Textron Motors 408014 Diagnostic Manual Download

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Textr

n Motors GmbH

Zepernicker Chaussee 23-37
16321 Bernau bei Berlin
Germany
www.weber-motor.com

Textron Motors GmbH strives to make continual improvements as part of the ongoing technical development

of its products. All documentation is therefore subject to technical modifications.
Reprints and translations, in whole or in part, require written permission from Textron Motors GmbH.
All rights reserved according to the copyright law.

Summary of Contents for 408014

Page 1: ...846 MAR TC 120 408090 I2 846 MAR TC 155 408246 I2 846 MAR NA 80 This diagnostic manual is valid for the following engine models en_English DIAGNOSTIC MANUAL 4 Stroke Engine Read the introductory chap...

Page 2: ......

Page 3: ...H strives to make continual improvements as part of the ongoing technical development of its products All documentation is therefore subject to technical modifications Reprints and translations in who...

Page 4: ...light MIL 12 4 4 Temperature warning light 12 5 Troubleshooting with trouble codes 13 5 1 Displaying trouble codes 13 5 1 1 Displaying trouble codes with Textron Motors Diagnostic Tool 13 5 1 2 Displa...

Page 5: ...5 DHB MPE850 MAR Rev B 408014 408090 408101 408246 7 Wiring diagram 46 8 Components overview 47 Appendix 59 Overview of revisions 59 Index 60...

Page 6: ...words Item Meaning NOTICE The signal word NOTICE indicates potential property damage Information The signal word Information indicates specific features and recommendations 1 2 Change management Textr...

Page 7: ...t trained personnel have read and understand all introductory chapters and in particular the chapter on safety Observe all generally applicable laws and regulations in addition to the information in t...

Page 8: ...components in your engine have been carefully tested and fulfill strict quality and safety requirements Textron Motors offers spare parts to the highest quality Ensure that equivalent spare parts cor...

Page 9: ...ed engine fluids immediately Fuel is highly flammable Vapors may ignite and cause an explosion Do not smoke in the vicinity of the engine and do not allow open flames or sparks near the engine or the...

Page 10: ...case Figure Description Textron Motors diagnostic interface module Diagnostic cable Figure Description USB cable Data on USB flash drive Textron Motors Diagnostic Software english Manual german and e...

Page 11: ...ng light Illuminates until the required oil pressure is achieved Illuminates while the engine is running NOTICE Oil pressure too low Serious engine damage due to insufficient lubrication Switch off th...

Page 12: ...indicator light MIL and wiring See the vehicle manufacturer s documentation Flashes when the ignition is on and the engine is running Emission related malfunction There is at least one trouble code sa...

Page 13: ...e diagnostic connector is integrated in the wire harness and closed with an orange cap Diagnostic connector 1 Notice Wire harness damage due to corrosion Always close the diagnostic connector with the...

Page 14: ...isplayed corresponding the following flow diagram Ignition ON Light testing Start of the 1st flash code sequence 1st flash code 132 13 times long illuminating corresponds to 13 2 times short illuminat...

Page 15: ...sh code Trouble code 41 P0118 42 P0117 43 P0116 44 P0113 45 P0112 46 P0114 47 P2123 48 P2122 49 P2128 50 P2127 51 P061B 52 P0132 53 P0131 54 P0130 55 P0152 56 P0151 57 P0150 58 P0123 59 P0122 60 P0223...

Page 16: ...h code Trouble code 154 P0136 155 P0158 156 P0157 157 P0156 158 P0038 159 P0037 160 P0036 161 P0058 162 P0057 163 P0056 164 P2261 165 P2262 166 P0546 167 P0545 168 P0172 169 P0171 170 P0175 171 P0174...

Page 17: ...crankshaft and sensor camshaft are not synchronous Rough engine running Engine does not start or stalls Sensor crankshaft Check wiring in the wire harness to the affected part See chapter 7 Wiring di...

Page 18: ...en circuit at part or wire harness Loss of power Rough engine running Sensor lambda 2 Check wiring in the wire harness to the affected part See chapter 7 Wiring diagram Replace the affected part See t...

Page 19: ...repair or cleaning of the throttle body may endanger the safety of persons Always replace a defective throttle body Corrosion or soiling in the throttle body can cause the fault Check the throttle bod...

Page 20: ...manifold pressure temperature Check wiring in the wire harness to the affected part See chapter 7 Wiring diagram Replace the affected part See the repair manual P0116 Engine Coolant Temperature Circui...

Page 21: ...he wire harness to the affected part See chapter 7 Wiring diagram Replace the affected part See the repair manual P0128 Coolant Thermostat Coolant Temperature Below Thermostat Regulating Temperature C...

Page 22: ...ve caused by aging Replace the affected part See the repair manual P0136 O2 Sensor Circuit Bank 1 Sensor 2 Open circuit at part or wire harness Loss of power Rough engine running Sensor lambda 2 Check...

Page 23: ...ual P0172 System Too Rich Bank 1 Fueling too rich The lambda control works outside of permissible limits Loss of power Rough engine running The engine stalls Sensor lambda 1 A too high fuel pressure c...

Page 24: ...eck the thermostat See chapter 6 Test procedures at engine P0222 Throttle Pedal Position Sensor Switch B Circuit Low Open circuit or short circuit to ground at part or wire harness Unusual or no throt...

Page 25: ...ge Performance Open circuit at part or wire harness Loss of power Valve boost pressure control Check wiring in the wire harness to the affected part See chapter 7 Wiring diagram Replace the affected p...

Page 26: ...ine does not start or stalls Relay fuel pump Check wiring in the wire harness to the affected part See chapter 7 Wiring diagram Replace the affected part See the repair manual Check the fuel pump and...

Page 27: ...ring diagram Replace the affected part See the repair manual P0265 Cylinder 2 Injector Circuit High Short circuit to plus at part or wire harness Engine does not start Rough engine running Injector 2n...

Page 28: ...Check if the affected part is unusually dirty Check the cam spike at rocker arm See chapter 6 Test procedures at engine Check wiring in the wire harness to the affected part See chapter 7 Wiring diag...

Page 29: ...ing diagram Replace the affected part See the repair manual P0373 Timing Reference High Resolution Signal A Intermittent Erratic Pulses Erratic signal at the sensor crankshaft Engine does not start Se...

Page 30: ...See chapter 7 Wiring diagram Replace the affected part See the repair manual P0617 Starter Relay Circuit High Short circuit to plus at part or wire harness The engine does not crank Relay starter Che...

Page 31: ...rness to the affected part See chapter 7 Wiring diagram Replace the affected part See the repair manual P063A Auto Configuration Throttle Input Adaptation condition exceeded Throttle body Check wiring...

Page 32: ...e Input Upper position is not reached Throttle body Check wiring in the wire harness to the affected part See chapter 7 Wiring diagram Replace the affected part See the repair manual P0641 Sensor Refe...

Page 33: ...utside from 5 V 1 V 5 V power supply from engine control unit Check the connected parts and wiring See the vehicle manufacturer s documentation Replace the engine control unit See the repair manual P0...

Page 34: ...e the affected part See the repair manual P0686 ECM PCM Power Relay Control Circuit Low Short circuit to ground at part or wire harness The engine cranks but does not start Relay main Check wiring in...

Page 35: ...repair manual P2103 Throttle Actuator Control Motor Circuit High Short circuit to plus at part or wire harness Unusual or no throttle response Throttle body Check wiring in the wire harness to the aff...

Page 36: ...rt See chapter 7 Wiring diagram Replace the affected part See the repair manual P211A Throttle Actuator Control Throttle Body Range ERROR Throttle body Subsequent fault to throttle body sensor faults...

Page 37: ...art See chapter 7 Wiring diagram Replace the affected part See the vehicle manufacturer s documentation P2135 Throttle Pedal Position Sensor Switch A B Voltage Correlation Implausible values of the se...

Page 38: ...es at the valve boost pressure control can cause the fault Check the hoses P2301 Ignition Coil A Primary Control Circuit High Short circuit to plus at part or wire harness Rough engine running Engine...

Page 39: ...meter 8 mm black wires Check all electrical contacts for corrosion and proper mechanical connection Make a diode test with all relevant wires Diode test with multimeter Cross checking Diode tester pro...

Page 40: ...electrical contacts for corrosion and proper mechanical connection Make a continuity test with all relevant wires Continuity test with multimeter GX1 Engine ground A B C GX1 A d d B d C d Continuity...

Page 41: ...ngine 6 3 Checking crankshaft reluctor 6 3 Checking crankshaft reluctor Crankshaft reluctor 1 Gap 2 missing teeth 2 Marking for valve timing 3 Perform a visual inspection of the crankshaft reluctor If...

Page 42: ...ng thermostat Information The thermostat is fitted with a wax element Opening temperature from 82 C 179 F The thermostat is fully open at 88 C 190 F Thermostat closed 1 Thermostat opened 2 Perform a v...

Page 43: ...6 1 1 6 Test procedures at engine 6 5 Checking cam spike at rocker arm 6 5 Checking cam spike at rocker arm Cam spike at rocker arm 1 Perform a visual inspection of the cam spike at rocker arm If mech...

Page 44: ...run the engine at idle Measure oil pressure with oil pressure tester according to the manufacturer s instructions Required oil pressure while idle Minimum 1 5 bar Maximum 5 5 bar 0 5 bar Increase eng...

Page 45: ...l Oil pressure too low no Replace the oil pressure valve yes Oil pressure valve always opened See the repair manual no Replace the oil pressure pump yes The oil pressure pump is defective Clean the lu...

Page 46: ...BN BKBN BKWT 64P P4 64P F3 64P H2 BKBL Roll Over Signal nc nc Power Limit SW nc Roll Over 5V nc nc Sport SW Neutral SW Roll Over SGND nc nc CAN High CAN Low Oil Pressure Warning Light nc RDBK 64P E4...

Page 47: ...H E A B C F D G H E J K L O M P Q N A1 64P A1 32P 1 2 3 4 4 3 2 1 8 Components overview 8 Components overview Engine models I2 846 MAR TC 80 TC 100 und TC 120 A1 Engine control unit 1 Engine model I2...

Page 48: ...8 Components overview Engine models I2 846 MAR NA 80 A1 Engine control unit 3 Connector pin assignment The catalyzer housing and exhaust cooler are not shown in the figure B1 Switch oil pressure 4 At...

Page 49: ...intake manifold pressure temperature 6 B4 Sensor intercooler pressure 5 Engine model I2 846 MAR NA 80 B3 Sensor intake manifold pressure temperature 9 Connector pin assignment Engine model I2 846 MAR...

Page 50: ...gine bracket is not shown in the figure B5 Sensor crankshaft 10 Connector pin assignment B6 Sensor lambda 1 12 Or the sensor lambda 1 is installed behind the exhaust manifold B7 Sensor lambda 2 11 Con...

Page 51: ...is not shown in the figure B9 Sensor coolant temperature 14 Connector pin assignment 8 Components overview Hoses are not shown in the figure Connector pin assignment Engine models I2 846 MAR TC 80 TC...

Page 52: ...F3 F4 F1 X2 F2 17 2 1 8 Components overview Included in fuse box X2 F1 Fuse FUEL fuel pump F2 Fuse SERVICE F3 Fuse IGK terminal 30 key switch F4 Fuse VBR terminal 30 after relay main F5 Fuse VBD term...

Page 53: ...4 408090 408101 408246 18 B C A 19 20 F5 K2 K1 F3 F4 F1 X2 F2 8 Components overview G1 Generator 18 Connector pin assignment stator Stator 19 Rotor 20 Included in fuse box X2 K1 Relay MAIN relay main...

Page 54: ...1 1 2 4a 3 15 8 Components overview The intake manifold is not shown in the figure K3 Relay starter 23 Starter cable at relay starter 21 M1 Starter 22 N1 Voltage regulator 24 Connector pin assignment...

Page 55: ...2 3 6 7 5 8 9 14 15 20 21 26 27 32 34 35 28 27 8 Components overview Engine models I2 846 MAR TC 80 TC 100 und TC 120 X1 Vehicle connector Engine Chassis 27 Connector pin assignment Engine model I2 84...

Page 56: ...2 3 6 7 5 8 9 14 15 20 21 26 27 32 34 35 29 Engine models I2 846 MAR TC 80 TC 100 und TC 120 X2 Fuse box 30 X3 Connection engine ground 31 Connector pin assignment Engine model I2 846 MAR TC 155 X1 V...

Page 57: ...7 6 5 4 3 2 1 A B C D F5 F K2 K1 F3 F4 F1 K2 35 34 33 32 8 Components overview Connector pin assignment Engine model I2 846 MAR NA 80 X2 Fuse box 34 X3 Connection engine ground 35 Engine model I2 846...

Page 58: ...3 37 36 A B 8 Components overview Connector pin assignment Engine models I2 846 MAR TC 80 TC 100 TC 120 TC 155 Y3 Valve boost pressure control 38 Connector pin assignment Y4 Throttle body 39 Y1 Inject...

Page 59: ...B 408014 408090 408101 408246 Appendix Overview of revisions Overview of revisions Revision Date Chapter Description Note Rev 1 0 10 01 2014 1st edition diagnostic manual Rev B 06 07 2015 Engine model...

Page 60: ...nts overview 53 Relay starter components overview 54 Rotor components overview 53 S Sensor camshaft components overview 50 Sensor coolant temperature components overview 51 Sensor crankshaft component...

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