Light - Error 18C. Antonio Valcasser - FPT Antonio Lacanale CS&Q Jan Lemaire Customer Service. Customer Service - Workshop Methods & Diagnostics

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1 Light - Error 18C Antonio Valcasser - FPT Antonio Lacanale CS&Q Jan Lemaire Customer Service Turin, October 2008 Customer Service - Workshop Methods & Diagnostics

2 Závada 18C Závada 18C - riešenie závady 18C pozri servisnú informáciu CET Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 2

3 Short description: (From F&R list) Fuel Mean Value Adaption Failure (via Lambda and Air Flow) Detailed description: (From F&R list) The Fuel Mean Value Adaption function (FMA) consists of a map model containing the fuel quantity error over the engine operating range (speed and injection quantity). The fuel quantity error is the difference between the currently measured injection quantity and the the fuel quantity demanded by the EDC. The currently injected fuel quantity is calculated from the measured signals of the air mass sensor and the lambda probe. The map points of Fuel Mean Value Adaption model are adapted to the currently measured fuel quantity errors and the values aquired in this way are used to correct the injection quantity demanded by the EDC. The monitoring function at hand checks if the learned map point values (adapted quantity error) lie within a reasonable range and do not exceed an upper or lower limit. The FMA map values are checked once during EDC initialization. The FMA adaption is only carried if various conditions are fulfilled, such as: No system errors present (indicated by Fid_FMASwtOff%_mp.0=0, %=1 or 3), sufficient air, engine and fuel temperature, no filter regeneration running, no overrun or quick fuel quantity changes present, lambda air ratio inside defined range and does not change too quickly, the lambda signal is valid (LSU_stO2Valid.0=1), sufficient atmospheric pressure and the influence of the injection quantity on the lambda value is considerable. Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 3

4 Warning lights in display: Error 18C is only OBD relevant for heavy duty vehicles. In light duty, the failure is stored, but there is no lamp on (neither MIL nor diagnostic lamp) Up to P16 datasets, the failure was stored itself as long term failure, from P17 on, there is only an indication about the long term failure, but 18C can be deleted again! Dataset vehicle OBD EDC ECU >=P17 HD on Different strategie for pop up long term (18C) LD Error in ECU (18C) <P17 HD LD on Long term (18C) Errore in ECU (18C) Turin, October 2008 Customer Service - Workshop Methods & Diagnostics

5 Reason for failure: (F&R List) Excessive injection quantity due to leakage or jammed injector valve in open position, inaccurate or defective air flow meter (HFM) or lambda sensor Possible external failures: Fuel Quality (Ex. Water) Bio Diesel (%Bio Diesel, max 5% by European law) Tuning (Pay attention for quick installations kits. Ex. Kits to install on the rail pressure sensor.) Diagnosis: (F&R List) Check injectors for correct dosing amount, check air flow meter and lambda sensor for accuracy Number of failures from the field: SGQ OC Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 5

6 Experience from the field: Fictive replacements of the component: -Air mass sensor - Injectors Fictive replacement = Do not replace the component as HW but only make the SW replacement of the component with EASY -> Specific Functions -> Components replacement Result: When telling the ECU, that there are new injectors, the FMA learning values are set back to 0, which deletes the failure. If the injector has still a problem, the failure will reappear after some mileage, when the FMA values have been learnt again! The same is valid for the Air mass sensor. After reset of the FMA, the FMA are learnt again after: first the lambda sonde must be ready (2 to 15 minutes) and then all operating (speed / load) must be run nearly stationary for some seconds (~20s) Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 6

7 Practical Example 1: Sympthom: Customer complains about sporadic engine stop during driving Vehicle: 35C10 Km s: Warranty Start: 22/11/2007 Failure Memory Failure Diagnosis: Workshop replaced the gasoil filters and cancelled the failure memory -> Not possible to reset DTC18C Intervention FE: - Engine test + Flight Recorder ET1 FR1 - Check gazoil low pressure side: Pressure on pump = +- 6bar (Normal = +-5 bar) Return pressure = bar (Normal = bar) Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 7

8 Practical Example 1: Diagnosis: - Measured injectors return fuel -> Injector 1 = 15 ml Injector 2 = 15 ml Injector 3 = 10 ml Injector 4 = 30 ml (too high) They made a fictive replacement of the injector 4 and reprogrammed the same IMA Code in the EDC. After programming the IMA code it was possible to cancel the DTC 18C. They have made test on the road for Km s without problem. After the fictive replacement and test drive a 2 engine test and flight recorder are done. ET2 FR2 Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 8

9 Practical Example 2: Sympthom: Vehicle arrives with EOBD warning light ON. Reading the error memory only error 18C is present. FR1 Diagnosis: Workshop made engine test: No direct indication of injectors out of tolerance but already serious deviation present. Solution: After replacement of the 4 injectors the problem was solved. Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 9

10 Diagnosis to follow: -> Failure Memory reading. -> Check the sensor value to reference values by parameter reading Parameter reading Boost pressure, air temperature, high pressure sensor -> Check the Lambda sensor by parameter reading Voltage level at ouput Lambda sensor between ~ 50mV and ~950mV. -> Make EGR Test to evaluate the air intake system functioning -> Make Engine Test to evaluate the injectors. Small deviations % could be the source for this problem -> Flight Recorder (.ecf file) -> Visual check on Air Inlet system, high presence of soot -> Check return fuel from injectors -> Check fuel low pressure system Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 10

11 How to proceed: In case the checks / tests - Sensors (boost, temp., ) OK - Lambda sensor OK -EGR Test OK - Engine Test OK - Fuel low pressure system OK - Injector fuel return quantity OK - Air intake system clean OK the possible solution could be to do the fictive replacement of the injectors and make test drive for +- 50Km s to understand the problem reappears or not. In case the problem reappear after test drive, replace injectors. In all cases with error 18C, inform THD and THD should create One Call or SGQ with all above data. Turin, October 2008 Customer Service - Workshop Methods & Diagnostics 11

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