 Coupler module
2 Control valve
3 Bypass
4 Nozzle needle
5 Restrictor
6 Control volume
7 Outlet
8 Fuel feed

35
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Notes:

14 - Piezo injector, injection end

36. What is different about the fuel return line in an engine with piezo injectors by
comparison with an engine with solenoid valve injectors?

Notes:

36
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Engine electrics
37. Affix to the vehicle or dismantled engine sticky dots with numbers
corresponding to the following graphic. If you cannot reach a component
directly, affix the dot as close as possible to it. Refer to the BMW diagnostic
system if you need assistance.

Index Explanation Index Explanation

1 Digital Diesel Electronics (DDE) 12 Exhaust temperature sensor
2 Accelerator pedal module 13 Exhaust back pressure sensor
3 Crankshaft sensor 14 DDE main relay
4 Boost-pressure sensor 15 Fuel filter heater
5 Coolant temperature sensor 16 Actuator for exhaust turbocharger
6 Intake air temperature sensor 17 EPPC exhaust gas recirculation
(EGR)
7 Rail-pressure sensor 18 Electric change-over valve for swirl
flaps
8 Oxygen sensor 19 Rail-pressure regulating valve
9 Camshaft sensor 20 Volume control valve
10 Hot-film air mass meter 21 Fuel injectors
11 Throttle valve 22 Preheater control unit

37
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Sensors
38. Remove the sensors listed below from the dismantled engine. Using the BMW
diagnostic system, determine the functions of these sensors and note down
these functions on the worksheet.
Then refit the sensors.

Component Function

Accelerator pedal module

Crankshaft sensor

Boost-pressure sensor

Coolant temperature sensor

Intake air temperature sensor

38
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Component Function

Rail-pressure sensor

Oxygen sensor

Camshaft sensor

Hot-film air mass meter (HFM)

Intake-manifold pressure
sensor

Throttle valve sensor

39
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Notes:

40
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Actuators
39. Remove the actuators listed below from the dismantled engine. Using the BMW
diagnostic system, determine the functions of these actuators and note down
these functions on the worksheet.
Then refit the actuators.

Component Function

Throttle valve

Electropneumatic pressure
converter (EPDW)

Electric change-over valve

Volume control valve

Preheater control unit

41
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Diagnostics

Lighting of the emissions warning lamp

40. The emissions warning lamp lights up, but no faults can be detected on the
vehicle. Carry out diagnostics on the vehicle and find the cause.

In the process, note down:

• Each stage of your procedure
• The fault description in the fault code memory
• The individual stages in the test module
• The cause behind the emissions warning lamp lighting up.
Summarize your procedure on a flipchart.

Solution:

42
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Vehicle cannot be started

41. The vehicle cannot be started. Faults relating to the fuel supply are stored in the
fault code memory.

In the process, note down:

• Each stage of your procedure
• The fault description in the fault code memory
• The individual stages in the test module
• The cause behind the emissions warning lamp lighting up.
Summarize your procedure on a flipchart.

Solution:

43
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Vehicle cannot be started

42. The vehicle intermittently fails to start. Various faults are stored.

In the process, note down:

• Each stage of your procedure
• The fault description in the fault code memory
• The individual stages in the test module
• The cause behind the emissions warning lamp lighting up.
Summarize your procedure on a flipchart.

Solution:

44
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