WORKSHOP MANUAL Citea SLF / SLFA FPT E6 EBS1-C Main group 2

Transcription

1 WORKSHOP MANUAL Main group 1733

2 Foreword This workshop manual contains all the relevant information to help when tracing and solving technical problems, when making adjustments and when carrying out repair work. The book contains diagrams, system descriptions, fault finding instructions and work instructions. It also contains safety regulations, which must be strictly observed. Experienced mechanics The technical information and the explanations of the repair work stated in this workshop manual have been compiled with the utmost care. Whilst compiling this workshop manual, it has been assumed that the mechanic has the necessary experience and has had the required education or training to be able to carry out the work in a responsible and safe manner. Vehicle type The information in this manual has been updated until the time of printing and only concerns the following vehicle series: - Citea SLF FPT E6 - Citea SLFA FPT E6 - Citea SLFA FPT E6 - Citea SLFA FPT E6 - Citea SLFA FPT E6 In this manual, this series of vehicles is referred to as: "". The letter A in the type indication stands for "articulated". The letters FPT indicate that this manual relates to the 9 litre Cursor engine from FPT Industrial. E6 indicates that this manual contains guidelines for the engines which meet the Euro 6 emission requirements. EBS1-C indicates that this vehicle series has a 1st generation EBS brake system.

3 CONTENTS Technical information Engine - general information Identification Explanation of the definitions Engine Specifications and adjustment information Engine tightening torques... - Battery terminal clamp tightening torques Engine filling volumes Belt tension Cooling system General information Filling quantities Tightening torques Lubrication system General information Tightening torques Other technical information Sump filling unit (optional) General information Air conditioning compressor Component overview Special tools Diagnosis Engine general information Engine error codes Engine functions fault finding tables Cooling system Fault finding tables Exhaust gas after-treatment system Hydraulic fan - tracing faults Hydraulic pump fault finding tables Hydraulic oil fault finding tables Hydraulic motor fault finding tables Electrical fault finding tables Engine Safety regulations General information Location of the components Identification Component description Inspection and adjustment Engine poly V-belts: inspecting (Poly) V-belts: inspection points (Automatic) belt tensioner: inspecting Engine rubbers and engine brackets: inspecting Coolant heating element: inspecting Removal and installation Battery terminal clamps: removing and installing...4- Drive unit: removing and installing Hydraulic pump: removing and installing Coolant heating element: removing and installing Engine poly V-belts: removing and installing rd generator: removing and installing Vibration dampers: removing and installing Cleaning Engine: cleaning Cooling system Safety regulations General information...-1 Description of the cooling system...-1 Component description Expansion tank Cooling system pressure cap...3- Coolant level sensor Thermostat Cooling unit Inspection and adjustment Coolant level: checking and topping up...4- Cooling system: checking for leaks and damage Coolant hoses: inspecting Coolant: checking the specific density Thermostat: inspecting Removal and installation Expansion tank: removing and installing...5- Cooling unit: removing and installing Coolant hoses: removing and installing Coolant level sensor: installing Draining and filling the cooling system Cooling system: draining Cooling system: filling and bleeding the entire system Cooling system: filling and bleeding (only the engine) Cleaning Cooling system: cleaning (rinsing)

4 CONTENTS Hydraulic fan drive Hydraulic fan drive Sump filling unit Safety regulations General information General information Overview diagram of the sump filling unit... - Operation of the sump filling unit System description Electrical circuit diagram Function diagrams Oil level sensor Inspection and adjustment Sump filling unit: inspecting Sump filling unit oil level: checking Air conditioning compressor drive Safety regulations General information Inspection and adjustment...-1 Air conditioning compressor: inspecting...-1 Air conditioning compressor poly V-belt: inspecting...- Removal and installation Air conditioning compressor poly V-belt: removing and installing Air conditioning compressor service workshop manual Valeo TM Valeo TM Valeo TM55/ Heating Safety regulations General information Disassembly and assembly Safety during maintenance work Inspection and maintenance General information...-1 Location of the components...- Component description...-4 Preheater

5 Disclaimer 1733 VDL Bus & Coach bv, Valkenswaard, The Netherlands. In the interest of continuous product development VDL Bus & Coach reserves the right to change specifications, products or documents at any time without prior notice. For the most recent version of this document, consult the VDL Bus & Coach Documentation Portal. No part of this publication may be reproduced and/or published by printing, by photocopying, in digital format or in any way whatsoever without the prior consent in writing of VDL Bus & Coach. This manual shall be governed by and applied in accordance with the laws of the Netherlands. Any dispute here under shall be referred to the decision of the District Court of s-hertogenbosch in the Netherlands Next remark is relevant if the text has been translated for your convenience from the English original into an other language. A translation, however, can have the consequence that differences of interpretation arise with respect to the content and meaning of the text. In all cases, therefore, the English version of this document will be regarded exclusively as the single and authentic source to establish the content and the meaning of the text in case of a dispute. - 3

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7 TECHNICAL INFORMATION TECHNICAL INFORMATION 0

8 TECHNICAL INFORMATION 0

9 TECHNICAL INFORMATION Engine - general information 1. ENGINE - GENERAL INFORMATION 1.1 IDENTIFICATION 0 Engine identification by means of the engine number See -. Identification ( -3) for the engine identification plate. ILAz04 The engine number is located in two places on the engine: 1. On the engine identification plate, which is fitted on the engine s cylinder head cover. ILAz05. On the engine number plate on the right-hand side of the engine. ILAz06 1-1

10 TECHNICAL INFORMATION Engine - general information 0 1. EXPLANATION OF THE DEFINITIONS COLD engine An engine which has cooled down for at least six hours after having been at the operating temperature. WARM engine An engine which has stood still for no more than thirty minutes after having been at the operating temperature. Engine s direction of rotation The engine s direction of rotation is anticlockwise, as viewed from the flywheel side of the engine. Engine s first cylinder The engine s first cylinder is the cylinder located on the engine s vibration damper. Left-hand and right-hand side of the engine The right-hand side of the engine is the side where the electronic unit is located. The left-hand side of the engine is the side where the turbo compressor and the oil filter are located. 1 -

11 TECHNICAL INFORMATION Engine. ENGINE.1 SPECIFICATIONS AND ADJUSTMENT INFORMATION ENGINE Manufacturer FPT Type Cursor 9-310/360 Location Vertically behind the rear axle Construction method 4-stroke diesel engine, direct injection, 6 cylinders in line, turbo and intercooler. Number of valves 4 Bore x stroke 117 x 135 Cylinder volume 8.7 litres Compression ratio 15.9:1 Max. power 8 kw (310 hp) at,00 rpm 65 kw (360 hp) at,00 rpm Unloaded engine speed Approx. 550 rpm Max. loaded engine speed,00 rpm Max. torque Cursor 9-310: Cursor 9-360: Speed limiter Emission Euro 6 Weight 910 ± 5 kg 1,300 Nm between 1,100-1,675 rpm 1,600 Nm between 1,100-1,675 rpm Via EDC engine management.1. VALVE CLEARANCE Valve clearance Valve clearance (cold 1 / warm ) Inlet Outlet 0.40 mm 0.40 mm 1. Cold: an engine which has cooled down for at least six hours after having been at the operating temperature.. Hot: an engine which has stood still for no more than thirty minutes after having been at the operating temperature. - 1

12 TECHNICAL INFORMATION Engine 0. ENGINE TIGHTENING TORQUES Air compressor Attachment bolts (1) M1 x ± 5 Nm Nut () M18 x ± 10 Nm Valve mechanism Cylinder head cover attachment bolts Cylinder head cover top cover attachment bolts Valve adjustment bolt lock nut Sump ventilation filter (blow-by filter) Sump ventilation centrifugal filter cover Sump ventilation centrifugal filter attachment bolts a. Lock with Loctite 43. Hydraulic pump Hydraulic pump nut (3) PTO adaptor (5) attachment bolts (8) 3 Nm 9 Nm 39 Nm 9 ± 1 Nm 10 ± a Nm 65 ± 5 Nm 0 ± Nm ILAj301 ILAj1411 Coolant heating element Tightening torque Max. 110 Nm Screw thread: M4 x 1.5 -

13 TECHNICAL INFORMATION Engine Water pump/generator poly V-belt For the tightening torques and technical information, see DD1030_xx on the VDL Bus & Coach Documentation Portal. 0 Air conditioning compressor drive Pulley (A) attachment bolts Belt tensioner attachment bolt (B) Air conditioning bracket attachment bolt (C) See DD1030_xx on the VDL Bus & Coach Documentation Portal. M10 45 Nm M M ± 4 Nm 110 ± 8 Nm ILAj1714-3

14 TECHNICAL INFORMATION Engine 0 3rd generator (optional) 1 Attachment bolts (M8 x 1.5 x 30) 1-5 Nm Attachment bolt (M14 x x 40) Nm a Attachment bolt (M14 x x 40) (alternative) Nm 3 Guide roller attachment bolt (M10 x 1.5 x 70) Nm 4 Lower bracket attachment bolts (M10 x 30) Nm 5 Upper bracket attachment bolts (M8 x 35) 1-5 Nm 6 V-belt tensioner attachment bolt (M10 x 1.5 x 80) Nm 7 V-belt tensioner attachment bolt (M8 x 1.5 x 55) 1-5 Nm 8 Generator to upper bracket attachment bolt (M10 x 45) Nm 9 Generator to lower bracket attachment bolt (M1 x 160) 7-88 Nm ILAj115-4

15 TECHNICAL INFORMATION Engine Chassis-side/engine-side engine bracket 0 ILAj1119-5

16 TECHNICAL INFORMATION Engine 0 Engine bracket on same side as engine A Hexagonal bolt for the vibration damper to the engine bracket M ± 30 Nm B Flange bolt for the engine bracket to the flywheel housing M ± 0 Nm C Hexagonal bolt for the vibration damper to the engine bracket M ± 30 Nm D Flange bolt for the engine bracket to the flywheel housing M ± 0 Nm E Flange bolt for the vibration damper to the chassis M ± 15 Nm F Vibration damper to engine bracket flange bolt M ± 15 Nm G Flange bolt for the engine bracket to the engine block M ± 15 Nm H Cylinder head bolt for the engine bracket to the engine block M ± 13 Nm I Flange bolt for the vibration damper to the chassis bracket M ± 15 Nm J Flange bolt for the vibration damper to the chassis bracket M ± 15 Nm K Flange bolt for the engine bracket to the end beam M ± 15 Nm ILAj110 B Flange bolt for the engine bracket to the flywheel housing M ± 0 Nm D Flange bolt for the engine bracket to the flywheel housing M ± 0 Nm G Flange bolt for the engine bracket to the engine block M ± 15 Nm H Cylinder head bolt for the engine bracket to the engine block M ± 13 Nm - 6

17 TECHNICAL INFORMATION Engine.3 BATTERY TERMINAL CLAMP TIGHTENING TORQUES 0 A Battery terminal clamp + a : 1 ± Nm B Battery terminal clamp + a 40 ± 4 Nm C Battery terminal clamp - a 1 ± Nm D Battery terminal clamp - a 30 ± 4 Nm a. To prevent corrosion, lubricate the outside of the connections with acid-free Vaseline. ILAh ENGINE FILLING VOLUMES Lubrication system Total engine volume (including the engine oil filter and the oil cooler) Oil sump volume at the minimum level Oil sump volume at the maximum level Approx. 7.5 litres Approx litres Approx. 5 litres.5 BELT TENSION The belts of the water pump, generators and the air conditioning compressor drive are tensioned by automatic belt tensioners. Therefore, it does not need to be adjusted. - 7

18 TECHNICAL INFORMATION Engine 0-8

19 TECHNICAL INFORMATION Cooling system 3. COOLING SYSTEM 3.1 GENERAL INFORMATION 0 Thermostat Thermostat opening temperature - Thermostat opens at: 85 ± 1.5 C - Thermostat stroke 9 mm at 95 C Expansion tank pressure cap Opening pressure of pressure relief valve Opening pressure of vacuum valve Pressure testing the cooling system Pressurization pressure bar. 0.1 bar bar. Cooling system cleaning agent Cleaner RP VDL Bus & Coach no Coolant level sensor Resistance R1 = 100 Ohm R = 51 Ohm Daily inspection S Alarm S1 The sensor can be checked by disconnecting the connector and measuring the resistance (see the table below). ILAj1395 Level Nominal resistance Measured resistance Consequence Normal 151 W W LED in the fuel cowl is lit Low 100 W W LED in the fuel cowl is not lit + Symbol on instrument panel is lit Too low 0 W < 85 W Symbol on instrument panel is lit Sensor error > 470 W Symbol on instrument panel flashes 3-1

20 TECHNICAL INFORMATION Cooling system 0 3. FILLING QUANTITIES Cooling system Engine block cooling system Total cooling system (excluding heating) Total cooling system (including heating) Coolant tank Difference between min. and max. levels Approx. 15 litres Approx. 40 litres Approx. 60 litres 4. litres 3.3 TIGHTENING TORQUES Coolant level sensor Level sensor 10 Nm 3 -

21 TECHNICAL INFORMATION Lubrication system 4. LUBRICATION SYSTEM 4.1 GENERAL INFORMATION 0 Oil filter Type Disposable filter Quantity 1 Position in the oil circuit Full flow Oil level sensor (minimum) Manufacturer Type Supply voltage Function inspection Error message time delay Tightening torque Bedia CLS , 4 V, EVZ sec. MVZ 7 sec. 4 V ± 5% sec. after the contact switch has been turned on 7 ± 5% sec. after the contact switch has been turned on 5 Nm 1 Positive (+) Min (-) 3 Signal (S) ILAh0906 Filling quantities Engine lubrication system Sump volume, minimum level Sump volume, maximum level 13.4 litres 5.0 litres 4-1

22 TECHNICAL INFORMATION Lubrication system 0 4. TIGHTENING TORQUES Oil filter element screw cap Oil filter screw cap plug Engine sump oil drain plug (1) (standard) 60 Nm 30 Nm 40 Nm ILAj117 Femco engine sump oil drain plug () (optional) 40 Nm ILAj OTHER TECHNICAL INFORMATION For further technical information concerning the lubrication system, such as the oil pressure, see DD1030_xx on the VDL Bus & Coach Documentation Portal. 4 -

23 TECHNICAL INFORMATION Sump filling unit (optional) 5. SUMP FILLING UNIT (OPTIONAL) 5.1 GENERAL INFORMATION 0 Oil level sensor (sump filling signal) Manufacturer Type Supply voltage Function inspection Error message time delay Tightening torque Bedia CLS , 4 V, EVZ sec. MVZ 7 sec. 4 V ± 5% sec. after the contact switch has been turned on 7 ± 5% sec. after the contact switch has been turned on 5 Nm 1 Positive (+) Min (-) 3 Signal (S) ILAh

24 TECHNICAL INFORMATION Sump filling unit (optional) 0 Oil reservoir with pump unit Manufacturer Type Supply voltage Oil reservoir volume Groeneveld Oilmaster 6L 4 VDC 6 litres ILAj18 5 -

25 TECHNICAL INFORMATION Air conditioning compressor 6. AIR CONDITIONING COMPRESSOR 6.1 COMPONENT OVERVIEW 0 Air conditioning compressor Manufacturer Valeo Type TM 16 For further technical information concerning the Valeo air compressor, such as the maximum pressure etc., see DD14_xx on the VDL Bus & Coach Documentation Portal. ILAg0093 Manufacturer Valeo Type TM 31 For further technical information concerning the Valeo air compressor, such as the maximum pressure etc., see DD15_xx on the VDL Bus & Coach Documentation Portal. ILAg

26 TECHNICAL INFORMATION Air conditioning compressor 0 Manufacturer Type Valeo TM 55/TM65 For further technical information concerning the Valeo air compressor, such as the maximum pressure etc., see DD17_xx on the VDL Bus & Coach Documentation Portal. ILAg

27 TECHNICAL INFORMATION Special tools 7. SPECIAL TOOLS 0 Cooling system pressurization pump Midlock no. TE-10 ILAk0053 Refractometer LR no. FT030 Midlock no. TE10 ILAk0054 ILAk0007 Belt tension gauge, Optikrik I ( N) Belt tension gauge, Optikrik II (500 1,400N) Belt tension gauge, Optikrik III (1,300 3,100N) 7-1

28 TECHNICAL INFORMATION Special tools 0 V-belt frequency gauge Optibelt TT3 VDL Bus & Coach no (rechargeable battery) VDL Bus & Coach no (disposable battery) ILAk0055 ILAk0049 Navigator TXT VDL Bus & Coach no contract (VDL Bus & Coach diagnosis tool) For an overview of the various VDL Bus & Coach diagnosis tools, see DD154_xx on the VDL Bus & Coach Documentation Portal. 7 -

29 DIAGNOSIS DIAGNOSIS 1

30 DIAGNOSIS 1

31 DIAGNOSIS Engine general information 1. ENGINE GENERAL INFORMATION 1.1 ENGINE ERROR CODES If there is a fault in the system, then, in most cases, this fault will be detected by the electronic unit in the form of an error code. This error code can be read with the aid of the diagnosis equipment or a flash code. 1 For an up-to-date overview of the various error codes and the corresponding fault diagnosis, see DD1030_xx on the VDL Bus & Coach Documentation Portal. 1-1

32 DIAGNOSIS Engine general information 1. ENGINE FUNCTIONS FAULT FINDING TABLES 1 FAULT: POOR ACCELERATION/RESPONSE FROM THE ENGINE Possible cause Remedy The fuel level is low. Fill the fuel tank with fuel. There is a fuel leak. Check the fuel lines/connections and the fuel filters for leaks. The fuel fine filter/preliminary filter-water separator is Replace the fuel preliminary filter and clean the system. blocked. The fuel pump is faulty. Check the fuel pump and, if necessary, replace it. There are electronic error codes. Delete the electronic error codes. Programmable parameters or the options to be selected Check the parameter settings and the options. have been configured incorrectly. The ECM unit has been calibrated incorrectly. Recalibrate the ECM unit (or have it done by somebody else). There is air in the fuel system. Bleed the fuel system. The fuel line between the fuel pump and the injectors is Check the lines and, if necessary, replace them. blocked. The fuel delivery pipe leaks. Check the fuel delivery pipe and, if necessary, replace it. The fuel pump regulator s solenoid valve is faulty. Check the fuel pump regulator's solenoid and, if necessary, replace it. The fuel rail s pressure regulating valve is faulty. Check the fuel rail s pressure regulating valve and, if necessary, replace it. The fuel pump s pressure regulating valve is faulty. Check the fuel pump s pressure regulating valve and, if necessary, replace it. The fuel pump is faulty. Check the fuel pump and, if necessary, replace it. The intercooler is blocked/leaks. Check the intercooler. There is a (mechanical) fault with the accelerator pedal sensor. The boost pressure/intake air temperature sensor is faulty. The crankshaft sensor (engine speed) is faulty. There is a mechanical fault with the injector or it is blocked. There is a leak in the air intake system. There is a leak in the exhaust system. The exhaust system is blocked. The J1939 vehicle systems interfere with the ECM. The turbo compressor is faulty. The turbo is faulty/the wastegate activation is not correct. Poor fuel quality. The valve clearance has not been configured correctly. Check the mechanical connection between the sensor/ accelerator pedal and check the accelerator pedal sensor. Check the boost pressure/air temperature sensor and, if necessary, replace it. Check the crankshaft sensor and, if necessary, replace it. Replace the injector. Pressure-test the intake system. Check the exhaust system. Check the exhaust gas back pressure. Disconnect the systems one by one until the communication with the ECM is restored. Check the turbo compressor. Check the turbo/waste-gate activation. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Check the valve clearance. 1 -

33 DIAGNOSIS Engine general information FAULT: POOR ACCELERATION/RESPONSE FROM THE ENGINE Possible cause Remedy The brakes rub. Check whether the brakes run freely. The gearbox is faulty. Check the gearbox. The fan drive is faulty. Check the fan drive. The engine has an internal fault. Analyse the oil and check the filters. 1 FAULT: THE ENGINE DECELERATES SLOWLY Possible cause There is a (mechanical) fault with the accelerator pedal sensor. There is a mechanical fault with the injector or it is blocked. The J1939 vehicle systems interfere with the ECM. The retarder is faulty. Remedy Check: - The mechanical connection of the sensor/accelerator pedal. - The accelerator pedal sensor. Replace the injector. Disconnect the systems one by one until the communication with the ECM is restored. Check the operation of the retarder. FAULT: THE ENGINE IS DIFFICULT TO START/DOES NOT START Possible cause Remedy The fuel level is low. Fill the fuel tank with fuel. There are active electronic error codes or a lot of nonactive error codes. Battery voltage too low. The crankshaft speed is too low. The fuel fine filter/preliminary filter-water separator is blocked. The crankshaft sensor (engine speed) is faulty. There is a fuel leak. The fuel delivery pipe leaks. There is air in the fuel system. The fuel pump is faulty. The fuel line between the fuel pump and the injectors is blocked. Poor fuel quality. There is a leak in the air intake system. The exhaust system is blocked. The valve clearance has not been configured correctly. The fuse is faulty Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Charge the batteries. Check the crankshaft speed. If the crankshaft speed is less than 150 rpm, see The crankshaft does not rotate or rotates too slowly". Replace the fuel filter and clean the system. Check the crankshaft sensor and, if necessary, replace it. Check the fuel lines/connections and the fuel filters for leaks. Check the fuel delivery pipe and, if necessary, replace it. Bleed the fuel system. Check the fuel pump and, if necessary, replace it. Check the lines and, if necessary, replace them. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Pressure-test the air intake system. Check the exhaust gas back pressure. Check the valve clearance. Check the fuses and, if necessary, replace them. 1-3

34 DIAGNOSIS Engine general information 1 FAULT: THE ENGINE IS DIFFICULT TO START/DOES NOT START Possible cause Remedy The ECM unit's battery voltage is too low or interrupted. The delivery pump is faulty. There is moisture in the connectors. The ECM unit has been calibrated incorrectly. The engine safety device is in operation or is faulty. The ECM unit is faulty. The engine has an internal fault. Check the connections and the fuses for the ECM unit. Check the delivery pump. Check the connectors. Recalibrate the ECM unit (or have it done by somebody else). Check the operation of the engine safety device. Replace the ECM unit. Analyse the oil and check the filters. FAULT: REDUCED ENGINE POWER Possible cause There are active electronic error codes or a lot of nonactive error codes. The engine safety device error codes reduce the engine s power and the engine speed. The fuel level is low. There is a fuel leak. The fuel fine filter/preliminary filter-water separator is blocked. The fuel pump regulator s solenoid valve is faulty. The fuel rail s pressure regulating valve is faulty. The fuel pump s pressure regulating valve is faulty. Programmable parameters or the options to be selected have been configured incorrectly. The ECM unit has been calibrated incorrectly. The J1939 control units interfere with the ECM. There is a (mechanical) fault with the accelerator pedal sensor. There is a leak in the air intake system. There is a leak in the exhaust system. The boost pressure/intake air temperature sensor is faulty. There is no vehicle speed signal. The tachograph has not been calibrated or is faulty. There is air in the fuel system. The fuel return line is blocked. The valve clearance has not been configured correctly. 1-4 Remedy Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Read the error codes and the engine safety codes with the VDL Bus & Coach diagnosis equipment. Fill the fuel tank with fuel. Check the fuel lines/connections and the fuel filters for leaks. Replace the fuel filter and clean the system. Check the fuel pump regulator s solenoid valve. Check the fuel rail s pressure regulating valve and, if necessary, replace it. Check the fuel pump s pressure regulating valve and, if necessary, replace it. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Recalibrate the ECM unit (or have it done by somebody else). Disconnect the systems one by one until the communication with the ECM is restored. Check: - The mechanical connection of the sensor/accelerator pedal. - The accelerator pedal sensor. Pressure-test the air intake system. Check the exhaust system. Check the sensor. Check the vehicle speed signal and the sensor. Check the tachograph. Bleed the fuel system. Replace or clean the fuel return line. Check the valve clearance.

35 DIAGNOSIS Engine general information FAULT: REDUCED ENGINE POWER Possible cause The fuel delivery pipe leaks. There is a mechanical fault with the injector or it is blocked. The turbo compressor is faulty. The turbo is faulty/the wastegate activation is not correct. The intercooler leaks/is blocked. Poor fuel quality. The exhaust system is blocked. The engine oil level is above the maximum level. The fuel pump is faulty. The engine has an internal fault. Remedy Check the fuel delivery pipe and, if necessary, replace it. Replace the injector. Check the turbo compressor. Check the turbo/waste-gate activation. Check the intercooler. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with fuel. Check the exhaust gas back pressure. Check the engine oil level. Check the fuel pump and, if necessary, replace it. Analyse the oil and check the filters. 1 REDUCED ENGINE POWERTHE ENGINE RUNS ERRATICALLY/STALLS Possible cause Remedy The engine is cold. Check whether the engine reaches the operating temperature. There are active electronic error codes or a lot of nonactive error codes. The ECM unit has been calibrated incorrectly. The idling speed has not be set correctly. The load is too great at the idling speed. There is air in the fuel system. There is a fuel leak. The fuel fine filter/preliminary filter-water separator is blocked. The fuel pump regulator s solenoid valve is faulty. The fuel pump is faulty. The fuel return line is blocked. The fuel line between the fuel pump and the injectors is blocked. The fuel delivery pipe leaks. The valve clearance has not been configured correctly. There is a mechanical fault with the injector or it is blocked. There is moisture in the connectors. The crankshaft sensor (engine speed) is faulty. The camshaft sensor is faulty. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Recalibrate the ECM unit (or have it done by somebody else). Check the setting using the VDL Bus & Coach diagnosis equipment. Check the setting using the VDL Bus & Coach diagnosis equipment. Bleed the fuel system. Check the fuel lines/connections and the fuel filters for leaks. Replace the fuel filter and clean the system. Check the fuel pump regulator s solenoid valve. Check the fuel pump and, if necessary, replace it. Replace or clean the fuel return line. Check the lines and, if necessary, replace them. Check the fuel delivery pipe and, if necessary, replace it. Check the valve clearance. Replace the injector. Check the connectors. Check the crankshaft sensor and, if necessary, replace it. Check the camshaft sensor and, if necessary, replace it. 1-5

36 DIAGNOSIS Engine general information 1 REDUCED ENGINE POWERTHE ENGINE RUNS ERRATICALLY/STALLS Possible cause Remedy Poor fuel quality. The engine mounting is faulty. The vibration damper is damaged. The add-on components on the distribution side are faulty. The camshaft gear wheel is not aligned correctly. The engine has an internal fault. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with fuel. Check the engine mounting. Check the vibration damper. Check the hydraulic motor/pump, the fuel pump and the air compressor for vibrations. Check the alignment of the distribution. Analyse the oil and check the filters. FAULT: THE ENGINE STALLS DURING DECELERATION Possible cause Remedy The engine cannot be restarted. See the complaint The engine is difficult to start/does not start. The fuel level is low. Fill the fuel tank with fuel. Programmable parameters or the options to be selected have been configured incorrectly. The engine protection system is faulty. The contact switch circuit is faulty. The ECM unit's battery voltage is too low or interrupted. The crankshaft sensor (engine speed) is faulty. The camshaft sensor is faulty. There is moisture in the connectors. There is a fuel leak. There is air in the fuel system. The fuel pump regulator s solenoid valve is faulty. The fuel rail s pressure regulating valve is faulty. Poor fuel quality. There is a mechanical fault with the injector or it is blocked. The fuel pump is faulty. The ECM unit is faulty. The engine has an internal fault. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Check the engine protection system. Check the contact switch circuit. Check the connections and the fuses for the ECM unit. Check the crankshaft sensor and, if necessary, replace it. Check the camshaft sensor and, if necessary, replace it. Check the connectors. Check the fuel lines/connections and the fuel filters for leaks. Bleed the fuel system. Check the fuel pump regulator s solenoid and, if necessary, replace it. Check the fuel rail s pressure regulating valve and, if necessary, replace it. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Replace the injector. Check the fuel pump and, if necessary, replace it. Replace the ECM unit. Analyse the oil and check the filters. FAULT: THE IDLING SPEED VARIES Possible cause The fuel level is low. There are active electronic error codes or a lot of nonactive error codes. Remedy Fill the fuel tank with fuel. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. 1-6

37 DIAGNOSIS Engine general information FAULT: THE IDLING SPEED VARIES Possible cause The fuel fine filter/preliminary filter-water separator is blocked. The ECM unit has been calibrated incorrectly. Programmable parameters or the options to be selected have been configured incorrectly. The J19339 control units interfere with the ECM. There is a (mechanical) fault with the accelerator pedal sensor. There is moisture in the connectors. The fuel pump regulator s solenoid valve is faulty. There is a fuel leak. The crankshaft sensor (engine speed) is faulty. The camshaft sensor is faulty. There is no vehicle speed signal. There is air in the fuel system. The fuel delivery pipe leaks. There is a mechanical fault with the injector or it is blocked. Poor fuel quality. The turbo compressor is faulty. The turbo is faulty/the wastegate activation is not correct. The fuel pump is faulty. The vibration damper is damaged. The flywheel housing is not aligned correctly. The gearbox is faulty. The engine has an internal fault. Remedy Replace the fuel filter and clean the system. Recalibrate the ECM unit (or have it done by somebody else). Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Disconnect the systems one by one until the communication with the ECM is restored. Check: - The mechanical connection of the sensor/accelerator pedal. - The accelerator pedal sensor. Check the connectors. Check the fuel pump regulator s solenoid and, if necessary, replace it. Check the fuel lines/connections and the fuel filters for leaks. Check the crankshaft sensor and, if necessary, replace it. Check the camshaft sensor and, if necessary, replace it. Check the vehicle speed signal and the sensor. Bleed the fuel system. Check the fuel delivery pipe and, if necessary, replace it. Replace the injector. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Check the turbo compressor. Check the turbo/waste-gate activation. Check the fuel pump and, if necessary, replace it. Check the vibration damper and, if necessary, replace it. Check the alignment of the flywheel housing. Check the gearbox. Analyse the oil and check the filters. 1 FAULT: THE ENGINE SPEED VARIES WHEN THERE IS A HEAVY LOAD Possible cause Remedy The fuel level is low. Fill the fuel tank with fuel. There are active electronic error codes or a lot of nonactive error codes. The fuel fine filter/preliminary filter-water separator is blocked. The ECM unit has been calibrated incorrectly. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Replace the fuel filter and clean the system. Recalibrate the ECM unit (or have it done by somebody else). 1-7

38 DIAGNOSIS Engine general information 1 FAULT: THE ENGINE SPEED VARIES WHEN THERE IS A HEAVY LOAD Possible cause Remedy Programmable parameters or the options to be selected have been configured incorrectly. The J19339 control units interfere with the ECM. There is a (mechanical) fault with the accelerator pedal sensor. There is moisture in the connectors. The fuel pump regulator s solenoid valve is faulty. There is a fuel leak. The crankshaft sensor (engine speed) is faulty. The camshaft sensor is faulty. There is no vehicle speed signal. There is air in the fuel system. The fuel delivery pipe leaks. There is a mechanical fault with the injector or it is blocked. Poor fuel quality. The turbo compressor is faulty. The turbo is faulty/the wastegate activation is not correct. The fuel pump is faulty. The vibration damper is damaged. The flywheel housing is not aligned correctly. The gearbox is faulty. The engine has an internal fault. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Disconnect the systems one by one until the communication with the ECM is restored. Check: - The mechanical connection of the sensor/accelerator pedal. - The accelerator pedal sensor. Check the connectors. Check the fuel pump regulator s solenoid and, if necessary, replace it. Check the fuel lines/connections and the fuel filters for leaks. Check the crankshaft sensor and, if necessary, replace it. Check the camshaft sensor and, if necessary, replace it. Check the vehicle speed signal and the sensor. Bleed the fuel system. Check the fuel delivery pipe and, if necessary, replace it. Replace the injector. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Check the turbo compressor. Check the turbo/waste-gate activation. Check the fuel pump and, if necessary, replace it. Check the vibration damper and, if necessary, replace it. Check the alignment of the flywheel housing. Check the gearbox. Analyse the oil and check the filters. FAULT: THE ENGINE STARTS BUT STALLS AGAIN Possible cause The fuel level is low. The ECM unit's battery voltage is too low or interrupted. There are active electronic error codes or a lot of nonactive error codes. There is moisture in the connectors. The contact switch circuit is faulty. The engine stop when idling parameter. There is a fuel leak. Remedy Fill the fuel tank with fuel. Check the connections and the fuses for the ECM unit. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the connectors. Check the contact switch circuit. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Check the fuel lines/connections and the fuel filters for leaks. 1-8

39 DIAGNOSIS Engine general information FAULT: THE ENGINE STARTS BUT STALLS AGAIN Possible cause The fuel fine filter/preliminary filter-water separator is blocked. There is air in the fuel system. Poor fuel quality. Remedy Replace the fuel filter and clean the system. Bleed the fuel system. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. 1 FAULT: THE ENGINE DOES NOT REACH THE NOMINAL ENGINE SPEED Possible cause Remedy There are active electronic error codes or a lot of nonactive error codes. The engine stop when idling parameter. Programmable parameters or the options to be selected have been configured incorrectly. There is a (mechanical) fault with the accelerator pedal sensor. The tachograph has not been calibrated or is faulty. The crankshaft sensor (engine speed) is faulty. The camshaft sensor is faulty. There is no vehicle speed signal. The fuel fine filter/preliminary filter-water separator is blocked. Reduced engine power. The fuel pump is faulty. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Check: - The mechanical connection of the sensor/accelerator pedal. - The accelerator pedal sensor. Check the tachograph. Check the crankshaft sensor and, if necessary, replace it. Check the camshaft sensor and, if necessary, replace it. Check the vehicle speed signal and the sensor. Replace the fuel filter and clean the system. See the complaint Reduced engine power. Check the fuel pump and, if necessary, replace it. FAULT: THE ENGINE CANNOT BE TURNED OFF Possible cause There are active electronic error codes or a lot of nonactive error codes. The contact switch circuit is faulty. There is an oil leak from the turbo compressor. The ECM unit is faulty. There is a fault with an electrical component/the wiring in the wiring harness. The supply voltage to the electronic unit is not turned off. The power supply to the electronic unit after the contact switch has been turned on is not turned off with the engine stop button. Remedy Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the contact switch circuit. Check the turbo compressor. Replace the ECM unit. Check the electrical system. 1-9

40 DIAGNOSIS Engine general information 1 FAULT: TOO HIGH FUEL CONSUMPTION Possible cause There are active electronic error codes or a lot of nonactive error codes. Programmable parameters or the options to be selected have been configured incorrectly. The ECM unit has been calibrated incorrectly. The engine runs for too long at the idling speed. Accessories which have been fitted use fuel from the vehicle s fuel tank. The boost pressure/intake air temperature sensor is faulty. There is no vehicle speed signal. There is a fuel leak. There is a leak in the air intake system. There is a leak in the exhaust system. The fuel fine filter/preliminary filter-water separator is blocked. There is a signal error/short circuit/interruption with the engine coolant temperature sensor. There is a signal error/short circuit/interruption with the fuel temperature sensor. The turbo is faulty. The intercooler leaks/is blocked. The exhaust system is blocked. The engine oil level is above the maximum level. Poor fuel quality. The valve clearance has not been configured correctly. An injector is faulty. The engine has an internal fault. Remedy Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Recalibrate the ECM unit (or have it done by somebody else). Check the engine stop parameter settings when idling using the VDL Bus & Coach diagnosis equipment. Check the fuel consumption of the fitted accessories. Check the sensor. Check the vehicle speed signal and the sensor. Check the fuel lines/connections and the fuel filters for leaks. Pressure-test the air intake system. Check the exhaust system. Replace the fuel filter and clean the system. Check: - The engine coolant temperature sensor. - The wiring. Check: - The fuel temperature sensor. - The wiring. Check the turbo. Check the intercooler. Check the exhaust gas back pressure. Check the engine oil level. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Check the valve clearance. Check the injectors. Analyse the oil and check the filters. FAULT: THE INTAKE AIR TEMPERATURE IS TOO HIGH Possible cause Remedy The radiator, intercooler, oil cooler, air conditioning condenser are damaged/contaminated. There are active electronic error codes or a lot of nonactive error codes. Programmable parameters or the options to be selected have been configured incorrectly. The fan drive is faulty. Check the radiator, intercooler, oil cooler, air conditioning condenser for damage/contamination. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the parameter settings with the VDL Bus & Coach diagnosis equipment. Check the fan drive. 1-10

41 DIAGNOSIS Engine general information FAULT: THE INTAKE AIR TEMPERATURE IS TOO HIGH Possible cause Remedy There is an exhaust system leak in the engine compartment. The intake air temperature sensor is faulty. FAULT: THE BOOST PRESSURE IS TOO LOW Possible cause There is a leak in the air intake system. There is a leak in the exhaust system. There are active electronic error codes or a lot of nonactive error codes. The boost pressure sensor is faulty. The air compressor connection on the air intake system is loose. The exhaust system is blocked. The turbo compressor wastegate is faulty or is constantly open. The turbo is faulty. Reduced engine power. Check the exhaust system. Check the sensor. Remedy Pressure-test the air intake system. Check the exhaust system. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the sensor. Check the connection. Check the exhaust gas back pressure. Check the waste-gate. Check the turbo. See the complaint Reduced engine power. 1 FAULT: BLACK SMOKE IS PRODUCED Possible cause There are active electronic error codes or a lot of nonactive error codes. There is a fault in the electronic components/wiring. The ECM unit has been calibrated incorrectly. The boost pressure/intake air temperature sensor is faulty. There is a leak in the air intake system. There is a leak in the exhaust system. The exhaust system is blocked. The fuel pump regulator s solenoid valve is faulty. The valve clearance has not been configured correctly. An injector is faulty. The turbo compressor is faulty. The turbo compressor s oil line leaks. Poor fuel quality. The engine has an internal fault. Remedy Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the electrical system. Recalibrate the ECM unit (or have it done by somebody else). Check the sensor. Pressure-test the air intake system. Check the exhaust system. Check the exhaust gas back pressure. Check the fuel pump regulator s solenoid and, if necessary, replace it. Check the valve clearance. Check the injectors. Check the turbo compressor. Check the turbo compressor. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Analyse the oil and check the filters. 1-11

42 DIAGNOSIS Engine general information 1 FAULT: WHITE SMOKE IS PRODUCED Possible cause There are active electronic error codes or a lot of nonactive error codes. There is a fault in the electronic components/wiring. The ECM unit has been calibrated incorrectly. The engine is cold. The coolant temperature sensor is faulty. The boost pressure/intake air temperature sensor is faulty. Poor fuel quality. The fuel fine filter/preliminary filter-water separator is blocked. There is air in the fuel system. The fuel delivery pipe is blocked. The fuel pump does not supply a sufficient quantity of fuel. The valve clearance has not been configured correctly. There is a mechanical fault with the injector(s) or it/they is/are blocked. There is a coolant leak in the combustion chamber. The engine has an internal fault. Remedy Read and delete error codes with the VDL Bus & Coach diagnosis equipment. Check the electrical system. Recalibrate the ECM unit (or have it done by somebody else). Check whether the engine reaches the operating temperature. Check the coolant temperature sensor. Check the boost pressure/intake air temperature sensor. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. Replace the fuel filter and clean the system. Check to see whether air is drawn in via the suction line. Check the fuel delivery pipe and, if necessary, replace it. Check the fuel pump and, if necessary, replace it. Check the valve clearance. Replace the injector(s). Pressure-test the cooling system. Analyse the oil and check the filters. FAULT: THE VEHICLE SPEED REGULATOR DOES NOT WORK Possible cause Remedy There is a fault in the ECM unit s electronic components/ Check the electrical system. wiring. The cut-out conditions for the vehicle speed regulator Check for the presence of the cut-out condition(s). have been satisifed. FAULT: THE ENGINE SPEED REGULATOR DOES NOT WORK Possible cause Remedy There is a fault in the ECM unit s electronic components/ Check the electrical system. wiring of: - Wiring harness. - Electronic unit. The cut-out conditions for the engine speed regulator Check for the presence of the cut-out condition(s). have been satisfied. FAULT: THE CRANKSHAFT ROTATES SLOWLY OR DOES NOT ROTATE Possible cause Remedy There are active electronic error codes or a lot of nonactive error codes. Read and delete error codes with the VDL Bus & Coach diagnosis equipment. 1-1

43 DIAGNOSIS Engine general information FAULT: THE CRANKSHAFT ROTATES SLOWLY OR DOES NOT ROTATE Possible cause Remedy Battery voltage too low. The battery cables or connections are loose, broken or corroded (high resistance). The battery capacity is too low. The thickness and length of the battery cable does not meet the specifications. The oil pressure switch, gauge or sensor is faulty. The gearbox is not in neutral. The starter motor is faulty. The oil level is above the maximum level. The engine oil does not meet the specifications. The crankshaft does not rotate. The hydraulic lock in a cylinder. The engine has an internal fault. Charge the batteries. Check the cables and the connections. Check the specifications. Check the specifications. Check the oil pressure switch, gauge and sensor. Put the gearbox in neutral. Replace the starter motor. Check the oil level and, if necessary, drain some oil. Change the engine oil and the oil filters. Check the crankshaft. Remove the injectors, rotate the crankshafts and trace the cause of the liquid in the cylinder. Analyse the oil and check the filters

44 DIAGNOSIS Engine general information

45 DIAGNOSIS Cooling system. COOLING SYSTEM.1 FAULT FINDING TABLES FAULT: ENGINE TEMPERATURE BECOMES TOO HIGH Possible cause Remedy Faulty intake system. Check the intake system. There is a fault in the lubricating oil system. Check the lubricating oil system. Incorrect poly V-belt tension. Check the poly V-belt tension. If necessary, replace the poly V-belt or the poly V-belt tensioner. The coolant level is too low. Check the coolant level. If necessary, top it up. A coolant hose is cracked or blocked. Check and clean the coolant hoses. The intercooler/radiator is contaminated. Check/clean the intercooler and the radiator. The waste-gate setting too high. Check the waste-gate setting. The turbo compressor housing s air hose to the wastegate Check the air hose. If necessary, replace it. diaphragm leaks or is not connected. The pressure cap is faulty or does not work. Check the pressure cap. The thermostat opens insufficiently or does not open. Check the thermostat and its operation. The wrong type of thermostat is fitted. Check the thermostat and its operation. The coolant pump is faulty. Check the coolant pump s shaft, bearings and fan. If necessary, replace the coolant pump. The hydraulic fan drive is faulty. Check the operation of the fan drive. The temperature control is faulty. Check the coolant temperature sensor. Check the control flow s return control at a high temperature. The wrong injection nozzles have been fitted. Check whether the correct injection nozzles have been fitted. Poor fuel quality. Drain the fuel, rinse the fuel system, replace the fuel filters and fill the fuel tank with the specified fuel. There is a signal error/short circuit/break with the engine coolant temperature sensor. Check: - The coolant temperature sensor. - The wiring. 1 FAULT: EXTERNAL COOLANT LEAK Possible cause The radiator. The coolant pump leaks. The cooler. The pressure cap. The heater leaks. The coolant expansion reservoir leaks. The expansion plug(s) leak(s). Remedy Check the radiator. If necessary, pressure-test it. Check the coolant pump. If necessary, measure the bearing play. Check the oil cooler. If necessary, pressure-test it. Check the pressure cap. If necessary, pressure-test it. Check the heater lines. Check the expansion reservoir for leaks. Replace the expansion plug(s). - 1

46 DIAGNOSIS Cooling system 1 FAULT: INTERNAL COOLANT LEAK Possible cause The cylinder head gasket(s) is/are faulty. The cylinder head(s) or cylinder block are cracked. The injection nozzle bushes leak. The compressor s cylinder head gasket is faulty. The cooler. The expansion plugs in the striking chamber (cylinder block) or on the top of the cylinder heads are faulty. The cylinder head bolts have not been tightened. Remedy Check the cylinder head gasket(s). Check the cylinder heads and the cylinder block for internal cracks. If necessary, pressure-test it. Check the cylinder heads. If necessary, pressure-test it. Replace the compressor s cylinder head gasket. Check whether there is coolant in the lubrication oil system. Replace the expansion plug(s). Check the tightening torque of the cylinder head bolts. -

47 DIAGNOSIS Exhaust gas after-treatment system 3. EXHAUST GAS AFTER-TREATMENT SYSTEM Comment: For the error codes, see DD1030_xx on the VDL Bus & Coach Documentation Portal

48 DIAGNOSIS Exhaust gas after-treatment system 1 3 -

49 DIAGNOSIS Hydraulic fan - tracing faults 4. HYDRAULIC FAN - TRACING FAULTS 4.1 HYDRAULIC PUMP FAULT FINDING TABLES FAULT: NO PUMP DELIVERY Possible cause The hydraulic oil level is too low. The delivery line/hose is bent or pinched closed. The pump shaft is broken, the key is broken or missing. The pump rotates in the wrong direction. Remedy Check the oil level. Top up the oil and bleed the system. Check the system for leaks. Check the path of the oil lines/hoses. Replace any faulty parts. Check the pump s direction of rotation. 1 FAULT: THE PUMP MAKES TOO MUCH NOISE Possible cause The hydraulic oil level is too low. The delivery line/hose is bent or pinched closed. There is an air leak from the connections. There are air bubbles visible in the delivery oil. The hydraulic reservoir's bleed opening is blocked. The pump runs too fast. Some of the pump s components are worn/faulty. Remedy Check the oil level. Check the system for leaks. Top up the oil and bleed the system. Check the path of the oil lines/hoses. Tighten the couplings/connections. Use the specified hydraulic oil. Clean the bleed opening. Check the gear ratio. Replace any worn/faulty parts. FAULT: ABNORMAL WEAR Possible cause The oil filter is blocked/the oil has not been changed in time. The oil s viscosity is too low. The system pressure is too high (the pump pressure is greater than the permitted value). There is air in the system. Remedy Replace the oil filter/change the oil according to the maintenance schedule. Check whether the specified oil is used. Check the system pressure. Bleed the hydraulic system. FAULT: BROKEN COMPONENTS IN THE PUMP HOUSING Possible cause Remedy The system pressure is too high (the pump pressure is Check the pressure limiting valve. greater than the permitted value). There is (an) insufficient (supply of) oil. Check the oil level, the oil filter and the path of the oil lines/hoses. The attachment bolts have been overtightened. Check whether the correct tightening torques have been used. 4-1

50 DIAGNOSIS Hydraulic fan - tracing faults FAULT: EXTERNAL OIL LEAK Possible cause The oil seal(s) is/are faulty. Remedy Replace the faulty parts HYDRAULIC OIL FAULT FINDING TABLES FAULT: THE HYDRAULIC OIL TEMPERATURE IS TOO HIGH Possible cause Remedy There is an internal leak in the pump. Replace the pump. The oil s viscosity is too high. Use the specified hydraulic oil. The pump has been overhauled and there is too much Check the overhaul procedure. internal friction. The oil cooler is blocked. Check and clean the oil cooler. The delivery line/hose is damaged, bent or pinched Replace damaged lines and remove any blockages. closed. The lines/hoses are the wrong size. Check whether the original lines/hoses are used. 4.3 HYDRAULIC MOTOR FAULT FINDING TABLES FAULT: THE MOTOR RUNS IN THE WRONG DIRECTION Possible cause Remedy The delivery and return lines have been switched over. Connect the motor correctly. FAULT: THE MOTOR DOES NOT RUN OR HAS INSUFFICIENT TORQUE Possible cause Remedy The pressure relief valve has been incorrectly set. Check the system pressure and adjust the pressure relief valve. The pressure relief valve remains open. Clean/replace the pressure relief valve. The proportional valve is faulty. Replace the proportional valve. The system pressure is too low. Check the maximum system pressure. The pump s delivery is too small. Check the pump's delivery. Check whether the pressure limiting valve is stuck. If necessary, replace the pump. FAULT: EXTERNAL OIL LEAK Possible cause The oil seal(s) is/are faulty. Remedy Replace the faulty parts. Check the oil leak-off line for blockages. 4 -

51 DIAGNOSIS Hydraulic fan - tracing faults 4.4 ELECTRICAL FAULT FINDING TABLES FAULT: THE FAN DOES NOT RUN OR RUNS TOO SLOWLY Possible cause Remedy There is a hydraulic or a mechanical fault. See Hydraulic pump fault finding tables ( 4-1) or Hydraulic motor fault finding tables ( 4 -). There is no communication between the VFC and the Check the operation of the CAN bus. electronic fan unit. There is no supply voltage to the electronic fan unit. Check the fuses. The electronic fan unit is faulty. Replace the electronic fan unit. 1 FAULT: THE FAN RUNS TOO FAST Possible cause Remedy There is a hydraulic or a mechanical fault. See Hydraulic pump fault finding tables ( 4-1) or Hydraulic motor fault finding tables ( 4 -). There is no communication between the ICM and the Check the operation of the CAN bus. electronic fan unit. The connection between the electronic fan unit and the Check the connection. proportional valve is interrupted. The coolant temperature sensor is faulty. Check the operation of the sensor. The intake air temperature sensor is faulty. Check the operation of the sensor. The transmission oil temperature sensor is faulty. Check the operation of the sensor. The retarder oil temperature sensor is faulty. Check the operation of the sensor. There is no supply voltage to the electronic fan unit. Check the fuses. The electronic fan unit is faulty. Replace the electronic fan unit. 4-3

52 DIAGNOSIS Hydraulic fan - tracing faults 1 4-4

53 ENGINE ENGINE

54 ENGINE

55 ENGINE Safety regulations 1. SAFETY REGULATIONS The work described in this maintenance manual may only be carried out by trained and competent personnel. Always observe the local safety and environmental regulations. Comply with all the warnings and safety regulations given here. Always read and observe the instructions and warnings given on labels and stickers fitted to the vehicle s components. These stickers have been fitted for your health and safety. Do not ignore them! Always use the appropriate lifting gear or approved hoisting equipment when removing or installing heavy components. Attach the component securely to the lifting gear or hoisting equipment. Check the hoisting equipment before use. Do not leave tools unattended on or in the vehicle. If necessary, soundly support the components. Wear clean, well-fitting clothing and, if necessary, apply protective cream to the body. Make sure there is good ventilation or extraction equipment when carrying out work where vapours and/or gases are released. The engine stops automatically after a set time if the engine idles and the accelerator pedal is not depressed. Remain a safe distance from rotating and/or moving components. Be careful when changing the oil. Hot oil can cause serious injury. Avoid unnecessary contact with drained oil. Regular contact causes skin damage. To prevent the risk of fire, the engine and the area surrounding it must be free of highly inflammable liquids. Always protect the vehicle from rolling away by applying the parking brake and, for example, placing chocks in front of and behind the wheels. Always support the chassis with hoisting sheers when working under the vehicle. In order to prevent people from starting the engine when work is being carried out on the vehicle, always disconnect the battery s earth connection. 1-1

56 ENGINE Safety regulations Place a sign that reads DO NOT OPERATE on the dashboard. Never disconnect the battery terminal clamps when the engine is running. This will prevent damage to the electrical components. Turn off the contact switch and the main switch before disconnecting the connection between the battery terminal and the negative pole. Wait at least 80 seconds after turning off the contact switch before disconnecting the connection between the battery terminal clamp and the negative pole. The AdBlue lines may become blocked if the connection is disconnected too quickly. Be careful when working on systems which may be pressurized, such as the fuel system, cooling system, fan drive, etc. If possible, depressurize the system before starting the work. Fuel system Diesel is highly flammable. Avoid a naked flame, heat sources or a lit cigarette close to the fuel system: FIRE HAZ- ARD! Diesel is harmful to your health. Prevent diesel from coming into contact with skin, eyes or clothing. Do not inhale diesel fumes. If diesel is swallowed, contact a doctor immediately. 1 -

57 ENGINE General information. GENERAL INFORMATION.1 LOCATION OF THE COMPONENTS ILAj141 1 Fuel pump 10 Radiator supply line Camshaft sensor 11 Water pump 3 Fuel filter 1 Oil dipstick 4 Inlet manifold boost pressure temperature sensor 13 Sump 5 Inlet manifold 14 ECU 6 Hoisting eye 15 Steering pump 7 Sump ventilation bleed valve 16 Air compressor 8 Generator 17 Starter motor 9 Automatic V-belt tensioner - 1

58 ENGINE General information ILAj Exhaust butterfly valve 7 Gear casing Exhaust manifold 8 Oil cooler 3 Hoisting eye 9 Oil filter 4 Sump ventilation filter (blow-by filter) 10 Turbo compressor 5 Coolant lines to gearbox 11 Thermostat housing 6 Flywheel -

59 ENGINE General information. IDENTIFICATION Engine identification plate The engine identification sticker is fitted to the cylinder head cover. ILAz05 The engine identification sticker states various engine details, such as: Engine type Engine number Date ILAz04-3

60 ENGINE General information.3 COMPONENT DESCRIPTION.3.1 SUMP PAN ATTACHMENT The edge of the sump pan (1) is enclosed in a thick "C" rubber gasket (4). The entire unit is contained in and supported by an aluminium assembly flange (3), which is screwed on to the bottom of the engine block. Since the "C" rubber gasket is enclosed, it is better protected and, therefore, does not have to be replaced every time it is removed. It is NOT permitted to directly support the engine under the sump pan or by the edge of the sump pan. 1 C rubber gasket Sump pan 3 Assembly flange 4 Attachment bolt ILAj SUMP STRENGTHENING PLATE The underside of the cylinder block has a sump strengthening plate. This strengthening plate ensures that the underside of the engine block has a rigid construction, so that the engine produces less noise. ILAj1393-4

61 ENGINE General information.3.3 CONNECTING ROD The connecting rod bearing caps have been forcibly broken at an angle. The forced breaking of the connecting rod caps produces a unique breakage surface (1) for each connecting rod. The unique fracture surface ensures an extremely large shearing strength. This allows for a large transfer of force. The fracture surfaces of the connecting rod and the bearing cap must be handled with care. Dirt and/or damage will result in the connecting rod and the bearing cap no longer fitting each other. ILAj0713 Four reference marks have been added to aid correct assembly. 1 Coloured mark to indicate the weight. Coloured mark to indicate the diameter class. 3 Centring pin visible from the front of the engine. 4 Serial number for identification of the connecting rod. For additional information, see DD1030_xx on the VDL Bus & Coach Documentation Portal. ILAj1394-5

62 ENGINE General information.3.4 ENGINE MOUNTING RUBBERS The engine is mounted in four engine mounting rubbers; two on the same side as the vibration damper and two on the same side as the flywheel. The engine mounting rubbers are identical on the left and right-hand sides. Distribution side The engine mounting rubbers on the same side as the vibration damper consist of two steel plate parts with vulcanized rubber between them. The steel plate parts are not connected to each other. If the engine mounting rubber is cracked, then this may result in annoying vibrations and noises. This can be heard particularly at low engine speeds. This can be visually checked by using a tyre iron to lift up the top part of the engine bracket/engine mounting rubber. Flywheel side Vibration damper on the distribution side ILAj1400 The engine mounting rubbers on the same side as the flywheel consist of a steel plate holder with a hardened steel support in the middle. These parts are connected to each other via vulcanized rubber. Vibration damper on the flywheel side ILAj1399-6

63 ENGINE Inspection and adjustment 3. INSPECTION AND ADJUSTMENT Comment: For information on how to check and adjust engine-specific components, see DD1030_xx on the VDL Bus & Coach Documentation Portal. 3-1

64 ENGINE Inspection and adjustment 3.1 ENGINE POLY V-BELTS: INSPECTING The engine has three or four poly V-belts. One poly V-belt (A) for the generator drive. One poly V-belt (B) for the pulley drive. One poly V-belt (C) for the water pump drive. (Optional) One poly V-belt (D) for the pulley and 3rd generator drive. The poly V-belts have an automatic V-belt tensioner and cannot, therefore, be adjusted by hand. An incorrect poly V-belt tension can be caused by: A stretched poly V-belt. A faulty automatic V-belt tensioner. When working on the engine, turn OFF the main switch unless it is necessary to have it turned on for the work that is being carried out. Also make sure the engine cannot be started unintentionally. If the engine has been turned off, but is still warm, it is possible that the poly V- belts continue moving by themselves. Wait for the engine to cool down sufficiently before carrying out any work. Always fit the same type of poly V-belt. ILAj178 ILAj

65 ENGINE Inspection and adjustment Removing the poly V-belts 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. First remove the air conditioning compressor s poly V- belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 3. Remove the poly V-belts B and C (see Engine poly V-belts: removing and installing ( 4-18)). Inspecting the poly V-belt 1. Clean a dirty poly V-belt with a 1:10 mixture of glycerine and methylated spirit.. Check the poly V-belt for wear (see - 3. (Poly) V-belts: inspection points ( 3-4)). 3. If necessary, replace the poly V-belt. 4. Check the automatic belt tensioner (see (Automatic) belt tensioner: inspecting ( 3-9)). If the poly V-belt must be replaced, then it is recommended to also replace the belt tensioner and the guide wheels. ILAj0017 Installing the poly V-belt 1. Fit the poly V-belts (see Engine poly V-belts: removing and installing ( 4-18)).. If necessary, fit the air conditioning compressor s poly V- belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 3. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -)). 3-3

66 ENGINE Inspection and adjustment 3. (POLY) V-BELTS: INSPECTION POINTS When working on the engine, turn OFF the main switch unless it is necessary to have it turned on for the work that is being carried out. Also make sure the engine cannot be started unintentionally. General information DO NOT bend, rotate or twist (poly) V-belts inside out or with a radius of < 5 mm. Make sure (poly) V-belts and pulleys do not come into contact with oil or grease. The use of belt dressing or similar products on (poly) V- belts, pulleys and guide pulleys is not permitted. Fault causes ILAj

67 ENGINE Inspection and adjustment 3..1 FAULT FINDING TABLES Hardened/polished flanks Possible cause Belt tension Faulty belt tensioner. The ambient temperature is too high. Remedy Replace the (poly) V-belt. Adjust the belt tension. Replace the (poly) V-belt. Replace the belt tensioner. Check whether the correct type of V-belt has been fitted. If necessary, replace the V-belt. Uneven wear of the belt ribs Possible cause Unaligned pulleys/guide pulleys. The belt vibrations are too large. The ambient temperature is too high. Remedy Check the drive. Align or, if necessary, replace the pulleys/guide pulleys. Replace the (poly) V-belt. Check the belt tension. If necessary, adjust the belt tension/replace the (poly) V- belt. Check whether the correct type of V-belt has been fitted. If necessary, replace the V-belt. The rubber is damaged/corroded/comes loose Possible cause Belt dressing. Remedy The use of belt dressing is NOT permitted. 3-5

68 ENGINE Inspection and adjustment Noisy drive, running noises produced by the (poly) V-belt Possible cause The belt tension is too low. A worn V-belt Remedy Adjust the belt tension or replace the (poly) V-belt. Replace the (poly) V-belt. Tearing/pieces coming loose from the (poly) V-belt base/ribs Possible cause The belt tension is too high/too low. A worn V-belt Exterior influences. Remedy Adjust the belt tension and replace the (poly) V-belt. Replace the (poly) V-belt. Replace the (poly) V-belt. 3-6

69 ENGINE Inspection and adjustment Broken (poly) V-belt after a short running-in time Possible cause A faulty V-belt tensioner The V-belt is tightened far too tightly. Remedy Replace the belt tensioner if any grooves are observed. Replace the (poly) V-belt, adjust the belt tension correctly. Contamination on the (poly) V-belt Possible cause Leak from the engine, leak in the engine compartment. Remedy Replace the (poly) V-belt, repair any leaks. Unacceptable wear of the belt ribs Possible cause The pulleys/pulleys are damaged. The pulleys/pulleys are not aligned. Remedy Replace the (poly) V-belt. Replace damaged pulleys/guide pulleys. Replace the (poly) V-belt. Align the pulleys/guide pulleys or replace the pulleys/ guide pulleys. 3-7

70 ENGINE Inspection and adjustment Damage to the back of the (poly) V-belt Possible cause The pulley running surface is damaged. Remedy Replace the (poly) V-belt. Replace damaged pulleys/guide pulleys. Torn rear Possible cause The pulley diameter is too small. Slip. The ambient temperature is too high. Remedy Replace the pulleys with the correct type and replace the (poly) V-belt. Adjust the belt tension correctly/replace the (poly) V-belt. Replace the (poly) V-belt with the correct type. Extreme wear on the side Possible cause Remedy The (poly) V-belt rubs against something. Check the path of the (poly) V-belt/replace the (poly) V- belt. The belt tension is too high/too low. Adjust the belt tension correctly/replace the (poly) V-belt. The pulleys/pulleys are not aligned. Replace the (poly) V-belt. Align the pulleys/guide pulleys or replace the pulleys/ guide pulleys. 3-8

71 ENGINE Inspection and adjustment 3.3 (AUTOMATIC) BELT TENSIONER: INSPECTING When working on the engine, turn OFF the main switch unless it is necessary to have it turned on for the work that is being carried out. Also make sure the engine cannot be started unintentionally. The poly V-belt must ALWAYS be replaced when the belt tensioner is replaced. However, if the poly V-belt is replaced, it is not always necessary to replace the belt tensioner. Incorrect running of the poly V-belt 1. When the engine is running, check the running (position) of the poly V-belt over the belt tensioner s pulley. The V-belt must remain in the middle, or close to the middle, of the pulley. A belt that is not well positioned will wear more quickly and there is a chance that the belt will run off the pulley. There is also a chance that the belt tensioner will be damaged.. If the V-belt does not run in the middle of the pulley or moves across the pulley, then the V-belt and the belt tensioner must be checked for damage. Replace any damaged components. 3. When the engine is running, check whether the belt tensioner moves back and forth or makes a stroke that is greater than 1.5 mm. In both cases, the belt tensioner must be replaced. ILAj0195c Belt tensioner noise Be careful when working near rotating components! 1. When the engine is running, listen whether the belt tensioner makes an unusual noise, such as squeaking or rattling. This is an indication of a fault (or an imminent fault).. Turn off the engine. 3. Check whether the V-belt tensioner's pulley can be rotated by hand without any resistance being felt and without it making an unusual noise. If excessive resistance can be felt or an unusual noise is heard, then the belt tensioner must be replaced. ILAj0195a 3-9

72 ENGINE Inspection and adjustment 4. Place a 17 mm ring spanner on the automatic belt tensioner s hexagon and slowly move the belt tensioner s arm from the rest position to the assembly position. If excessive resistance or jolting can be felt, then the belt tensioner must be replaced. ILAj0195d Belt tensioner bearing 1. Turn off the engine and remove the poly V-belt.. Rotate the pulley by hand. Noise or resistance can be an indication of bearing damage. 3. Check the pulley s bearing. A small amount of play is normal. 4. If noise, resistance or an unusual amount of play is observed, then the belt tensioner must be replaced. Build-up of dirt 1. Remove the poly V-belt.. Check the belt tensioner for a build-up of contamination. If a build-up of dirt is observed, the belt tensioner must be removed and cleaned. Cracks, wear grooves and arm play 1. Remove the poly V-belt and the belt tensioner.. Check the belt tensioner and the pulley for cracks, deformation, dents and metal fatigue. Replace the V-belt tensioner if there are any faults. 3. Check the contact surfaces between the rotating and stationary sections of the belt tensioner for wear grooves. Wear grooves are an indication of bearing play. Replace the belt tensioner if any grooves are observed. 4. Visually check whether the tensioner arm makes contact with the spring housing. This can be recognized by shiny, smooth lines or grooves in the metal. Check the arm for play by moving the arm vertically up and down. If play can be felt, then the belt tensioner must be replaced. ILAj0195e Belt tensioner spring force 1. Turn off the engine and place a 17 mm ring spanner on the automatic belt tensioner s hexagon and tension the belt tensioner. When rotating the arm (ring spanner), the resistance of the spring must be clearly felt. If this is not the case, then the spring has lost its force and the belt tensioner must be replaced. 3-10

73 ENGINE Inspection and adjustment. Other indicators are the V-belt slipping or coming loose or when a component that is driven by the V-belt does not rotate any more. Replace the belt tensioner if one of the above situations occurs. ILAj0195b Belt tensioner noise 1. When the engine is running, listen whether the belt tensioner makes an unusual noise, such as squeaking or rattling. This is an indication of a fault (or an imminent fault). Be careful when working near rotating components!. Turn the engine off. Check whether the V-belt tensioner's pulley can be rotated by hand without any resistance being felt and without it making an unusual noise. If excessive resistance can be felt or an unusual noise is heard, then the belt tensioner must be replaced. 3. Place a 17 mm ring spanner on the automatic belt tensioner s hexagon and slowly move the belt tensioner s arm from the rest position to the assembly position. If excessive resistance or jolting can be felt, then the belt tensioner must be replaced. ILAj0195a Belt tensioner bearing 1. Turn off the engine and remove the poly V-belt.. Rotate the pulley by hand. Noise or resistance can be an indication of bearing damage. 3. Check the pulley s bearing. A small amount of play is normal. If noise, resistance or an unusual amount of play is observed, then the belt tensioner must be replaced. ILAj0195d 3-11

74 ENGINE Inspection and adjustment Build-up of dirt 1. Turn off the engine and remove the poly V-belt.. Check the belt tensioner for a build-up of contamination. If a build-up of dirt is observed, the belt tensioner must be removed and cleaned. Cracks, wear grooves and arm play 1. Remove the poly V-belt and the belt tensioner.. Check the belt tensioner and the pulley for cracks, deformation, dents and metal fatigue. Replace the V-belt tensioner if there are any faults. 3. Check the contact surfaces between the rotating and stationary sections of the belt tensioner for wear grooves. Wear grooves are an indication of bearing play. Replace the belt tensioner if any grooves are observed. 4. Visually check whether the tensioner arm makes contact with the spring housing. This can be recognized by shiny, smooth lines or grooves in the metal. 5. Check the arm for play by moving the arm vertically up and down. If play can be felt, measure the distance between the tensioner housing and the tensioner arm. If the distance (A) is greater than 3 mm, then the belt tensioner must be replaced. In general, the space at the bottom of the tensioner housing is greater than the space at the top. The tensioner pulls at an angle. As a result, the tensioner arm will then rub against the top of the tensioner housing, which will result in excessive wear. ILAj0195e 1 Tensioner cover Tensioner arm 3 Tensioner housing 4 Tensioner pulley A Play ILAj

75 ENGINE Inspection and adjustment Belt tensioner spring force 1. Turn off the engine and place a 17 mm ring spanner on the automatic belt tensioner s hexagon and tension the belt tensioner.. When rotating the arm (ring spanner), the resistance of the spring must be clearly felt. If this is not the case, then the spring has lost its force and the belt tensioner must be replaced. 3. Other indicators are the V-belt slipping or coming loose or when a component that is driven by the V-belt does not rotate any more. ILAj0195c 4. When the engine is not running, check whether the top or bottom tensioning arm stop lays against the cast cam on the tensioner housing. If one of the stops touches the cam: Check whether the correct poly V-belt has been fitted. If the correct belt has been fitted, replace it with a new poly V-belt (see Engine poly V-belts: inspecting ( 3 -)). If, after replacing the poly V-belt, one of the stops still lays against the cam, then the belt tensioner must be replaced. 5. Whilst the poly V-belt is removed, check whether the tensioner stop touches the cast cam on the tensioner housing. If this is not the case, then the tensioner must be replaced. ILAj0015 Belt tensioner fault finding table Fault Can be recognized by Causes Remedy Tilted tensioner/tension pulley Tensioner jolts Tensioner gets stuck Tensioner hits against the end stop (end of stroke) A-symmetrical opening between the tensioner housing and the tensioning arm. When rotating the tensioning arm along the entire stroke, jolts can be felt and a grinding noise can be heard. The tensioner does not tighten, the belt makes a loud noise. The belt makes a loud noise, a clapping noises due to contact between the stop cam and the tensioner housing. Worn friction bearing. The damping bushes are worn. Worn friction bearing and damping bushes. The belt is stretched too much. The belt is too long. Incorrect roll diameter. Worn belt. Replace the tensioner. Replace the tensioner. Replace the tensioner. Replace the belt. If necessary, replace the tensioner. 3-13

76 ENGINE Inspection and adjustment Belt tensioner fault finding table Fault Can be recognized by Causes Remedy Broken (off) components Bearings can be heard. The reset unit for the hexagonal nut is broken off. Noise when turning. When rotating the pulley by hand, the movement is jerky. Overloaded hexagonal nut due to reset unit pulling to one side. Contamination Overload Exterior damage. Replace the tensioner. Replace the tensioner. Corrosion/contamination Exterior/surface condition. Dust, water, etc. DO NOT replace the tensioner. If none of the above faults are observed, then the belt tensioner must NOT be replaced. 3-14

77 ENGINE Inspection and adjustment 3.4 ENGINE RUBBERS AND ENGINE BRACKETS: INSPECTING ILAj374 General information Check the engine rubbers and engine brackets for cracks. Check the attachment bolts (see 0 -. Engine tightening torques ( -) for the tightening torques). Checking the vibration dampers 1. Apply the parking brake.. Start the engine and apply the service brake. 3. Place the gearbox in drive (D). 3-15

78 ENGINE Inspection and adjustment 4. Slowly depress the accelerator pedal. Make sure the vehicle does not move. 5. Check whether the engine/gearbox moves. 6. If the engine is mounted correctly, the engine/gearbox will only move slightly. If the engine is not mounted correctly, the engine/gearbox will tilt/move up and down a lot. Rejection criteria If the engine bracket(s) on the same side as the vibration damper is/are worn, this will result in cracks in the vulcanized rubber. If the engine bracket s rubber is cracked, then the rubber must be replaced. 3-16

79 ENGINE Inspection and adjustment 3.5 COOLANT HEATING ELEMENT: INSPECTING Before starting work on the heating element, check whether the element/ engine coolant has cooled down. Not allowing the element/coolant to cool down sufficiently can result in a serious burn. Coolant is a harmful liquid. Therefore, avoid skin contact to prevent poisoning. Always read the safety data sheet. Inspection 1. Remove the plug from the plug socket. Allow the element to cool down before inspecting it.. Disconnect the connector from the heating element. 3. Connect an ohmmeter between both contact pins on the element. Check whether there is an interruption in the element. 4. If there is no interruption and the element does not work, check the cabling and check the element for scale deposits. Scale deposits/contamination of the heating element Scale deposits/contamination of the element may hinder the heat exchange or even result in the heating element not working. Extreme scale deposits/contamination may be the result of an excessive amount of antifreeze or additives in the coolant. Check whether the specific density of the coolant meets the VDL Bus & Coach specifications. The entire cooling system must be cleaned (see Cooling system: cleaning (rinsing) ( 7-1)) if the element is broken or the fuse has burnt through as a result of scale deposits/contamination. ILAh

80 ENGINE Inspection and adjustment 3-18

81 ENGINE Removal and installation 4. REMOVAL AND INSTALLATION Comment: For information on how to remove and install engine-specific components, see DD1030_xx on the VDL Bus & Coach Documentation Portal. 4-1

82 ENGINE Removal and installation 4.1 BATTERY TERMINAL CLAMPS: REMOVING AND INSTALLING In order to prevent the DTCO-1381 tachograph from saving an error code, the driver's card must be replaced by the workshop card before the battery terminal clamp and the negative pole are disconnected. Do not place any tools or other materials on or near the batteries. This could shortcircuit the battery or may even cause the battery to explode. Always disconnect the connection between the battery terminal clamp and the negative pole when working on the vehicle. To prevent damage to electronic components, never disconnect the battery terminal clamps when the engine is running. Turn off the contact switch before disconnecting the connection between the battery terminal clamp and the negative pole. Wait at least 80 seconds after turning off the contact switch before disconnecting the connection between the battery terminal clamp and the negative pole. The AdBlue lines may become blocked if the connection is disconnected too quickly. Avoid sparks and naked flames near the batteries. See Battery terminal clamp tightening torques ( -7) for the battery terminal clamp tightening torques. 4 -

83 ENGINE Removal and installation 4. DRIVE UNIT: REMOVING AND INSTALLING This chapter explains how to remove and install the complete drive unit. The drive unit consists of the engine plus the gearbox. Securely support the drive unit using approved tools. It is NOT permitted to directly support the engine under the sump pan or by the edge of the sump pan. Various types of fluid will be released when removing fluid lines. Collect the fluids separately and consider your personal safety and the fire risk. If necessary, remove the hoses. When removing the engine, make sure no components or dirt falls into the engine, radiator or other components. Therefore, plug all the openings. Electric wiring harnesses are fragile and may cause faults if damaged. Make sure the wiring harnesses do not have a current running through them and do not touch any moving parts. When removing the drive unit, use approved lifting columns to raise the vehicle. Fit all the attachment bolts and tighten them to the specified torque. Do not allow the engine to rest on the flywheel housing. It will easily get damaged by the weight of the engine. Removing 1. Disconnect the earth cable from the batteries (see Battery terminal clamps: removing and installing ( 4 -)).. Remove the vehicle s engine encapsulation. 3. Drain the cooling system (see Cooling system: draining ( 6-1)). 4-3

84 ENGINE Removal and installation 4. If necessary, mark the hoses and the connections. 5. Disconnect the line (1). ILAj Disconnect the exhaust pipe (). ILAj Drain the fan drive s hydraulic system (see DD1066_xx on the VDL Bus & Coach Documentation Portal). 8. Place an oil container under the hydraulic pump. 9. Disconnect the hydraulic pump's hoses (3). 10. Plug the openings on the gear pump and the lines/hoses immediately to prevent any dirt from getting into the system. 11. Remove the air conditioning compressor without disconnecting the air conditioning lines. Hang the air conditioning compressor on the chassis. ILAj

85 ENGINE Removal and installation 1. Disconnect the connector (1). 13. Disconnect the line () and the hose (3) between the air filter and the turbo compressor. 14. Disconnect the hoses (4) between the intercooler and the turbo compressor and between the intercooler and the air intake manifold. 15. Disconnect the hose (5) between the silencer and the air compressor at the air compressor. ILAj Depressurize the brake's pneumatic system. 17. Disconnect the air compressor line (1) at the air compressor. 18. Disconnect the air dryer's control line at the scuttle panel. ILAj

86 ENGINE Removal and installation 19. Drain the steering system (see Group 7). 0. Place an oil container under the steering pump. 1. Disconnect the hoses ( and 3) from the steering pump (4).. Immediately plug the lines/hoses and the openings on the steering pump to prevent dirt from entering the system. ILAe01 3. Disconnect the sump filling line (1). 4. Drain the fuel system. 5. Disassemble the electrical bracket (1). 6. Disassemble the cable bracket (). ILAj147 ILAj

87 ENGINE Removal and installation 7. Disconnect the hoses between the preliminary fuel filter/ water separator and the engine. Plug the lines. ILAj Disconnect the EAS line between the 3-way valve and the engine. Plug the hose. ILAj

88 ENGINE Removal and installation 9. Disconnect the earth cables from the engine block. 30. If necessary, mark the electrical connections. ILAh Disconnect the EDC unit's wiring/connectors. Make sure the ends of the wiring harness do not get stuck behind the engine when removing the engine. 3. Disconnect the speed sensor connector from the gearbox. ILAh

89 ENGINE Removal and installation 33. Disconnect the wiring of the tachograph (1). 34. Voith: Disconnect the Voith gearbox's connector (). 35. ZF: Disconnect the ZF gearbox's wiring harness. 36. Remove the drive shaft (see group 3). 37. Support the drive unit with a jack whose height can be adjusted. NOTE! The weight of the engine + gearbox is approximately 1,300 kg. It is NOT permitted to directly support the engine under the sump pan or by the edge of the sump pan. 38. Disconnect the front engine brackets from the chassis (see Vibration dampers: removing and installing ( 4-4)). 39. Disconnect the rear engine brackets from the engine (see Vibration dampers: removing and installing ( 4-4)). Voith Diwa.6 ZF Ecolife ILAe014 ILAe

90 ENGINE Removal and installation 40. Remove the end beam. In some cases, extra stop blocks or other protection may be fitted to protect the end bar. They must be removed first so that the end bar becomes accessible. 41. Disconnect the air conditioning compressor. 4. Secure the air conditioning compressor to the bodywork. Make sure it is secured in such a way that it does not hinder the removal of the drive unit. ILAj14 ILAj Remove the light unit together with the left-hand rear bracket. 44. Remove the engine bracket (1) to improve access. 45. Check whether the drive unit is completely free and carefully manoeuvre the drive unit backwards/downwards out of the vehicle. ILAj1439 Replacing the engine This procedure is only for when installing a new engine. Follow the installation procedure (for the drive unit) if the engine that is removed is also reinstalled in the vehicle. 1. Disassemble the gearbox (see Group 3). 4-10

91 ENGINE Removal and installation. Disassemble the cover of the FPT engine for the benefit of the hydraulic pump. 3. Dispose of the cover, the fasteners and the gasket. Do not reuse the gasket. 4. Fit a new gasket (6) and the PTO (5) for the hydraulic pump with washers (7) and bolts (8) to the FPT engine. 5. Tighten the bolts (8) to the specified torque (see 0 -. Engine tightening torques ( -)). ILAj141 ILAj Use the attachment bolts (1) to fit the hydraulic pump () to the PTO (5). Parts 5, 5a and 5b belong together (they are paired) and must not be swapped with the same parts that were delivered with another part. 7. Tighten the bolts (1) to the specified torque (see 0 -. Engine tightening torques ( -)). 8. Swap the following parts from the removed engine to the new engine (if they remained on the removed engine). Exhaust pipe on the butterfly valve. Lines on the compressor. Pipe on the inlet manifold. Pipe on the turbo compressor. 9. Install the gearbox (see Group 3). 10. Check the engine brackets mounting rubbers. If necessary, replace the brackets (see Vibration dampers: removing and installing ( 4-4)). 11. Manoeuvre the drive unit into the vehicle. ILAj

92 ENGINE Removal and installation 1. Fit the attachment bolts for all the engine brackets and tighten them by hand. 13. Tighten the engine mounting bolts to the specified torque (see 0 -. Engine tightening torques ( -)). Make sure the drive line is attached free of tension. 14. Fit the end bar. 15. Next, fit the components in the reverse order to which they were removed, observing the instructions given below: Tighten the connections to the specified torques (see "Technical information"). Make sure the electrical connections make good contact. Check the hoses and hose clips and, if necessary, replace them. Refit the wiring harnesses as they were originally fitted. Fasten the plastic lines as they were originally fitted so that there is no chance that they can rub through or vibrate themselves loose. 16. Fill the cooling system (see Cooling system: draining ( 6-1)). 17. Check the engine and gearbox oil level. If necessary, top up with the specified oil (see DW050335_xx on the VDL Bus & Coach Documentation Portal). 18. Fill and bleed the fuel system. 19. Fill the fan drive s hydraulic system (see document DD1066_xx00). 0. Fill the steering system with the specified oil (see DW050335_xx). 1. Connect the earth cable to the batteries (see 4.1 Battery terminal clamps: removing and installing ( 4 -)).. Bleed the hydraulic system. 3. Start the engine and leave it to run for a couple of minutes. After a couple of minutes, check the level of all the systems (coolant, hydraulic/power steering and engine oil). Pay attention to any leaks from the connections that were disconnected. 4. Fit the engine encapsulation. Installing 1. Check the engine brackets mounting rubbers. If necessary, replace the brackets (see Vibration dampers: removing and installing ( 4-4)).. Manoeuvre the drive unit into the vehicle. 3. Fit the attachment bolts for all the engine brackets and tighten them by hand. 4. Tighten the engine mounting bolts to the specified torque (see 0 -. Engine tightening torques ( -)). Make sure the drive line is attached free of tension. 5. Fit the end bar. 4-1

93 ENGINE Removal and installation 6. Next, fit the components in the reverse order to which they were removed, observing the instructions given below: Tighten the connections to the specified torques (see Technical information ( 0-1)). Make sure the electrical connections make good contact. Check the hoses and hose clips and, if necessary, replace them. Refit the wiring harnesses as they were originally fitted. Fasten the plastic lines as they were originally fitted so that there is no chance that they can rub through or vibrate themselves loose. 7. Fill the cooling system (see Cooling system: draining ( 6-1)). 8. Check the engine and gearbox oil level. If necessary, top up with the specified oil (see DW050335_xx on the VDL Bus & Coach Documentation Portal). 9. Fill and bleed the fuel system. 10. Fill the fan drive s hydraulic system (see document DD1066_xx). 11. Fill the steering system with the specified oil (see DW050335_xx). 1. Connect the earth cable to the batteries (see 4.1 Battery terminal clamps: removing and installing ( 4 -)). 13. Bleed the hydraulic system. 14. Start the engine and leave it to run for a couple of minutes. After a couple of minutes, check the level of all the systems (coolant, hydraulic/power steering and engine oil). Pay attention to any leaks from the connections that were disconnected. 15. Fit the vehicle s engine encapsulation. 4-13

94 ENGINE Removal and installation 4.3 HYDRAULIC PUMP: REMOVING AND INSTALLING Removing the hydraulic pump 1. Disconnect the earth cable from the batteries (see 4.1 Battery terminal clamps: removing and installing ( 4 -)).. Drain the hydraulic fan drive's hydraulic oil reservoir. To do so, disconnect the suction line (A) and the delivery line (B) on the gear pump and collect the hydraulic oil that escapes. 3. Plug the openings on the gear pump and the lines/hoses immediately to prevent any dirt from getting into the system. 4. Remove the two Allen screws (1) from the hydraulic pump () and remove the gear pump and the connecting piece (5b). 5. When replacing the gear pump, fit the old gear pump's connections to the new gear pump. ILAj1410 ILAj

95 ENGINE Removal and installation Installing the hydraulic pump 1. Fit a new O-ring to the hydraulic pump. ILAj1411. Use the connecting piece (5a) from the old hydraulic pump on the new hydraulic pump. Remove the locking washer (4) and the nut (3). Tighten the nut to the specified torque (see 0 -. Engine tightening torques ( -)). Parts 5, 5a and 5b belong together (they are paired) and must not be swapped with the same parts that were delivered with another part. 3. Use the attachment bolts (1) to fit the hydraulic pump () to the PTO (5). 4. Fit the suction line (A) and the delivery line (B). 5. Fill the fan drive s hydraulic system with the specified oil (see DW050335_xx on the VDL Bus & Coach Documentation Portal). 6. Connect the earth cable to the batteries (see Battery terminal clamps: removing and installing ( 4 -)). 7. Start the engine and leave it to run for a couple of minutes. The fan drive's hydraulic system is self-bleeding. After a while, check the fan drive's oil level. Pay attention to any leaks from the connections that were disconnected. ILAj

96 ENGINE Removal and installation 4.4 COOLANT HEATING ELEMENT: REMOVING AND INSTALLING Before starting work on the heating element, check whether the element/engine coolant has cooled down. Not allowing the element/coolant to cool down sufficiently can result in a serious burn. Coolant is a harmful liquid. Therefore, avoid skin contact to prevent poisoning. Always read the safety data sheet. Removing the heating element 1. Drain the coolant (see Cooling system: draining ( 6-1)).. If the element is hot, allow it to cool down before removing it. 3. Disconnect the heating element s connector. 4. Unscrew the heating element out of the engine block (SW36). ILAh

97 ENGINE Removal and installation Cleaning and inspecting the heating element 1. Thoroughly clean the screw thread/opening in the engine block with a clean cloth.. Clean the heating element with a clean cloth. Make sure the heating element is free of scale deposits and contamination. 3. If the scale deposits/contamination cannot be removed, then the element must be replaced. 4. Check the cabling for damage and faults. If necessary, replace it. Installing the heating element 1. Check the heating element's copper sealing ring (3) and check whether the sealing surfaces are clean.. Screw the nut () of the heating element (1) into the engine block (the nut and the heating element can rotated independently). Rotate the heating element so that the cabling does not touch the exhaust pipe. Tighten the nut (SW36) to the specified torque (see 0 -. Engine tightening torques ( -)). 3. Connect the heating element s connector. Never connect the heating element if there is no coolant in the engine. ILAh Fill the cooling system (see Cooling system: draining ( 6-1)). 5. Check the operation of the heating element. Insert the plug into the plug socket. The engine block around the heating element must become noticeably warm. 4-17

98 ENGINE Removal and installation 4.5 ENGINE POLY V-BELTS: REMOVING AND INSTALLING Always fit the same type of poly V-belt. The engine has three poly V-belts. One poly V-belt (A) for the generator drive. One poly V-belt (B) for the pulley drive. One poly V-belt (C) for the water pump drive. One poly V-belt (D) for the pulley and 3rd generator drive. ILAj178 ILAj

99 ENGINE Removal and installation GENERATOR DRIVE POLY V-BELT Removing the poly V-belt 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Place a suitable pry bar with a 3/8 connection in the arm of the automatic belt tensioner. 3. Slacken the poly V-belt so that it can be removed from the pulleys. 4. Remove the poly V-belt. 5. Allow the automatic belt tensioner to slowly spring back to the stop. ILAj118 Installing the poly V-belt 1. Inspect the pulleys for damage, rust and grease deposits.. Place the (new) poly V-belt over as many pulleys as possible. 3. Tighten the automatic belt tensioner and place the poly V-belt over the remaining pulleys. Allow the automatic belt tensioner to slowly spring back against the (new) poly V-belt. 4. If used, remove the blocking pin. The blocking pin can be removed by moving the pulley against the spring force. 5. Check that the poly V-belt is positioned in all of the pulleys' grooves. 6. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -)). 1 Automatic belt tensioner Generator pulley 3 Guide roller 4 Crankshaft pulley 5 Poly V-belt ILAj

100 ENGINE Removal and installation 4.5. PULLEY DRIVE POLY V-BELT Removing the poly V-belt 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Remove the air conditioning compressor s V-belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 3. Remove the generator drive's poly V-belt (1) (see Generator drive poly V-belt ( 4-19)). 4. Place a suitable pry bar with a 3/8 connection in the arm of the automatic belt tensioner. 5. Slacken the poly V-belt so that it can be removed from the pulleys. 6. Remove the poly V-belt. 7. Allow the automatic belt tensioner to slowly spring back to the stop. ILAj119 Installing the poly V-belt 1. Inspect the pulleys for damage, rust and grease deposits.. Place the (new) poly V-belt over as many pulleys as possible. 3. Tighten the automatic belt tensioner and place the poly V-belt over the remaining pulleys. Allow the automatic belt tensioner to slowly spring back against the (new) poly V-belt. 4. If used, remove the blocking pin. The blocking pin can be removed by moving the pulley against the spring force. 5. Check that the poly V-belt is positioned in all of the pulleys' grooves. 6. Fit the generator drive's poly V-belt (1) (see Generator drive poly V-belt ( 4-19)). 7. Fit the air conditioning compressor s poly V-belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 8. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -)). 1 Automatic belt tensioner Pulley drive pulley 3 Guide roller 4 Crankshaft pulley 5 Poly V-belt ILAj

101 ENGINE Removal and installation RD GENERATOR DRIVE POLY V-BELT Removing the poly V-belt 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Remove the air conditioning compressor s V-belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 3. Remove the generator drive's poly V-belt (1) (see Generator drive poly V-belt ( 4-19)). 4. Place a suitable pry bar with a 3/8 connection in the arm of the automatic belt tensioner. 5. Slacken the poly V-belt so that it can be removed from the pulleys. 6. Remove the poly V-belt. 7. Allow the automatic belt tensioner to slowly spring back to the stop. ILAj117 Installing the poly V-belt 1. Inspect the pulleys for damage, rust and grease deposits.. Place the (new) poly V-belt over as many pulleys as possible. 3. Tighten the automatic belt tensioner and place the poly V-belt over the remaining pulleys. Allow the automatic belt tensioner to slowly spring back against the (new) poly V-belt. 4. If used, remove the blocking pin. The blocking pin can be removed by moving the pulley against the spring force. 5. Check that the poly V-belt is positioned in all of the pulleys' grooves. 6. Fit the generator drive's poly V-belt (1) (see Generator drive poly V-belt ( 4-19)). 7. Fit the air conditioning compressor s poly V-belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 8. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -)). 1 Automatic belt tensioner Pulley drive pulley 3 Guide roller 4 Crankshaft pulley 5 Poly V-belt 6 3rd generator pulley ILAj

102 ENGINE Removal and installation WATER PUMP DRIVE POLY V-BELT Removing the poly V-belt 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Remove the air conditioning compressor s V-belt (see 3.1 Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 3. Remove the generator drive's poly V-belt (1) (see Generator drive poly V-belt ( 4-19)). 4. Remove the pulley drive's poly V-belt (see 4.5. Pulley drive poly V-belt ( 4-0)). 5. Place a 17 mm ring spanner on the automatic belt tensioner's hexagon. It is possible to temporarily block the tensioner by inserting a 4-5 mm thick pin through the first hole (see arrow) and the second hole (A). This will make it easier to assemble and disassemble the poly V-belt. ILAj Slacken the poly V-belt so that it can be removed from the pulleys. 7. Remove the poly V-belt. 8. If the tensioner has not been temporarily blocked, allow the automatic belt tensioner to slowly spring back to the stop. Installing the poly V-belt 1. Inspect the pulleys for damage, rust and grease deposits.. Place the (new) poly V-belt over as many pulleys as possible. 3. Use a 17 mm ring spanner to slacken the automatic belt tensioner (if it has not been temporarily blocked) and place the poly V-belt over the remaining pulleys. Allow the automatic belt tensioner to slowly spring back against the (new) poly V-belt. 4. If used, remove the blocking pin. The blocking pin can be removed by moving the pulley against the spring force. 5. Check that the poly V-belt is positioned in all of the pulleys' grooves. 6. Fit the pulley drive's poly V-belt (see 4.5. Pulley drive poly V-belt ( 4-0)). 7. Fit the generator drive's poly V-belt (1) (see Generator drive poly V-belt ( 4-19)). 8. Fit the air conditioning compressor s poly V-belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). 9. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -)). 4-1 Automatic belt tensioner Water pump pulley 3 Crankshaft pulley 4 Poly V-belt ILAj180

103 ENGINE Removal and installation 4.6 3RD GENERATOR: REMOVING AND INSTALLING Removing the 3rd generator 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Remove the 3rd generator s electrical connections. If necessary, remove the wiring harness bracket. 3. Remove the poly V-belts (see Engine poly V- belts: removing and installing ( 4-18)). 4. Remove the 3rd generator s attachment bolts (1 and ) and remove the generator (3). ILAj119 Installing the 3rd generator 1. Clean all the attachment surfaces and remove any grease, so that a good galvanic connection can be made between the generator and the engine block.. Fit the 3rd generator (3) and tighten the attachment bolts (1 and ) to the specified torque (see 0 -. Engine tightening torques ( -)). 3. Fit the poly V-belts (see Engine poly V-belts: removing and installing ( 4-18)). 4. Install the wiring harness bracket if it was removed. Fit the 3rd generator s electrical connections. 5. Connect the battery's earth cable (see -4.1Battery terminal clamps: removing and installing ( 4 -)). Checking the operation of all the generators 1. Check the condition of the batteries.. Check whether the warning light goes out after the engine has been started. 3. Turn on as many electrical consumers as possible. 4. Measure the nominal voltage across the battery terminals when the engine is running. 4-3

104 ENGINE Removal and installation 4.7 VIBRATION DAMPERS: REMOVING AND INSTALLING ILAj

105 ENGINE Removal and installation Securely support the engine using approved tools. It is NOT permitted to directly support the engine under the sump pan or by the edge of the sump pan. Various types of fluid will be released when removing fluid lines. Collect these fluids. Consider your own personal protection and avoid fire risks. Removing the front vibration dampers 1. Support the drive unit with a jack whose height can be adjusted.. Remove the attachment bolts (F and I) of both vibration dampers. 3. If necessary, jack up the drive unit so that the vibration dampers are accessible. 4. Remove the vibration dampers attachment bolts (J and K) from the brackets and remove the vibration dampers. Installing the front vibration dampers 1. Check all the brackets for cracks. If necessary, replace the brackets.. Support the drive unit with a jack whose height can be adjusted. 3. If necessary, slightly jack up the drive unit so that the vibration dampers can be fitted. 4. Tighten the vibration dampers attachment bolts (J and K) to the specified torque (see 0 -. Engine tightening torques ( -)). 5. Lower the jack so that the drive unit rests on the vibration dampers. 6. Fit the attachment bolts (F and I) and tighten them by hand. 7. Tighten the attachment bolts to the specified torque (see 0 -. Engine tightening torques ( -)). Removing the rear vibration dampers 1. Support the drive unit with a jack whose height can be adjusted.. Remove the vibration dampers attachment bolts (A and C) from the engine bracket. 3. If necessary, jack up the drive unit so that the vibration dampers are accessible. 4. Remove the vibration dampers' attachment bolts and remove the vibration dampers. 4-5

106 ENGINE Removal and installation Installing the rear vibration dampers 1. Check all the brackets for cracks. If necessary, replace the brackets.. Support the drive unit with a jack whose height can be adjusted. 3. If necessary, slightly jack up the drive unit so that the vibration dampers can be fitted. 4. Tighten the vibration dampers attachment bolts (E) to the specified torque (see 0 -. Engine tightening torques ( -)). 5. Lower the jack so that the drive unit rests on the vibration dampers. 6. Fit the attachment bolts (A and C) and tighten them by hand. 7. Tighten the attachment bolts to the specified torque (see 0 -. Engine tightening torques ( -)). 4-6

107 ENGINE Removal and installation 4-7

108 ENGINE Removal and installation 4-8

109 ENGINE Cleaning 5. CLEANING 5.1 ENGINE: CLEANING It is recommended to clean the engine before any work is carried out on it. This makes the mechanic's work easier and enables him to notice any faults with the engine at an early stage. Check the engine for leaks before cleaning it. Cleaning the engine with a high-pressure hose The engine and engine compartment can be cleaned with a high-pressure hose. If the engine is cleaned with a high-pressure hose, then attention must be given to the following: 1. When spraying the engine encapsulation, maintain a minimum distance of 50 cm between the engine encapsulation and the nozzle in order to avoid damage to the engine encapsulation.. Do not spray directly at the electrical components, such as the starter motor and the alternator. 3. Do not spray directly at electrical connections, such as the motor management system s connectors. 4. Be careful not to damage the element s lamellae when cleaning the radiator/intercooler. 5. Do not direct the jet of the high-pressure hose at the air conditioning system s condenser for too long. As a result of the high temperature, excessive pressure will build up in the system, which will cause damage to the system. 6. Make sure no water can enter the air intake system via the air inlet or its flexible seals. 7. Do not aim the spray too long at the same place, because this can result in the penetration of moisture. Cleaning the engine with a steam cleaner Wear protective clothing and safety goggles or a face mask when using a steam cleaner. Hot steam can cause a serious injury. The following components must not be cleaned with a steam cleaner: Electrical components Electric wiring harnesses Injection nozzles Fuel pump (Poly) V-belts and hoses Bearings (ball bearings and roller bearings) 5-1

110 ENGINE Cleaning Electronic control module (ECM) EBM connectors Dosing unit NOx sensor 5 -

111 COOLING SYSTEM COOLING SYSTEM 3

112 COOLING SYSTEM 3

113 COOLING SYSTEM Safety regulations 1. SAFETY REGULATIONS Do not allow the engine to run in a confined or unventilated space. Make sure the exhaust fumes are properly extracted. Remain a safe distance from rotating and/ or moving components. Various types of oil and other lubricants used on the vehicle can harm your health. This also applies to engine coolant, screenwash fluid, coolant in air conditioning systems, battery acid and diesel. Therefore, avoid internal and external bodily contact with these liquids. 3 Exhaust gases contain carbon monoxide. Carbon monoxide is a deadly, colourless and odourless gas which, when inhaled, deprives the body of oxygen, leading to asphyxiation. Serious carbon monoxide poisoning can result in brain damage or even death. For work that does not require the vehicle to have a power source, it is recommended to always disconnect the earth cable from the battery. Never remove the cooling system s filler cap when the engine is at the operating temperature. 1-1

114 COOLING SYSTEM Safety regulations 3 1 -

115 COOLING SYSTEM General information. GENERAL INFORMATION.1 DESCRIPTION OF THE COOLING SYSTEM 3 ILAj1401 A Cooling B Heating A01 Radiator B01 Right-hand roof radiator A0 Engine block B0 Left-hand roof radiator A03 Coolant pump B03 Driver radiator A04 Thermostat B04 Skirting-board heating A05 Transmission cooler B05 Skirting-board heating A06 Oil cooler B06 Webasto A07 Drain tap B07 Supply line tap A08 Quick-fill coupling B08 Return line tap A09 Expansion tank B09 Heating valve for the AdBlue tank and A10 Expansion reservoir pressure cap (100 kpa) EAS dosing unit B10 AdBlue tank Bleed lines B11 EAS dosing unit Internal minimum/maximum: Ø 6/10 mm. B1 Dosing module - 1

116 COOLING SYSTEM General information The task of the engine s cooling system is to keep the engine s temperature constant, irrespective of the varying engine load, engine speed and outside temperature. At this temperature, the engine is the most efficient and undergoes the least amount of wear. To achieve controlled engine cooling, the amount of coolant flowing through the radiator is regulated by a thermostat. Bleed lines are fitted in various places. These bleed lines go to the expansion reservoir and the radiator. This way, the system is automatically bled. The supply lines for the heating system are connected at the top of the engine. 3 The cooling system consists of a coolant pump (A03), a radiator with a hydraulic fan drive (A01), an expansion reservoir (A10), a transmission cooling (A05), an oil cooler (A06), a thermostat housing (A04) and some lines. The coolant flows to the motor block (A0) from the delivery side of the coolant pump via an opening at the rear of the coolant pump (A03). The coolant exits the motor block via the thermostat housing (A04). Depending on the temperature of the coolant, the thermostat, which is located in the thermostat housing (A04), either sends the coolant to the radiator (A01) or back to the coolant pump (A03). The coolant that flows to the radiator flows into the radiator at the top and flows out at the bottom. From the underside of the radiator, the coolant is fed back to the coolant pump (A03) through the return line via the thermostat housing. The connection line with to expansion reservoir (A09) is connected to the return line. -

117 COOLING SYSTEM General information A B C D Gearbox heat exchanger Engine Thermostat closed Thermostat open 1 Return from the radiator Return from the heat exchanger to the thermostat 3 Supply to the radiator 4 Recirculation (bleed valve) 5 To the coolant pump 6 Outlet from the cylinder head 7 Supply to the gearbox heat exchanger 3 ILAj140-3

118 COOLING SYSTEM General information.1.1 COOLING SYSTEM DIAGRAM - COLD 3 ILAj Water pump Cooling unit 3 Thermostat housing 4 Coolant reservoir A To gearbox heat exchanger B Return from gearbox heat exchanger - 4

119 COOLING SYSTEM General information.1. COOLING SYSTEM DIAGRAM - WARM 3 ILAj Water pump Cooling unit 3 Thermostat housing 4 Coolant reservoir A To gearbox heat exchanger B Return from gearbox heat exchanger - 5

120 COOLING SYSTEM General information.1.3 GEARBOX COOLING SYSTEM DIAGRAM 3 ILAj Thermostat housing Gearbox 3 Heat exchanger - 6

121 COOLING SYSTEM Component description 3. COMPONENT DESCRIPTION 3.1 EXPANSION TANK The cooling system is self-bleeding. There is a pressure cap () and a filler cap (3) fitted to the expansion tank (1). The bleed lines for components such as the radiator and the heating system are connected to the expansion tank via port (4). Port (6) is connected to the coolant supply line that goes to the coolant pump. This port makes it possible for coolant to flow between the expansion tank and the engine as the coolant temperature rises. The coolant level in the expansion tank is monitored by the coolant level sensor (5). There is a viewing glass (7) to visually check the coolant level. 3 1 Expansion tank Pressure cap 3 Filler cap 4 Bleed connection 5 Coolant level sensor 6 Water pump connection 7 Viewing glass ILAj

122 COOLING SYSTEM Component description 3. COOLING SYSTEM PRESSURE CAP The pressure cap and filler cap on the tank are attached to the tank by means of a screw connection. The pressure cap () can be removed when filling, so that the tank can be quickly bled. A filler cap (3) is fitted on the front of the expansion tank for filling the cooling system. The pressure cap and filler cap have two valves. Both valves are normally closed. 3 ILAj1403 Excess pressure in the cooling system If the pressure in the cooling system increases to approximately 0.9 bar, then the pressure relief valve in the pressure cap will open. The excess pressure in the cooling system allows a higher temperature in the cooling system without the coolant starting to boil. Vacuum pressure in the cooling system A vacuum pressure is created in the cooling system as a result of the coolant cooling down. The vacuum valve in the pressure cap opens at a pressure of approximately 0.1 bar and this increases the pressure in the system. This prevents the rubber hoses from being squeezed closed and ensures that the system is not topped up from the expansion tank. ILAj

123 COOLING SYSTEM Component description 3.3 COOLANT LEVEL SENSOR Coolant level sensor The coolant level sensor consists of two micro switches (reed switches). Micro switch S1 is switched in parallel with two resistances. Micro switch S is switched in parallel with one resistance. A magnetic field outside the sensor has an influence on the micro switches. If the coolant level falls, a float that floats on the coolant and which has a permanent magnet ensures that the micro switches are closed. Since the micro switches are closed, the resistance on the sensor s connection clamps changes. The VFC can determine the status of the switches based on the measured resistance value. 3 ILAj1396 Normal level For a measured resistance value of R1 + R, the switches S1 and S are open. This is a signal for the VFC that the coolant level is high enough. ILAj

124 COOLING SYSTEM Component description Low level For a resistance value equal to R1, switch S1 is still open, but switch S is closed. This is a signal for the VFC that the coolant level has dropped to the top-up level. Based on this, the VFC activates the above LED in the fuel cowl and the above symbol on the instrument panel so that it is clear during the next daily inspection that the coolant must be topped up. 3 ILAj1405 Too low level If the measured resistance value is 0 Ohm, then the VFC knows that both resistances have short-circuited and S1 is, therefore, closed. For the VFC, this is a signal that the coolant level is too low. Based on this, the VFC will activate the above symbol on the instrument panel. Faulty sensor If the measured resistance value is > 470 Ohm, then the VFC knows that the sensor is faulty. Based on this, the VFC will activate the instrument panel. The symbol shown above will flash. ILAj

125 COOLING SYSTEM Component description 3.4 THERMOSTAT Thermostat operation The coolant flows from the cylinder head to the thermostat. Depending on the temperature of the coolant, there are three possible thermostat positions: Thermostat closed (C) The coolant s temperature has not yet reached the thermostat's opening temperature. The supply duct (3) to the radiator is fully closed. The coolant returns to the engine block. The coolant pump pumps the coolant through the engine block (B). 3 Thermostat open (D) The coolant temperature rises and the supply duct (3) to the radiator opens. The coolant flows via the supply duct (3) to the radiator, where it will be cooled. It then flows back to the coolant pump (5) via the return duct (1). It is not permitted to remove the thermostat as a temporary emergency solution when the coolant temperature is too high. If there is no thermostat in the engine, the uncooled coolant will flow to the coolant pump via the bypass duct. This will only cause the temperature of the coolant to increase even further. A B C D Gearbox heat exchanger Engine Thermostat closed Thermostat open 1 Return from the radiator Return from the heat exchanger to the thermostat 3 Supply to the radiator 4 Recirculation (bleed valve) 5 To the coolant pump 6 Outlet from the cylinder head 7 Supply to the gearbox heat exchanger ILAj

126 COOLING SYSTEM Component description 3.5 COOLING UNIT 3 ILAj1407 The cooling unit is mounted in the longitudinal direction above the engine. A removable grille (screen) is fitted in front of the cooling unit to keep contamination of the cooling unit to a minimum. The fan is hydraulically driven. Certain hydraulic hoses in the engine compartment have fire-resistant protection called TEXSLEEVE. This hose protection prevents oil from being sprayed around uncontrollably if there is an oil leak. The hose protection is fire-resistant and mechanically wear-resistant. The fan drive is automatically turned off if there is a fire warning in the engine compartment. The cooling unit consists of the following: 1 Intercooler Oil cooler 3 Radiator 4 Air cooler 5 Fan 6 Fan drive hydraulic motor 7 Grille 3-6

127 COOLING SYSTEM Inspection and adjustment 4. INSPECTION AND ADJUSTMENT Comment: For information on how to check and adjust engine-specific components, see DD1030_xx on the VDL Bus & Coach Documentation Portal

128 COOLING SYSTEM Inspection and adjustment 4.1 COOLANT LEVEL: CHECKING AND TOPPING UP Coolant is a harmful liquid. Therefore, avoid skin contact to prevent poisoning. Always read the safety data sheet. Checking/topping up the coolant level 1. Turn the heater s rotary switch to "warm".. Remove the filler cap (1) from the expansion tank. 3. Start the engine and allow it to idle for a couple of minutes. 3 There is excess pressure in the cooling system when the coolant becomes hot. Carefully remove the filler cap to remove the excess pressure. 4. Turn off the engine and check the coolant level. 5. The coolant level must be between the maximum and minimum levels. If necessary, top up the coolant to the maximum level via the filler opening (1). Only top up the cooling system with the specified coolant (see DW050335_xx on the VDL Bus & Coach Documentation Portal). If the coolant level has been below the minimum level, the cooling system should be filled and bled. To prevent damage to the engine block, do not add cold coolant whilst the engine is warm. No other coolant, additives or antifreeze may be added to the mixture. ILAj0686 Comment: The coolant reservoir has a minimum level sensor. If the coolant level is too low, the symbol shown opposite will be displayed on the dashboard s main display. The symbol will disappear approximately 1 minute after the coolant has been topped up to the correct level. 4 -

129 COOLING SYSTEM Inspection and adjustment 4. COOLING SYSTEM: CHECKING FOR LEAKS AND DAMAGE 4..1 PRESSURE TESTING THE COOLING SYSTEM Coolant is a harmful liquid. Therefore, avoid skin contact to prevent poisoning. Always read the safety data sheet. The cooling system can be checked for leaks using a pressurization pump. Any leaks can be spotted more quickly if this is carried out whilst the engine is warm. Pressure testing the cooling system 1. Fill the cooling system to the maximum level. Top up the cooling system with the specified coolant (see DW050335_xx on the VDL Bus & Coach Documentation Portal). 3 To prevent damage to the engine block, do not add cold coolant whilst the engine is warm.. Increase the engine temperature. The engine does not have to be at the operating temperature. There is excess pressure in the cooling system when the coolant becomes hot. Carefully remove the filler cap to remove the excess pressure. 3. Remove the filler cap from the expansion tank. 4. Fit the pressurization pump. 5. The pressure cap is also checked by fitting the pressurization pump to the filler opening on the expansion tank. See General information ( 3-1) for the opening pressure of the pressure relief valve and the vacuum valve. Pressurize the system to the specified pressure (see General information ( 3-1)). The pressure must remain constant for at least 10 minutes. 6. Check the cooling system for leaks. ILAj0034 The cause of an external leak can be traced to the following components: Coolant hoses and/or lines. A leaking radiator, coolant pump or heater. Seals/gaskets. The pressure cap. The cause of an internal leak can be traced to the following components: Faulty head gasket or oil cooler. Cracked cylinder head or cylinder block The air compressor cylinder head 4-3

130 COOLING SYSTEM Inspection and adjustment 4.. CHECK THE COOLING UNIT 3 Checking the cooling unit 1. Check the cooling unit s mounting brackets and vibration dampers for faults.. Check whether all the line clamps and suspension straps are present and check their attachment. 3. Check the fan blade for damage. 4. Check whether the fan runs freely in the wind tunnel. 5. Check the hydraulic motor s bearings for play. 6. Check the rubber seal between the cooling unit and the bodywork for faults. 7. Check whether the hose between the hydraulic motor and the fan regulator has a Texsleeve protective sleeve. 8. Check whether the hose between the hydraulic pump and the fan regulator has a Texsleeve protective sleeve. ILAj

131 COOLING SYSTEM Inspection and adjustment 4.3 COOLANT HOSES: INSPECTING SAFETY REGULATIONS Coolant is a harmful liquid. Therefore, avoid skin contact to prevent poisoning. Always read the safety data sheet. Allow the cooling system to cool down before carrying out maintenance work. When working on the engine, turn OFF the main switch unless it is necessary to have it turned on for the work that is being carried out. Also make sure the engine cannot be started unintentionally POINTS OF ATTENTION If one hose is faulty, there is a chance that the other hoses have the same problem. Therefore, for preventative reasons, replace the other coolant hoses as well. When replacing the hoses, check whether the new hose is of the same type, diameter, length and shape as the hose being replaced GENERAL INSPECTION Check the coolant hoses for kinks and make sure the hoses do not touch any moving parts or sharp edges. Oil can damage the hoses. Check whether the hoses are swollen and check them for soft or sticky areas. Check the hose connections for leaks. Tighten the hose clamps or, if necessary, replace them. Check the physical condition of the hoses by squeezing them. 1. Make sure the cooling system has cooled down.. Use your thumb and fingers to check the hoses. Do not use your whole hand. A good hose must be elastic and flexible. If a hose feels very soft and flaccid, or is very hard and brittle, then it must be replaced. 3. Squeeze the hose connections. Any faults usually occur within 5 cm from the end of the hose. 4. Check whether there is a difference between the middle and the ends of the hose. 5. If the ends feel soft, then the hose must be replaced immediately. 4-5

132 COOLING SYSTEM Inspection and adjustment FAULT FINDING TABLES Swollen hose 3 Possible cause The hose has lost its elasticity and has swollen due to the pressure. The hose will easily crack. Hard hose Remedy Replace the hose. Possible cause The hose has become brittle. The hose will crack/leak. Remedy Replace the hose. Cracked hose Possible cause The hose (outer mantle) is cracked and will leak. Remedy Replace the hose. Soft hose Possible cause The hose has become flaccid. It will implode and close off completely. Remedy Replace the hose. 4-6

133 COOLING SYSTEM Inspection and adjustment Damaged/worn hose clamp Possible cause If old hose clamps are used to attach a new hose, it may not be possible to tighten the hose clamps. This will result in leaks and faults. Replace the hose and the hose clamps at the same time. Remedy Always replace the hose clamps together with the hose

134 COOLING SYSTEM Inspection and adjustment 4.4 COOLANT: CHECKING THE SPECIFIC DENSITY There is excess pressure in the cooling system when the coolant becomes hot. Carefully remove the filler cap to remove the excess pressure. Coolant is a harmful liquid. Therefore, avoid skin contact to prevent poisoning. 3 Procedure 1. Remove the cooling system s filler cap.. Use a refractometer (special tool) to check the coolant s specific density. Follow the manufacturer s instructions when doing so. 3. The specific density for a mixture of Mixing ratio 50% 40% Specific density at 0 C A mixture of more than 70% and less than 30% of Halvoline XLC is not permitted. Optimal protection for the cooling system is guaranteed with a mixture of 50-60% Halvoline with water. For the requirements placed on the water, see DW050335_xx on the VDL Bus & Coach Documentation Portal. 4. If necessary, change the density of the mixture. ILAj0031 If the cooling system must be topped up during use, then the coolant must be mixed so that it has the correct density. No other coolant, additives or antifreeze may be added to the mixture. To prevent damage to the engine block, do not add cold coolant whilst the engine is warm. 4-8

135 COOLING SYSTEM Inspection and adjustment 4.5 THERMOSTAT: INSPECTING 1. Remove the thermostat (see DD1030_xx on the VDL Bus & Coach Documentation Portal).. Check the thermostat seat for damage. 3. Check whether the thermostat is fully closed. 4. Visually check the thermostat for loose and broken off components which may have an adverse effect on its operation. 5. Place the thermostat in a container with clean water. 6. Place a thermometer in the container and heat the water. Check at which temperature the thermostat starts to open and whether the thermostat fully opens (see General information ( 3-1)). 3 A B Thermostat closed Thermostat open ILAj

136 COOLING SYSTEM Inspection and adjustment

137 COOLING SYSTEM Removal and installation 5. REMOVAL AND INSTALLATION Comment: For information on how to remove and install engine-specific components, see DD1030_xx on the VDL Bus & Coach Documentation Portal

138 COOLING SYSTEM Removal and installation 5.1 EXPANSION TANK: REMOVING AND INSTALLING Removing the expansion tank 1. Close the heating system s supply and discharge taps.. Fit a drainage hose to the bleed tap (A). Open the radiator s drain tap and drain the radiator. 3 ILAj Remove the hose (6) between the expansion tank and the coolant filler tube and drain the remaining coolant. Disconnect all the bleed hoses (4) connected to the expansion tank. 4. Disconnect the connector from the coolant level sensor (5). 5. Remove the attachment bolts of the expansion tank's mounting brackets and remove the expansion tank (1). ILAj

139 COOLING SYSTEM Removal and installation Installing the expansion tank 1. Fit the expansion tank (1) and secure it into place using the mounting brackets.. Connect all the disconnected (bleed) hoses to the expansion tank. Connect the hose (6) between the expansion tank and the coolant filler tube. Connect the coolant level sensor s connector. 3. Close the radiator s drain tap (A). 4. Open the heating system s supply and discharge taps. 5. Fill the cooling system (see Cooling system: draining ( 6-1)). 6. Start the engine and check whether all the connections are sealed. 3 ILAj

140 COOLING SYSTEM Removal and installation 5. COOLING UNIT: REMOVING AND INSTALLING Immediately plug all component, line and hose openings to prevent dirt from getting into the system. 3 Removing the cooling unit 1. Disconnect the earth cable from the batteries (see Battery terminal clamps: removing and installing ( 4 -)).. Drain the cooling system (see Cooling system: draining ( 6-1)). 3. Drain the fan drive s hydraulic system (see DD1066_xx on the VDL Bus & Coach Documentation Portal). 4. Disconnect the coolant supply and return hoses (1 and ) from the radiator. 5. Remove the bleed hose's cable ties (3). 6. Disconnect the bleed hose (4) from the radiator. ILAj Remove the flexible intercooler hoses (6). 8. Remove the suspension bracket of the hose (5). (The hose between the air compressor and the air vessel.) ILAj

141 COOLING SYSTEM Removal and installation 9. Disconnect the air line (7) from the cooling unit. 10. Remove the air line (8) and the bracket (9). 3 ILAj Remove the line (1) between the hydraulic motor (4) and the hydraulic reservoir. 1. Remove the return hose () between the hydraulic motor (4) and the hydraulic reservoir. 13. Remove the line (5) between the oil cooler and the hydraulic reservoir. 14. Disconnect the pressure regulating valve's connector (3). 15. Support the cooling unit. 16. Remove the seal between the cooling unit and the bodywork. ILAj

142 COOLING SYSTEM Removal and installation 17. Disconnect the pull rod between the cooling unit and the side wall. 18. Remove the mounting rubber s attachment nuts and remove the entire cooling unit and fan drive from the vehicle. Place the cooling unit on a workbench with the fan drive facing upwards. 19. Plug the cooling unit s inlet and outlet openings and lines. 0. If fitting a new cooling unit, remove the hoses, pipes and lines. 3 ILAj Remove the attachment nuts and remove the frame () together with the hydraulic motor.. If necessary, disassemble the cooling unit. ILAj

143 COOLING SYSTEM Removal and installation Installing the cooling unit 1. If removed, fit the fan drive s frame to the cooling unit.. Fit the hoses, pipes and lines to the cooling unit which have been disconnected. 3. Fit the entire cooling unit into the chassis and secure it into place. 4. Connect the pull rod between the cooling unit and the side wall. 5. Fit the seal between the cooling unit and the bodywork. 3 ILAj Fit the line (1) between the hydraulic motor (4) and the hydraulic reservoir. 7. Fit the return hose () between the hydraulic motor (4) and the hydraulic reservoir. 8. Fit the line (5) between the oil cooler and the hydraulic reservoir. 9. Connect the pressure regulating valve's connector (3). ILAj

144 COOLING SYSTEM Removal and installation 10. Connect the air line (7) to the cooling unit. 11. Fit the air line (8) and the bracket (9). 3 ILAj Fit the flexible intercooler hoses (6). 13. Fit the suspension bracket of the hose (5). (The hose between the air compressor and the air vessel.) ILAj

145 COOLING SYSTEM Removal and installation 14. Connect the coolant supply and return hoses (1 and ) to the radiator. 15. Use cable ties (3) to fit the bleed hose. 16. Connect the bleed hose (4) to the radiator. 17. Fill the cooling system (see Cooling system: draining ( 6-1)). 18. Fill the fan drive s hydraulic system (see DD1066_xx on the VDL Bus & Coach Documentation Portal). 19. Connect the earth cable to the battery terminal (see Battery terminal clamps: removing and installing ( 4 -)). 0. Start the engine and check whether all the connections are sealed and check the fan drive's operation. 3 ILAj

146 COOLING SYSTEM Removal and installation 5.3 COOLANT HOSES: REMOVING AND INSTALLING REMOVING 1. Drain the cooling system (see Cooling system: draining ( 6-1)). It is recommended to replace all the coolant hoses at the same time because they age at the same rate. 3. Remove the hose clip. 3. Carefully remove the hose with a rotating movement. 4. Check the hose connection and the groove/hose adaptor for damage, corrosion and sharp edges. 5. Clean the hose connection with a brush INSTALLING 1. Make sure the hose is fitted free of tension.. Always fit the specified type of hose clip (see Overview of hose clips ( 5-11)). 3. Make sure the hose falls over the ridge/hose adaptor by at least the width of the hose clamp. Make sure the hose clamp falls behind the ridge. 4. Tighten the hose clip. 5. Fill the cooling system (see 3-6. Cooling system: filling and bleeding the entire system ( 6-4)). 6. Run the engine and check the connection(s) for leaks. Check the connections again when the engine is at the operating temperature. ILAj

147 COOLING SYSTEM Removal and installation OVERVIEW OF HOSE CLIPS Different types of hose clamp are used with the cooling system: 1. FBS Normaclamp. Torro Normaclamp The Torro Normaclamp hose clamps must be tightened to a torque of Nm. ILAj Stepless screw clamps (Oetiker) Assembling Screw the hose clip open as far as possible. The bolt (1) must not come out of the nut (5). Place the hose clamp over the hose. If necessary, open the hose clamp. Make sure the tongue (3) and the hooks (4) fall into the correct recesses. Set the hose clip to the smallest possible diameter. Tighten the bolt until the coils of the spring () touch each other and then tighten the bolt a further 3 x 360 to obtain the correct pretension. The opening (A) between the D nuts must now be at least 3 mm. ILAj0407 Max. tightening torque of the hose clamp bolt: Green spring: Ncm Colourless spring: Ncm 1 Bolt Spring 3 Tongue 4 Hook 5 D-nut ILAj

148 COOLING SYSTEM Removal and installation 5.4 COOLANT LEVEL SENSOR: INSTALLING Installing the coolant level sensor 1. Screw the sensor (5) a couple of turns into the tank.. Apply soapsuds or a special insert lubricant to the O-ring. Do not use grease, oil or Vaseline with the O-ring. 3. Screw the sensor into the expansion reservoir unil the hexagon touches the tank's contact surface. 4. Tighten the sensor to the specified torque (see Tightening torques ( 3 -)). 3 ILAj

149 COOLING SYSTEM Draining and filling the cooling system 6. DRAINING AND FILLING THE COOLING SYSTEM 6.1 COOLING SYSTEM: DRAINING There is excess pressure in the cooling system when the coolant becomes hot. Carefully remove the filler cap to remove the excess pressure. Coolant is a harmful liquid. Avoid skin contact in order to prevent poisoning. Always read the safety data sheet. To prevent damage to the engine block, do not add cold coolant whilst the engine is warm. 3 Coolant is harmful to the environment and must be processed as industrial waste after use. Draining the cooling system 1. Remove the filler cap from the coolant reservoir. Collect the coolant in a suitable container. Coolant is harmful to the environment and must be processed as industrial waste after use.. Close the heating system's discharge taps (15, 16 and 17) if only draining the engine's cooling system. To drain the entire cooling system, the heating system s supply and discharge taps (15, 16 and 17) must be opened. ILAj19 6-1

150 COOLING SYSTEM Draining and filling the cooling system 3. Drain the cooling system as much as possible via the drain plug (10) Fit the discharge hose to the drain tap. Open the radiator s drain tap (A) and drain the radiator. ILAj18 ILAj

151 COOLING SYSTEM Draining and filling the cooling system Draining a Voith gearbox 1. Place a container under the heat exchanger.. Remove the delivery and discharge lines from the heat exchanger and drain the coolant via the lines. 3. Reconnect the lines after the gearbox has been drained. 4. Clean any spilt coolant. 3 ILAc0138 Draining a ZF gearbox 1. Place a container under the heat exchanger.. Remove the delivery and discharge lines from the heat exchanger and drain the coolant via the lines. 3. Reconnect the lines after the gearbox has been drained. 4. Clean any spilt coolant. ILAc0139 Draining the heating system 1. See Group 1 of the Workshop Instruction Manual for instructions on how to drain the heating system. Collect the coolant in a suitable container. Coolant is harmful to the environment and must be processed as industrial waste after use.. Rinse the cooling system (see Cooling system: cleaning (rinsing) ( 7-1)). 6-3

152 COOLING SYSTEM Draining and filling the cooling system 6. COOLING SYSTEM: FILLING AND BLEEDING THE ENTIRE SYSTEM No other coolant, additives or antifreeze may be added to the mixture. To prevent damage to the engine block, do not add cold coolant whilst the engine is warm. 3 Preparation 1. Turn off the engine.. Check the filling installation: The pressure filling installation must have a volume of at least 100 litres. The pump must have a delivery rate of at least 0 ± l/min. Bleed the filling installation so that no air is pumped into the cooling system. Read the filling installation's instruction manual. 3. Check whether the drain points have been connected/ closed. 4. Remove the filler cap from the coolant reservoir. 5. Connect the filler installation s filler hose to the quick-filling plug (9). ILAj18 6-4

153 COOLING SYSTEM Draining and filling the cooling system Filling and bleeding 1. Start the pump (max. 1 bar). Slowly fill the system (while the engine is not running) with coolant up to the maximum level indicated on the gauge glass. Use the specified coolant (see DW050335_xx on the VDL Bus & Coach Documentation Portal). When filling, check the coolant level in the expansion reservoir. Never fill it to above the maximum level on the gauge glass.. Turn off the pump when the maximum level has been reached. Wait a couple of minutes and, if necessary, top it up to the maximum level. 3. Turn the pump off, but leave the pressure hose connected. 4. Use the VDL Bus & Coach diagnosis tool to open the EAS tank heating valve. 5. Open all the heating taps (electrical and mechanical). Close the heating system s supply and discharge taps (B07, the tap after B06 and B08). 6. Turn on the preheater pump. 7. Fill the cooling system to the maximum coolant level indicated on the gauge glass. 8. Fit the filler cap on the coolant reservoir. 9. Start the engine and allow it to idle until the thermostat is fully open. Check the coolant level and, if necessary, top it up (while the engine is not running) to the maximum level indicated on the gauge glass. 10. Stop the filling procedure when the engine is turned off and the coolant level is at the maximum level. 11. Turn off the filler pump and disconnect the filling hose. Fit the cap to the quick-filling nipple. 1. Check the cooling system for leaks (see 3-4. Cooling system: checking for leaks and damage ( 4-3))

154 COOLING SYSTEM Draining and filling the cooling system 13. Check the level in the tank when the engine has cooled down. It must be between the min. and max. levels (). If necessary, top up the system via the filler opening (1). 3 ILAj

155 COOLING SYSTEM Draining and filling the cooling system 6.3 COOLING SYSTEM: FILLING AND BLEEDING (ONLY THE ENGINE) No other coolant, additives or antifreeze may be added to the mixture. To prevent damage to the engine block, do not add cold coolant whilst the engine is warm. Preparation 1. Turn off the engine.. Check the filling installation: The pressure filling installation must have a volume of at least 100 litres. The pump must have a delivery rate of at least 0 ± l/min. Bleed the filling installation so that no air is pumped into the cooling system. Read the filling installation's instruction manual. 3. Check whether the drain points have been connected/ closed. 4. Remove the filler cap from the coolant reservoir. 5. Connect the filler installation s filler hose to the quick-filling plug (9). 3 ILAj18 Filling and bleeding 1. Start the pump (max. 1 bar). Slowly fill the system (while the engine is not running) with coolant up to the maximum level indicated on the gauge glass. Use the specified coolant (see DW050335_xx on the VDL Bus & Coach Documentation Portal). When filling, check the coolant level in the expansion reservoir. Never fill it to above the maximum level on the gauge glass. 6-7

156 COOLING SYSTEM Draining and filling the cooling system 3. Turn off the pump when the maximum level has been reached. Wait a couple of minutes and, if necessary, top it up to the maximum level. 3. Turn the pump off, but leave the pressure hose connected. 4. Fit the filler cap on the coolant reservoir. 5. Start the engine and allow it to idle until the thermostat is fully open. Check the coolant level and, if necessary, top it up (while the engine is not running) to the maximum level indicated on the gauge glass. 6. Turn off the engine. 7. Use the VDL Bus & Coach diagnosis tool to open the EAS tank heating valve. 8. Fill the cooling system to the maximum coolant level indicated on the gauge glass. 9. Start the engine and allow it to idle until the thermostat is fully open. Check the coolant level. Slowly fill the system (while the engine is not running) with coolant up to the maximum level indicated on the gauge glass. 10. Stop the filling procedure when the engine is turned off and the coolant level is at the maximum level. 11. Turn off the filler pump and disconnect the filling hose. Fit the cap to the quick-filling nipple. 1. Check the cooling system for leaks (see 3-4. Cooling system: checking for leaks and damage ( 4-3)). 6-8

157 COOLING SYSTEM Draining and filling the cooling system 13. Check the level in the tank when the engine has cooled down. It must be between the min. and max. levels (). If necessary, top up the system via the filler opening (1). 3 ILAj

158 COOLING SYSTEM Draining and filling the cooling system

159 COOLING SYSTEM Cleaning 7. CLEANING 7.1 COOLING SYSTEM: CLEANING (RINSING) Coolant is a harmful liquid. Avoid skin contact in order to prevent poisoning. Coolant is harmful to the environment and must be processed as industrial waste after use. 1. Fully drain the cooling system (see Cooling system: draining ( 6-1)).. Fill the cooling system with tap water and add a cooling system cleaner (see 0-3. Cooling system ( 3-1)). 3. Run the engine until the thermostat is fully open. 4. Allow the engine to idle for a further 45 minutes. 5. Completely drain the cooling system. 6. Fill the cooling system with tap water. 7. Run the engine until the thermostat is fully open. 8. Allow the engine to idle for a further 5 minutes. 9. Completely drain the cooling system. 10. Top up the cooling system with the specified coolant (see DW050335_xx on the VDL Bus & Coach Documentation Portal). 11. Check the coolant level (see Coolant level: checking and topping up ( 4 -))

160 COOLING SYSTEM Cleaning 3 7 -

161 HYDRAULIC FAN DRIVE HYDRAULIC FAN DRIVE 4

162 HYDRAULIC FAN DRIVE 4

163 HYDRAULIC FAN DRIVE Hydraulic fan drive 1. HYDRAULIC FAN DRIVE For additional information, see DD1066_xx on the VDL Bus & Coach Documentation Portal

164 HYDRAULIC FAN DRIVE Hydraulic fan drive 4 1 -

165 SUMP FILLING UNIT SUMP FILLING UNIT 5

166 SUMP FILLING UNIT 5

167 SUMP FILLING UNIT Safety regulations 1. SAFETY REGULATIONS Do not allow the engine to run in a confined or unventilated space. Make sure the exhaust fumes are properly extracted. Remain a safe distance from rotating and/ or moving components. Various types of oil and other lubricants used on the vehicle can harm your health. Therefore, to prevent skin damage, avoid unnecessary contact with the lubrication oil. Exhaust gases contain carbon monoxide. Carbon monoxide is a deadly, colourless and odourless gas which, when inhaled, deprives the body of oxygen, leading to asphyxiation. Serious carbon monoxide poisoning can result in brain damage or even death. For work that does not require the vehicle to have a power source, it is recommended to always disconnect the earth cable from the battery. Wait at least 80 seconds after turning off the contact switch before disconnecting the connection between the battery terminal clamp and the negative pole. The AdBlue lines may become blocked if the connection is disconnected too quickly

168 SUMP FILLING UNIT Safety regulations 5 1 -

169 SUMP FILLING UNIT General information. GENERAL INFORMATION.1 GENERAL INFORMATION The automatic sump filling unit ensures that the oil level remains at the optimal level. The advantages of an automatic sump filling unit include: Oil of the same quality is added. The oil is always at the optimal level. There is less need for maintenance and repairs. It is easy to monitor the oil consumption. 5-1

170 SUMP FILLING UNIT General information. OVERVIEW DIAGRAM OF THE SUMP FILLING UNIT 5 1 Pump unit Oil reservoir 3 Filler cap 4 Filling line 5 Banjo bolt 6 Bleed hose 7 Sump pan connection block 8 Oil level sensor (level too low) 9 Sump filling unit oil level sensor (level low) 10 Sump pan ILAj111 -

171 SUMP FILLING UNIT General information.3 OPERATION OF THE SUMP FILLING UNIT The sump filling unit checks whether the engine oil must be topped up when the contact switch is turned on, provided the main switch is in the start position and the engine is not running. Once the engine has been turned off for more than 15 minutes (waiting time), the main switch is in the start position and the contact switch is turned on, the oil level in the sump will be checked by the oil level sensor. The sensor is fitted in the connecting block, which is fitted against the sump. If the oil level is low, the VFC activates the pump unit. The pump unit s electronic unit (1) starts a pump cycle. The pump cycle starts with filling the calibration reservoir (3). The pump (5) pumps oil from the oil reservoir to the calibration reservoir (3) via the check valve () until the level switch (4) reports that the calibration reservoir is full. The pump s direction of rotation is then switched over so that the pump pumps the oil from the calibration reservoir to the engine s sump via the check valve (6). Since the level switch (4) cannot detect whether the calibration reservoir is empty, the pump continues running for a certain (preset) time. 5 Pump unit 1 Electronic unit Check valve in the line from the oil reservoir 3 Calibration reservoir 4 Calibration reservoir oil level switch 5 Pump 6 Check valve in the line to the sump 7 Oil reservoir level switch 8 Connector ILAj OIL LEVEL SYMBOLS ON THE INSTRUMENT PANEL Minimum engine sump oil level The symbol shown opposite is displayed on the instrument panel s main display as soon as the oil level in the engine sump reaches the minimum oil level. ILBh0033-3

172 SUMP FILLING UNIT General information Sump filling unit oil reservoir oil level too low When the main switch is turned on, the symbol shown opposite is displayed on the instrument panel s main display as soon as the oil level in the oil reservoir reaches the minimum oil level. The symbol is only activated if there is no LED indicator in the fuel cowl. ILBh0034 The oil level in the oil reservoir can also be visually checked by the level indicator on the oil reservoir. Sump filling unit oil level LED in the fuel cowl If the engine oil level in the reservoir is above the minimum level, then this LED will be lit when the main switch is turned on. If the LED is not lit when the main switch is turned on, then the oil must be topped up to the maximum level. ILAh

173 SUMP FILLING UNIT General information.4 SYSTEM DESCRIPTION The multiplex system is started when the main switch is turned on. The oil level in the oil reservoir is checked via the oil level sensor. If the oil level in the oil reservoir is too low, a signal is sent to the VFC (A001) via IOU A011. If the engine is NOT running and the contact switch is turned ON, the Sump filling unit oil reservoir oil level too low symbol on the ICM (P001) will be lit via the VFC. At the same time, a signal is offered to the MTS unit via the VFC for the bodybuilder. The LED indicator in the fuel cowl is activated via this MTS unit when the oil level in the sump filling unit's oil reservoir is too low. The engine start delay function (Sump Oil Level Measurement Start Delay) is intended to ensure that an accurate measurement of the engine oil level can be made before the engine is started. The internal Sump Oil Level Measurement Start Delay signal is sent to the Engine Start/Stop function to delay the start. The signal is activated for seconds under the following conditions: The contact switch is turned on. The Sump Oil Level Measurement Start Delay Control is not active. 5 If the oil level in the oil reservoir is CORRECT and the contact switch is turned on, it is calculated how much time has elapsed after the engine was turned off (the waiting time). If this waiting time is more than 15 minutes, the engine oil level in the sump is low and there are no CAN error messages, the pump unit (A037) is turned on by the VFC..4.1 PUMP CYCLE A pump cycle is started when the pump unit is activated. During this pump cycle, the contents of the calibration reservoir (0.5 litres) is added to the sump. The quantity of oil for one pump cycle is always the same (the contents of the calibration reservoir). The pump cycle can only be completed if the main switch is turned on. The pump unit receives a voltage if the main switch is turned on. Comment: The oil will not be topped up in the following cases: The oil level in the oil reservoir is too low. The B00 oil level sensor is faulty. There is an electrical fault or a faulty fuse. - 5

174 SUMP FILLING UNIT General information.5 ELECTRICAL CIRCUIT DIAGRAM 5 A001 A011 A037 A040 A13 B00 P001 Vehicle Function Controller (VFC). IOU electronic unit Oil tank electronic unit FPT engine electronic unit MTS electronic unit Engine sump oil level sensor Instrument Cluster Module (ICM) ILAh0995-6

175 SUMP FILLING UNIT General information.6 FUNCTION DIAGRAMS For the function diagrams, see Group 5 of the Workshop Instruction Manual. 5-7

176 SUMP FILLING UNIT General information.7 OIL LEVEL SENSOR The oil level sensor is a capacitive sensor. A capacitor is used as a sensor. The capacity of the capacitor can be changed by altering the dielectric material between the capacitor plates. (The relative dielectric constant of air is different to that of oil.) The change of capacity around the sensor s electrode makes a high-frequency oscillator start to vibrate (frequency approx. 600 khz). This signal is processed by the sensor s electronics. The sensor and the electronics form one unit. A signal is sent to the VFC via IOU A011 as soon as the sensor is no longer surrounded by oil (the sensor lays completely free). The sensor has a built-in function control. If the sensor is connected to a power supply, then a voltage will be applied across the sensor for seconds to signify that everything is in working order. If no voltage is measured across the sensor, then the sensor must be inspected. 1 Positive (+) Min (-) 3 Signal (S) ILAh A B C D E Air Oil Sensor Screen Electrical field ILAj037-8

177 SUMP FILLING UNIT Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 SUMP FILLING UNIT: INSPECTING Inspecting the lines and connections 1. Check all the lines for wear and leaks. If in doubt, always replace the line.. Check all the line connections for leaks. 3. Check the path of the lines. When doing so, pay attention to the following: The lines must not be fitted twisted. To make it easier to check this, a mark may be drawn on the hoses (sometimes text). The lines must not touch anything (think of the possibility of them rubbing through). The lines must not make any sharp turns. The lines must not be clamped off by other components. To prevent skin damage, avoid unnecessary contact with the oil. Always read the safety data sheet. Preparations for checking the operation To prevent skin damage, avoid unnecessary contact with the oil. Always read the safety data sheet Make sure the vehicle is on a flat, horizontal surface.. Turn OFF the main switch at least 15 minutes before starting the inspection. 3. Check whether the pump unit's electronic connector is connected. 4. Drain the oil in the engine sump until it is 1 cm below the minimum level marked on the dipstick. 5. Drain the oil from the oil reservoir until it is 1 cm below the minimum level. 6. Disconnect the filling line (4) on the same side as the engine (5) and hang it in an oil measuring jug. 7. Keep a can with the specified oil available for topping up the oil reservoir (). ILAj

178 SUMP FILLING UNIT Inspection and adjustment Checking the oil level notifications This inspection requires two people: one in the driver s location and one by the sump filling unit Turn on the vehicle s main switch and contact switch, but do not start the engine.. Check whether the notification Minimum engine sump oil level is displayed on the main display. 3. Check whether the notification Sump filling unit oil reservoir oil level too low is displayed on the main display. 4. Turn off the vehicle's contact switch. 5. Fill the sump filling unit s oil reservoir to the maximum level. Use the specified engine oil. For more information, see DW050335_xx on the VDL Bus & Coach Documentation Portal. Checking the operation 1. Turn on the vehicle s main switch and contact switch, but do not start the engine. If the sump filling unit s oil reservoir is sufficiently filled but the sump is not, the pump unit starts working and the oil container is filled.. Check whether the notification Sump filling unit oil reservoir oil level too low is no longer shown on the display. 3. Check whether the pump unit pumps oil into the container and whether the volume is approximately 0.5 litres per pump cycle. 4. Turn off the vehicle's contact switch. Final inspection 1. Reconnect the filler line.. Top up the engine sump to the maximum level. 3. Fill the oil reservoir to the maximum level. 4. Check the system for oil leaks. 5. Check all of the system's attachment bolts. ILBh0033 ILBh0034 ILBh

179 SUMP FILLING UNIT Inspection and adjustment 3. SUMP FILLING UNIT OIL LEVEL: CHECKING Avoid skin contact with oil. Oil is harmful to your skin and health. Always read the safety data sheet. 1. Make sure the vehicle is on a flat, horizontal surface.. Check the oil level in the oil reservoir using the oil level indication on the reservoir (indication on the left-hand side in litres). 3. Make sure the oil reservoir always remains topped up to the maximum level. 4. If necessary, top up the oil via the filler cap (1). Always use oil from the same manufacturer with the same specifications. ILAj

180 SUMP FILLING UNIT Inspection and adjustment 5 3-4

181 AIR CONDITIONING COMPRESSOR DRIVE AIR CONDITIONING COMPRESSOR DRIVE 6

182 AIR CONDITIONING COMPRESSOR DRIVE 6

183 AIR CONDITIONING COMPRESSOR DRIVE Safety regulations 1. SAFETY REGULATIONS 1.1 GENERAL INFORMATION The air conditioning system may only be opened and filled by a specialist. Furthermore, in many countries, there is a compulsory qualification system for this type of work. When working on an air conditioning system where there is a risk that R134A coolant will be released, always wear well-fitting safety glasses and rubber gloves. Also protect all other exposed parts of the skin. Handling coolant Always wear safety glasses and protective gloves! At normal atmospheric pressures and ambient temperatures, liquid coolant vaporizes so quickly that frostbite may occur on contact with the skin or eyes (risk of blindness). If coolant comes into contact with skin, the skin must be rinsed with plenty of cold water. Never rub the area! Contact a doctor immediately! The work area must be well ventilated when working on the coolant circuit. Inhaling large concentrations of gaseous coolant may lead to dizziness and asphyxiation. Work on the coolant circuit may not be performed from a work pit. Since gaseous coolant is heavier than air, large concentrations may collect in the work pit. Do not smoke! The heat from a cigarette may cause the coolant to separate into poisonous substances. Never allow coolant to come into contact with a naked flame or hot metal. Deadly gases may be released. Never allow coolant to escape into the open air. If the coolant reservoir or the air conditioning system is opened, the contents will be released at a high pressure. The pressure depends on the temperature. The higher the temperature, the higher the pressure. Prevent the air conditioning system s components from becoming too hot. After being painted, vehicles must not be heated to a temperature greater that 75 C (drying oven). If it is not possible to ensure this, the air conditioning system must be drained beforehand. When disconnecting the vehicle s service hoses, the end of the hoses must not face towards the mechanic. Coolant residue can still escape. When cleaning the vehicle, the steam jet must not be aimed directly at parts of the air conditioning system. Never alter the factory settings

184 AIR CONDITIONING COMPRESSOR DRIVE Safety regulations 6 1 -

185 AIR CONDITIONING COMPRESSOR DRIVE Inspection and adjustment. INSPECTION AND ADJUSTMENT.1 AIR CONDITIONING COMPRESSOR: INSPECTING For information on how to perform maintenance work on the air conditioning compressors, see 6-4. Air conditioning compressor service workshop manual ( 4-1). 6-1

186 AIR CONDITIONING COMPRESSOR DRIVE Inspection and adjustment. AIR CONDITIONING COMPRESSOR POLY V-BELT: INSPECTING Air conditioning mounting models There are three possible air conditioning mounting models. For all the models, the poly V-belt has an automatic V-belt tensioner and cannot, therefore, be adjusted by hand. An incorrect poly V-belt tension can be caused by: A stretched poly V-belt. A faulty automatic V-belt tensioner. When working on the engine, turn OFF the main switch unless it is necessary to have it turned on for the work that is being carried out. Also make sure the engine cannot be started unintentionally. Always fit the same type of poly V-belt. Model 1 6 ILAj14 -

187 AIR CONDITIONING COMPRESSOR DRIVE Inspection and adjustment Model ILAj143 Model 3 6 ILAj144-3

188 AIR CONDITIONING COMPRESSOR DRIVE Inspection and adjustment..1 INSPECTING THE POLY V-BELT Removing the poly V-belt 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Remove the poly V-belt (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)). Inspecting the poly V-belt 1. Check the pulleys for damage, rust and grease deposits. If necessary, clean the pulleys.. Clean a dirty poly V-belt with a 1:10 mixture of glycerine and methylated spirits. 3. Check the poly V-belt for cracks, damage and excessive wear. If necessary, replace it. 4. Check the automatic belt tensioner (see (Automatic) belt tensioner: inspecting ( 3-9)). If the poly V-belt must be replaced, then it is recommended to also replace the belt tensioner and the guide wheels. ILAj Installing the poly V-belt 1. Fit the poly V-belts (see Air conditioning compressor poly V-belt: removing and installing ( 3-1)).. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -)). - 4

189 AIR CONDITIONING COMPRESSOR DRIVE Removal and installation 3. REMOVAL AND INSTALLATION 3.1 AIR CONDITIONING COMPRESSOR POLY V-BELT: REMOVING AND INSTALLING A poly V-belt is removed and installed in the same way for all the different models. Removing the poly V-belt 1. Disconnect the earth cable from the battery (see Battery terminal clamps: removing and installing ( 4 -)).. Slacken the poly V-belt and remove it from the pulleys. Carry out the following: a. Place a 17 mm ring spanner (1) on the hexagon of the belt tensioner (). b. Use the ring spanner to tilt the belt tensioner in the direction indicated by the arrow (see ILAj0). c. Block the belt tensioner by placing a 4-5 mm thick pin (3) in the holes that are now facing each other. This makes it easier to remove and install the poly V-belt. d. Remove the poly V-belt (4). e. If the belt tensioner is not blocked, allow the belt tensioner to slowly spring back to the stop. ILAj0 Installing the poly V-belt Always fit the same type of poly V-belt. 1. Inspect the pulleys for damage, rust and grease deposits.. Place the (new) poly V-belt over as many pulleys as possible. 3. Use a 17 mm ring spanner to slacken the automatic belt tensioner (if it has not been temporarily blocked) and place the poly V-belt over the remaining pulleys. Allow the automatic belt tensioner to slowly spring back against the (new) poly V-belt. 4. If used, remove the blocking pin. The blocking pin can be removed by moving the pulley against the spring force. 5. Check that the poly V-belt is positioned in all of the pulleys' grooves. 6. Connect the earth cable to the battery (see Battery terminal clamps: removing and installing ( 4 -))