citea lle cm2150

Citea LLE

1113 DD039400

Main group 4

WORKSHOP MANUAL

Citea LLE

ForewordThis 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 mechanicsThe 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 typeThe information in this manual has been updated until the time of printing and only concerns the following vehicle series:

- Citea LLE 120-225 ISB6.7 E5/EEV

In this manual, this series of vehicles is referred to as: "Citea LLE".

ISB6.7 indicates that the contents of this manual relate to the 6.7 litre ISB6.7 engine from Cummins.

E5/EEV indicates that this manual contains guidelines for the engines which meet the Euro 5 and EEV emission requirements.DD039400

Citea LLECONTENTS4

Technical informationEngine general information ...................... 1-1General information ........................................ 1-1Specifications and adjustment information ..... 1-3

Fuel system ................................................... 2-1General information ........................................ 2-1Tightening torques .......................................... 2-3

Intake/exhaust system.................................. 3-1General information ........................................ 3-1Tightening torques .......................................... 3-2

Throttle control ............................................. 4-1General information ........................................ 4-1Tightening torques .......................................... 4-3

Technical informationTraction problems......................................... 1-1Traction problems ........................................... 1-1

Fuel system ................................................... 2-1Introduction ..................................................... 2-1Fault finding tables.......................................... 2-2

Intake/exhaust system.................................. 3-1Introduction ..................................................... 3-1Fault finding tables.......................................... 3-2

Throttle control ............................................. 4-1Introduction ..................................................... 4-1ISB6.7 fault finding table ................................. 4-2

Engine error codes ....................................... 5-1General information ........................................ 5-1

Exhaust gas after-treatment system ........... 6-1General information ........................................ 6-1Fault finding tables.......................................... 6-1Error codes ..................................................... 6-2

Safety instructions........................................ 1-1General information ........................................ 1-1Areas of risk .................................................... 1-2

General information...................................... 2-1Location of the components............................ 2-1System description.......................................... 2-3

Component description................................ 3-1Fuel tank/AdBlue tank construction ................ 3-1Fuel level sensor/suction unit.......................... 3-4Fuel tank valve................................................ 3-5Fuel tank cap .................................................. 3-6AdBlue tank cap.............................................. 3-7Preliminary fuel filter/water separator ............. 3-8Fuel fine filter .................................................. 3-8High-pressure pump ....................................... 3-9

Fuel return overflow valve .............................3-14

Inspection and adjustment ...........................4-1Bleeding the fuel system .................................4-1

Removal and installation ..............................5-1Removing and installing the battery terminal clamps .............................................................5-1Removing and installing the AdBlue tank ........5-3Removing and installing the fuel tank..............5-6Removing and installing the AdBlue injector ...5-9Removing and installing the fuel level sensor............................................................5-11Removing and installing the AdBlue sensor ..5-14

Cleaning .........................................................6-1Cleaning the fuel level sensor filter..................6-1Cleaning the AdBlue injector ...........................6-3

Intake/exhaust systemSafety instructions ........................................1-1General information .........................................1-1Areas of risk.....................................................1-2

General information ......................................2-1Location of the components ............................2-1System description ..........................................2-3

Inspection and adjustment ...........................3-1Inspecting the air filter blockage indicator .......3-1Checking the negative intake pressure ...........3-2Inspecting the air intake system ......................3-3Inspecting the exhaust system ........................3-5Inspecting the exhaust gas back pressure ......3-7Inspecting the exhaust gas after-treatment system ...........................................................3-10Inspecting the catalytic converter in the event of error code 1664 ...............................3-13

Removal and installation ..............................4-1Removing and installing the battery terminal clamps .............................................................4-1Removing and installing the intercooler unit ....4-2Removing and installing the air filter element..4-3Removing and installing the catalytic convertor/silencer ............................................4-6Removing and installing the exhaust gas after-treatment systems air filter/oil separator .........................................................4-9Removing and installing the AdBlue injector .4-11Removing and installing the exhaust gas temperature sensor .......................................4-13Removing and installing the NOx sensor ......4-15Removing and installing the AdBlue dosing module...........................................................4-16DD039400

Fuel pump regulator solenoid ....................... 3-11Injector .......................................................... 3-12Pressure limiting valve .................................. 3-14

Cleaning .........................................................5-1Cleaning the radiator, the oil cooler and the intercooler element ..........................................5-1Cleaning the AdBlue injector ...........................5-4

4CONTENTSCitea LLE

Throttle controlSafety instructions........................................ 1-1Safety instructions........................................... 1-1

General information...................................... 2-1Location of the components............................ 2-1System description.......................................... 2-2Functional description of the throttle interlock. 2-4

Component description................................ 3-1Engine electronic unit (ECM) .......................... 3-1Accelerator pedal sensor ................................ 3-2

Inspection and adjustment .......................... 4-1Adjusting the accelerator pedal....................... 4-1

Exhaust gas after-treatment systemSafety instructions........................................ 1-1Safety instructions........................................... 1-1

General information...................................... 2-1Warning........................................................... 2-1Location of the components............................ 2-2System description.......................................... 2-3Operation of the exhaust gas after-treatment system............................................................. 2-4

Component description................................ 3-1Air supply ........................................................ 3-1Air/oil separator............................................... 3-1Dosing module ................................................ 3-1Air supply ........................................................ 3-2Electronic unit (ECM) ...................................... 3-2AdBlue tank..................................................... 3-3AdBlue temperature/level sensor.................... 3-4AdBlue injector................................................ 3-5Exhaust gas temperature sensor before the catalytic converter ........................................... 3-6Exhaust gas temperature sensor after the catalytic converter ........................................... 3-6NOx sensor after the catalytic converter......... 3-7Description of the dosing module.................... 3-8

Catalytic converter........................................ 4-1Catalytic converter .......................................... 4-2

Webasto water heaterWebasto water heater................................... 1-1DD039400

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Disclaimers

1113 VDL Bus & Coach bv, Valkenswaard, The Netherlands.

In the interest of continuous product development VDL Bus & Coach reserves the right to change specifications or products at any time without prior notice.

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 - 3DD039400

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TECHNICAL INFORMATION

TECHNICAL INFORMATIONDD039400

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TECHNICAL INFORMATIONEngine general information

1. ENGINE GENERAL INFORMATION

1.1 GENERAL INFORMATION

A COLD and WARM engine are defined as follows:

COLD engineAn engine which has cooled down for at least six hours after having been at the operating temperature.

WARM engineAn engine which has stood still for no more than thirty minutes after having been at the operating temperature.

Engines direction of rotationThe engines direction of rotation is clockwise, as viewed from the same side of the engine as the vibration damper.

Engines first cylinderThe engines first cylinder is the cylinder located on the same side as the engines vibration damper.

Left-hand and right-hand side of the engineThe 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.

Engine identification by means of the engine numberFor a description of the engine identification plate, see Group 2.

The engine number is located in two places on the engine:

1. On the engine identification plate, which is fitted on the engines cylinder head cover.

ILAj0532

ILAj05311 - 1DD039400

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2. Stamped on the engine block, on the oil cooler above the oil filter.

ILAj05271 - 2 DD039400

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1.2 SPECIFICATIONS AND ADJUSTMENT INFORMATION

1.2.1 ENGINE

Engine codesThe ISB6.7 type number indicates:

General specifications

1.2.2 VALVE CLEARANCE1

Check the valve clearance when the engine is cold

Cold valve clearance adjustment measurement

ISB Engine family 6 cylinder6.7 Euro emission Euro 5/EEV

Manufacturer CumminsType: ISB 6.7Environmental standard Euro 5 / EEVEngine management system CM2150No. of cylinders and cylinder configura-tion

6 in line, vertical

Valves 4 per cylinderBore x stroke 107 x 124 mmCylinder volume 6.7 litresCompression ratio 17.3 : 1Idling engine speed 700 rpmFuel injection High-pressure common rail, direct injec-

tionInjection sequence 1-5-3-6-2-4Injection pressure 500 - 1,800 barAir intake system Turbo intercoolingEmission after-treatment system SCR catalytic convertor (Selective Cata-

lyst Reduction) with air-assisted Urea (AdBlue) dosing system

Cooling FluidWeight Approx. 522 kgInjection pressure Approx. 500 1,800 bar

Type Power hp (kW)/rpm) Torque (Nm/rpm)ISB6.7 225 (166) / 2,300 850 / 1,100 - 1,700

When checking and adjusting the valve clearance, the engines coolant temperature must not be greater than 60 C.

Inlet 0.152 - 0.381 mmOutlet 0.381 - 0.762 mm

Inlet 0.254 mmOutlet 0.508 mm1 - 3DD039400

1. See https://quickserve.cummins.com for the currently applicable adjustment sizes.

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TECHNICAL INFORMATIONEngine general information1 - 4 DD039400

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TECHNICAL INFORMATIONFuel system

2. FUEL SYSTEM


Fuel system

Fuel tank

Fuel level sensor/suction unit

Fuel level sensor resistance value L = 495 mm

ILAh0615

Idling engine speed 700 rpmMaximum governed engine speedVehicle speed = 0 km/hVehicle speed > 0 km/h 2,500 rpm

2,750 rpm

Contents 240 litresOpening pressure of the pres-sure relief valve

0.34 bar

Vacuum pressure valve 0.01 < P < 0.02 bar

Pressure relief valve 0.16 < P < 0.20 bar

Length H (mm) Resistance (Ohm)

>426 10426 28405 46384 68363 95342 122321 149300 176279 203258 230237 257216 287195 317174 347153 377132 407111 43790 46769 5002 - 1DD039400

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AdBlue level sensor

AdBlue level sensor resistance value L = 515 mm

AdBlue tank

ILAh01551 Earth2 Signal3 Earth4 Signal

Sensor type Level/TemperatureAdBlue level sensor type Reed switch in com-

bination with resist-ances

AdBlue temperature sensor type NTCAdBlue temperature sensor resistance value

3.3 kOhm ( 5%) at 25 C

ILAh0614

Length H (mm) Resistance (Ohm)

>431 240431 353410 483389 623368 781347 955326 1,151305 1,371284 1626263 1,927242 2,275221 2,705200 3,215179 3,835158 4,655137 5,755116 7,25595 9,40574 12,80553 19,0052 - 2 DD039400

For other technical details about the fuel system see https://quickserve.cummins.com.

Contents Approx. 26 litres

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2.2 TIGHTENING TORQUES

The tightening torques stated in this chapter deviate from the standard tightening torques given in the standard tightening torques overview.The threaded connections which are not stated here must, therefore, be tightened to the torque given in the standard tightening torques overview.If any attachment aids (attachment nuts and bolts) are replaced, it is very important that the new attachment aids are exactly the same length and quality as those being replaced, unless otherwise stated.

Fuel filter

Fuel tank

Fuel level sensor

Fuel level sensor assembly

Exhaust gas after-treatment system

For other fuel system tightening torques, see https://quick-serve.cummins.com.

ILAh0616

Fuel filter 3/4 revolution after touching the sealing ring (34 Nm)

Drain plugs 50 7 NmTop of plug 50 7 NmFuel tank valve 25 NmFuel tank valve attachment screws

4 Nm

Clamping strap attachment nuts 30 Nm

A. Water heater return 2 - 3 NmB. Fuel tank supply 20 NmC. Water heater supply 2 - 3 NmD. Fuel tank return 20 NmE. Fuel tank bleed valve 2 - 3 Nm

Compression force (downwards) 30 - 40 kgTorque (30 clockwise) Max. 50 Nm

Dosing module attachment bolt 30 NmDosing module inlet and outlet connection

12.5 Nm

Air filter/oil separator 3/4 - 1 revolution after touching the sealing ring2 - 3DD039400

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Battery terminal clamp

ILAh0338

A Battery terminal clampa +:

a. To prevent corrosion, lubricate the outside of the connections with acid-free Vaseline.

12 2 NmB Battery terminal clampa + 40 4 NmC Battery terminal clampa - 12 2 NmD Battery terminal clampa - 30 4 Nm2 - 4 DD039400

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TECHNICAL INFORMATIONIntake/exhaust system

3. INTAKE/EXHAUST SYSTEM


Exhaust gas back pressure for a new vehicle (indicative)

K value for the soot emissionThe K value (m-1) for the soot measurement is stated in the top right-hand corner of the engines type plate.

For other technical information about the intake/exhaust sys-tem, see QuickServe Online. See https://quickserve.cum-mins.com.

Intake vacuum pressure

ISB6.7 Euro 5/EEV engines 200 mbar

ILAj0532Engine type Layout K value (m-1)ISB6.7E5 225B 0.85ISB6.7 EEV 225B 0.85

At maximum loaded engine speed (clean air filter)

25 mbar

At maximum loaded engine speed (contaminated air filter)

65 mbar3 - 1DD039400

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The tightening torques stated in this chapter deviate from the standard tightening torques given in the standard tightening torques overview.The threaded connections which are not stated here must, therefore, be tightened to the torque given in the standard tightening torques overview.

If any attachment aids (attachment nuts and bolts) are replaced, it is very important that the new attachment aids are exactly the same length and quality as those being replaced, unless otherwise stated.

Intake system

ILAj0835Hose clampsA. Norma clamp Breeze Torca 7.5 Nm (SW 11)B. Norma clamp GBS 20 Nm (SW 13)C. Norma clamp TORRO 5 Nm (SW 7)D. Norma clamp GBS 25 Nm (SW 17)3 - 2 DD039400

Air filter indicator hose nipple on the air filter housing Max. 0.2 Nm

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Exhaust system

For other tightening torques for the intake/exhaust system, see QuickServe Online. See https://quickserve.cum-mins.com.

A. V-clamp 14 NmaB. AdBlue injector 60 NmbC. Exhaust pipe clamping straps 14 NmaD. IN/OUT temperature sensors 30 NmbE. NOx sensor 50 Nmb

a. Fit with heat-resistant grease, such as Loctite 8009. The grease must not contain any silicon.3 - 3DD039400

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TECHNICAL INFORMATIONIntake/exhaust system3 - 4 DD039400

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TECHNICAL INFORMATIONThrottle control

4. THROTTLE CONTROL


4.1.1 ACCELERATOR PEDAL SENSOR (CM-2150)

ILAh0725

Con-nec-tion on ECM

Description Measure-ment value on connec-tion

Meas-ure-ment unit

Explanation

J2/22 Accelerator pedal sensor earth (B230), position sensor 2

0 VDC

J2/25 Accelerator pedal sensor input signal (B230), position sensor 2

0.5 - 0.6 VDC Idling, accelerator pedal not depressed (0%)

1.7 - 1.9 VDC Full load (approx. 80%)2.0 - 2.2 VDC Kickdown (100%)

J2/26 Accelerator pedal sensor power supply (B230), position sensor 2

5 VDC Open voltage with disconnected sensor con-nector

J2/27 Accelerator pedal sensor power supply (B230), position sensor 1

5 VDC Open voltage with disconnected sensor con-nector

J2/28 Accelerator pedal sensor earth (B230), position sensor 1

0 VDC

J2/35 Accelerator pedal sensor input signal (B230), position sensor 1

1.0 - 1.25 VDC Idling, accelerator pedal not depressed (0%)

3.3 - 3.8 VDC Full load (approx. 80%)4.0 - 4.4 VDC Kickdown (100%)4 - 1DD039400

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ILAh0786A032 Engine's electronic unit (ECM)B230 Accelerator pedal sensor

ILAh0723A. Position sensor 1 power supply (APS1)B. Position sensor 1 earth (GND1)C. Position sensor 2 output signal (VCC1)D. Position sensor 2 output signal (VCC2)E. Position sensor 2 earth (GND2)4 - 2 DD039400

F. Position sensor 2 power supply (APS2)

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The tightening torques stated in this chapter deviate from the standard tightening torques given in the standard tightening torques overview.The threaded connections which are not stated here must, therefore, be tightened to the torque given in the standard tightening torques overview.

If any attachment aids (attachment nuts and bolts) are replaced, it is very important that the new attachment aids are exactly the same length and quality as those being replaced, unless otherwise stated.

Accelerator pedal sensorAccelerator pedal sensor 9.5 Nm4 - 3DD039400

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TECHNICAL INFORMATIONThrottle control4 - 4 DD039400

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TECHNICAL INFORMATIONTraction problems

1. TRACTION PROBLEMS

1.1 TRACTION PROBLEMS

1.1.1 LOSS OF PULLING FORCE

General information Is this symptom the result of a technical fault? External factors or improper use can also lead to this fault. It is important to get the correct image of the complaint by

asking the customer or the driver for as much information as possible.

Question Ask for a good description of the problem. What are the conditions under which the loss of pulling

force is experienced (uphill, in rain, warm or cold engine, etc.)?

Ask for reliable information concerning consumption during journeys.

Ask for tachograph cards of journeys. Can the customer or driver to reproduce the problem? Has the customer or a third party made changes to the

vehicle (for example, changes to the software, rear axle gear ratio, gearbox, tyre size, etc.)?

Check The motor management and EAS for saved error codes

and the correct software version. The vehicle specifications.

Action: Carry out an acceleration test. Make a boost pressure curve.

Checking the boost pressure will, in general, only be of use if the vehicle has been driven at least 20,000 km.1 - 1DD039400

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TECHNICAL INFORMATIONTraction problems

Discuss the results with the customer or the driver.

If the acceleration time is not achieved, check the following possible causes.Possible cause Remedy

Incorrect type of components fitted. Check whether the correct components have been fitted. This refers to the turbo compressor, the filters, etc.

The vehicle is poorly aligned. Check the alignment of the vehicle.The wrong tyres are used. Check the type and size of the tyres.The brakes drag. See the fault finding table: Brakes drag, Disc brake con-

struction in Group 6.Fault in the electronic system. Check the symptom with the diagnosis equipments con-

ductor diagnosis. driveline, engine, engine behaviour.Fault in the fuel system. See the fault finding table: Loss of pulling force, Fuel

system 1 - 1.1.1 Loss of pulling force (1 - 1).Fault in intake and/or exhaust system. See the fault finding table: Loss of pulling force, Intake/

exhaust system 1 - 1.1.1 Loss of pulling force (1 - 1).1 - 2 DD039400

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2. FUEL SYSTEM

2.1 INTRODUCTION

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 diagnosis equipment or a flash code. Possible causes of symptoms that are not detected by the electronic unit are given in the fault finding tables.

CommentSee https://quickserve.cummins.com for detailed fault find-ing tables and error code tables.2 - 1DD039400

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2.2 FAULT FINDING TABLES

2.2.1 THERE IS A FUEL LEAK.


Possible cause RemedyThere is an external fuel system leak. Check for leaks.The high-pressure pump is faulty. Check the contact surface between the fuel delivery

pump and the high-pressure pump. If a leak is observed, then replace the high-pressure pump.

Check the fuel pressure from the return circuit to the fuel tank if fuel comes out of the high-pressure pumps drain opening.

There is an internal fuel system leak (dilution of the oil). There are constrictions in the fuel return circuit to the fuel tank. Check the fuel pressure from the return circuit to the fuel tank.

The fuel injector O-rings leak.

The high-pressure pump is faulty (internal leak). After the pump has been replaced, check the fuel pressure of the return circuit to the fuel tank.

This general symptom can be explained based on one of these more detailed causes.Possible cause Remedy

The engine looses power during acceleration or when under a heavy load

See the fault finding table: "The engine looses power during acceleration or when under a heavy load" (1 - 2.2.3 The engine looses power during acceleration or when under a heavy load (2 - 3)).

Reduced power at all engine speeds See the fault finding table: "Reduced power at all engine speeds" 1 - 2.2.4 Reduced power at all engine speeds (2 - 4).2 - 2 DD039400

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2.2.3 THE ENGINE LOOSES POWER DURING ACCELERATION OR WHEN UNDER A HEAVY LOAD

Possible cause RemedyFault in the fuel system. Use the fault finding table: The engine looses power

during acceleration or when under a heavy load.

Fault finding table: The engine looses power during acceleration or when under a heavy load.Step Check Remedy1 Check the engine power. OK: Problem solved.

Not OK: Go to step 2.2 Check the pressure relief valve on the fuel rail. OK: Go to step 3.

Not OK: replace the pressure relief valve.3 Check the fuel pressure on the inlet side of the fuel

fine filter.OK: Go to step 4.Not OK: Go to step 5.

4 Check the pressure drop across the fuel fine filter by checking the fuel pressure on the inlet side of the high-pressure pump.

OK: Go to step 7.Not OK: Replace the fuel fine filter.

5 Check the vacuum pressure on the suction side of the fuel delivery pump.

OK: Go to step 7.Not OK: Go to step 6.

6 Check the fuel delivery for constrictions and block-ages.

OK: Replace the high-pressure pump and go to step 1.Not OK: Rectify the fuel delivery and go to step 1.

7 Check for internal fuel leaks. Carry out an internal leak test.

OK: Go to step 8.Not OK: Rectify the internal leak and go to step 1.

8 Check the flow of fuel through the high-pressure pump.

OK: No problem in the fuel system.Not OK: Replace the high-pressure pump and go to step 1.2 - 3DD039400

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2.2.4 REDUCED POWER AT ALL ENGINE SPEEDS

2.2.5 HIGH FUEL CONSUMPTION

2.2.6 THE STARTER TURNS THE ENGINE OVER BUT

Possible cause RemedyPoor fuel quality. Drain the fuel, rinse the fuel system, replace the fuel fil-

ters and fill the fuel tank with fuel.The accelerator pedal sensor has a mechanical fault. Check the mechanical connection of the sensor/acceler-

ator pedal.Check the accelerator pedal sensor.

There is a mechanical fault with the injector(s). Check the operation of the injector(s).Fault in the fuel system. Carry out the checks in the step-by-step table: Reduced

engine power at all engine speeds.

Fault finding table: Reduced engine power at all engine speedsStep Check Remedy1 Check the engine power. OK: Problem solved.

Not OK: Go to step 2.2 Check the fuel pressure on the inlet side of the fuel

fine filter.OK: Go to step 3.Not OK: Go to step 4.

3 Check the pressure drop across the fuel fine filter by checking the fuel pressure on the inlet side of the high-pressure pump.

OK: Go to step 6.Not OK: Replace the fuel fine filter.

4 Check the vacuum pressure on the suction side of the fuel delivery pump.




6 Check for internal fuel leaks. Carry out an internal leak test.



OK: No problem in the fuel system.Not OK: Replace the high-pressure pump and go to step 1.


ters and fill the fuel tank with fuel.There is an internal or external fuel system leak. Check for leaks.There is a mechanical fault with the injector(s). Check the operation of the injector(s).2 - 4 DD039400

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THE ENGINE DOES NOT START

Possible cause RemedyNo fuel delivery. Check the fuel level.

Check the lines for blockages and leaks.Check the drive of the fuel delivery pump.

The fuel fine filter/fuel coarse filter is blocked. Replace the fuel fine filter/fuel coarse filter and clean the system.

When carrying out an engine test with the VDL Bus & Coach diagnosis equipment, communication with the VDL Bus & Coach diagnosis equipment was broken.

Remove the earth cable from the battery and refit it.

There is a fault in the glow installation. Check the glow installation.There is air in the fuel system. Check whether any air is drawn in. Pay particular atten-

tion to the suction line and the oil seal for the fuel delivery pump.Bleed the fuel system.

Poor fuel quality. Drain the fuel, rinse the fuel system, replace the fuel fil-ters and fill the fuel tank with fuel.

Fault in the fuel system. Carry out the checks in the step-by-step table: The starter turns the engine over but the engine does not start.

Fault finding table: The starter turns the engine over but the engine does not start.Step Check Remedy1 Check whether the engine turns over and starts. OK: Problem solved.

Not OK: Go to step 2.2 Check whether the value given by the rail pressure

sensor is less than 30 bar when the contact switch is turned on and when the engine is not running. Use the VDL Bus & Coach diagnosis equipment for this.

OK: Go to step 3.Not OK: Replace the rail pressure sensor and go to step 1.

3 Check the rail pressure when starting. Use the VDL Bus & Coach diagnosis equipment.


4 Check the fuel pressure on the inlet side of the fuel filter when starting the engine.


5 Check the vacuum pressure on the suction side of the fuel delivery pump when starting the engine.


6 Check the pressure drop across the fuel fine filter by checking the fuel pressure on the inlet side of the high-pressure pump when starting the engine.

OK: Go to step 8.Not OK: Replace the fuel fine filter and go to step 1.



8 Check for internal fuel leaks. Carry out an internal fuel leak test when starting the engine.


9 Check the resistance of the fuel pump regulators solenoid valve.

OK: Go to step 10.2 - 5DD039400

Not OK: Replace the fuel pump regulator's solenoid valve and go to step 1.

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OK: Replace the fuel pump regulator's solenoid valve and go to step 1.Not OK: Replace the high-pressure pump and go to step 1.

Fault finding table: The starter turns the engine over but the engine does not start.Step Check Remedy2 - 6 DD039400

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2.2.7 THE ENGINE IS DIFFICULT TO START


ters and fill the fuel tank with fuel.There is air in the fuel system. Check whether any air is drawn in.

Bleed the fuel system.The fuel fine filter/fuel coarse filter is blocked. Replace the fuel fine filter/fuel coarse filter and clean the

system.The battery voltage is too low. Charge the batteries.There is a mechanical fault with the injector(s) or it/they is/are blocked.

Check the operation of the injector(s).

The fuel delivery pumps delivery is too small. Check the fuel supply pump and, if necessary, replace it.Check the gallery pressure.

There is an internal leak between the fuel delivery pipe and the injector.

Check the connection between the fuel delivery pipe and the injector for internal leaks.

Fault in the fuel system. Carry out the checks in the step-by-step table: The engine is difficult to start.

Fault finding table: The engine is difficult to start.Step Check Remedy1 Check whether the engine turns over and starts. OK: Problem solved.

Not OK: Go to step 2.2 Check whether the value given by the rail pressure

sensor is less than 30 bar when the contact switch is turned on and when the engine is not running. Use the VDL Bus & Coach diagnosis equipment for this.

OK: Go to step 3.Not OK: Replace the rail pressure sensor and go to step 1.

3 Check the rail pressure when starting. Use the VDL Bus & Coach diagnosis equipment.


4 Check the fuel pressure on the inlet side of the fuel filter when starting the engine.


5 Check the vacuum pressure on the suction side of the fuel delivery pump when starting the engine.


6 Check the pressure drop across the fuel fine filter by checking the fuel pressure on the inlet side of the high-pressure pump when starting the engine.

OK: Go to step 8.Not OK: Replace the fuel fine filter and go to step 1.



8 Check for internal fuel leaks. Carry out an internal fuel leak test.


9 Check the resistance of the fuel pump regulators solenoid valve.

OK: Go to step 10.Not OK: Replace the fuel pump regulator's solenoid valve and go to step 1.

10 Check the flow of fuel through the high-pressure OK: Replace the fuel pump regulator's solenoid 2 - 7DD039400

pump. valve and go to step 1.Not OK: Replace the high-pressure pump and go to step 1.

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2.2.8 THE ENGINE STALLS, BUT RUNS AGAIN AFTER IT HAS BEEN RESTARTED

2.2.9 THE ENGINE RUNS ERRATICALLY

2.2.10 DIESEL KNOCK DURING ACCELERATION

Possible cause RemedyThere is air in the fuel system. Check whether any air is drawn in. Pay particular atten-

tion to the suction line and the oil seal for the fuel delivery pump.

Bleed the fuel system.


ters and fill the fuel tank with fuel.There is air in the fuel system. Check whether any air is drawn in. Pay particular atten-


The fuel fine filter/fuel coarse filter is blocked. Replace the fuel fine filter/fuel coarse filter and clean the system.

The fuel rails pressure relief valve does not close prop-erly.

Check the pressure relief valve.

The fuel delivery pumps pressure is too low. Check the low pressure fuel system.Check the fuel supply pump and, if necessary, replace it.

The high-pressure pumps delivery is too low. Check the flow of fuel through the high-pressure pump.There is a mechanical fault with the injector(s). Check the operation of the injector(s).There is a mechanical fault in one of the cylinders (valves, cylinder and piston).

Carry out a cylinder cut-out test with the aid of the VDL Bus & Coach diagnosis equipment to determine the faulty cylinder and check the valves, the cylinder and the piston.

Possible cause RemedyThere is air in the fuel system. Check whether any air is drawn in. Pay particular atten-


Poor fuel quality. Drain the fuel, rinse the fuel system, replace the fuel fil-ters and fill the fuel tank with fuel.

Faulty injector(s). Check the operation of the injector(s).2 - 8 DD039400

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2.2.11 WHITE AND/OR BLUE SMOKE DEVELOPMENT

2.2.12 BLACK SMOKE DEVELOPMENT


ters and fill the fuel tank with fuel.There is air in the fuel system. Check whether any air is drawn in. Pay particular atten-


The fuel filter is blocked. Replace the fuel filter and clean the system.There is a mechanical fault with the injector(s). Check the operation of the injector(s).

Possible cause RemedyThe intake air boost pressure and temperature sensor gives incorrect values.

Check the intake air boost pressure and temperature using the VDL Bus & Coach diagnosis equipment.

There is a mechanical fault with the injector(s). Check the operation of the injector(s).2 - 9DD039400

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TECHNICAL INFORMATIONFuel system2 - 10 DD039400

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3. INTAKE/EXHAUST SYSTEM

3.1 INTRODUCTION

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 diagnosis equipment or a flash code. Possible causes of symptoms that are not detected by the electronic unit are given in the fault finding tables.

CommentSee https://quickserve.cummins.com for detailed fault find-ing tables and error code tables.3 - 1DD039400

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3.2.2 REDUCED POWER AT ALL ENGINE SPEEDS

3.2.3 REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

3.2.4 THE EXHAUST GAS BACK PRESSURE IS TOO HIGH

This general symptom can be explained based on one of these more detailed causes.Possible cause Remedy

Reduced power above a certain engine speed See the fault finding table: "Reduced power above a cer-tain engine speed" 1 - 3.2.3 Reduced power above a certain engine speed (3 - 2).

Reduced power at all engine speeds See the fault finding table: "Reduced power at all engine speeds" 1 - 3.2.2 Reduced power at all engine speeds (3 - 2).

Possible cause RemedyThe air filter is blocked. Replace the air filter.There is an air leak in the intake system. Pressure-test the intake system.There is a constriction in the exhaust system. Check the exhaust system for constrictions.The turbo compressor is faulty. Check the turbo compressor.The wastegate is controlled incorrectly. Check the control of the wastegate.

Possible cause RemedyThe air filter element is partially blocked. Check/replace the air filter element.There is an air leak in the intake system. Pressure-test the intake system.There is a constriction in the exhaust system. Check the exhaust system for constrictions.

Possible cause RemedyNo original silencer fitted. Check the silencer.The exhaust pipe has been squeezed closed or has been internally blocked by a loose part.

Check the exhaust system for blockages and/or damage.

The catalytic converter in the silencer is blocked. Replace the silencer.3 - 2 DD039400

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3.2.5 THE INLET VACUUM PRESSURE IS TOO HIGH.

3.2.6 RISING AND FALLING NOISES FROM THE TURBO COMPRESSOR

Possible cause RemedyThe air filter element is blocked. Replace the air filter element.The air filters air inlet is blocked. Check the filters air inlet.

Possible cause RemedyThe air inlet to the turbo compressor is blocked. Check the air intake pressure.

Check the air inlet and remove any blockages.The compressor side of the turbo compressor is contam-inated.

Clean the compressor side with a non-corrosive cleaning product or a soft brush.Check the inlet side for carbon deposits or other contam-ination.

There is a gas leak between the exhaust manifold and the turbo compressor.

Check the seal between the exhaust manifold and the turbo compressor.

The turbo compressor is damaged. Replace the turbo compressor and trace the cause.3 - 3DD039400

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TECHNICAL INFORMATIONIntake/exhaust system3 - 4 DD039400

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4. THROTTLE CONTROL

4.1 INTRODUCTION

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 diagnosis equipment or a flash code. Possible causes of symptoms that are not detected by the electronic unit are given in the fault finding tables.4 - 1DD039400

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4.2 ISB6.7 FAULT FINDING TABLE

4.2.1 THE ENGINE ONLY IDLES AND DOES NOT REACT TO THE ACCELERATOR PEDAL

4.2.2 GREATLY REDUCED POWER AT ALL ENGINE SPEEDS

Possible cause RemedyThe accelerator pedal sensor is faulty. Check

- The mechanical connection of the sensor/accelerator pedal.- The accelerator pedal sensor.

Possible cause RemedyAccelerator pedal sensor, signal error/short circuit/break in connection.

Check- The accelerator pedal sensor.- The wiring.- The accelerator pedal sensor setting.4 - 2 DD039400

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TECHNICAL INFORMATIONEngine error codes

5. 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 diagnosis equipment or a flash code.

For an up-to-date overview of the error codes and fault diag-nosis, please refer to https://insite.cummins.com/insite/index.html or https://quickserve.cummins.com.5 - 1DD039400

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TECHNICAL INFORMATIONEngine error codes5 - 2 DD039400

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TECHNICAL INFORMATIONExhaust gas after-treatment system

6. EXHAUST GAS AFTER-TREATMENT SYSTEM


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 diagnosis equipment or a flash code.

In the fault finding tables, a description of the error code is given after the error code.

For an up-to-date overview of the error codes and fault diag-nosis, please refer to https://insite.cummins.com/insite/index.html or https://quickserve.cummins.com.


6.2.1 THE ADBLUE INJECTOR FREQUENTLY GETS BLOCKED

Possible cause RemedyThe electronic system cuts out too quickly. Check the systems cut-out time.The air pressure is too low Check the supply of air to the dosing module.There is an internal fault in the dosing module. Replace the dosing module.6 - 1DD039400

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TECHNICAL INFORMATIONExhaust gas after-treatment system

6.3 ERROR CODES

6.3.1 EXHAUST GAS AFTER-TREATMENT SYSTEM FAULT FOR EURO 5/EEV (ECM-2150)

From serial number 966211000057912++, the dosing mod-ule has a preliminary filter. This preliminary filter is fitted on the dosing module's AdBlue inlet.

If the preliminary filter becomes blocked, it must be replaced with a new filter. VDL Bus & Coach no. 30032776.

For an up-to-date overview of the error codes and fault diag-nosis, please refer to https://insite.cummins.com/insite/index.html or https://quickserve.cummins.com.

It is NOT permitted to clean the preliminary filter.

Possible cause RemedyThe dosing modules preliminary filter is blockedAs a result, error code 3548, 3738, 2272 or 2773 is given.

Replace the preliminary filter and clean the system.Delete the error codes.Check the operation of the exhaust gas after-treatment system.6 - 2 DD039400

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cDD039400

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TECHNICAL INFORMATIONSafety instructions

1. SAFETY INSTRUCTIONS


The work described in this document may only be carried out by trained and competent personnel.

Always observe the locally applicable legal safety and envi-ronmental regulations.Always observe the health and safety regulations.

Observe all the warnings and safety instructions given in this document. Always first read and observe the instructions and warnings written on the labels and stickers which are placed on various vehicle components. Do not ignore them. They are there to ensure your health and safety!

If these labels and stickers are damaged/illegible, they must be replaced.Wear clean, well fitting clothes and, if necessary, apply pro-tective cream to unprotected parts of your body.Always wear safety goggles and safety shoes when carrying out work on the vehicle.

Do not run the engine unnecessarily in an enclosed or unventilated area. In other words, make sure the exhaust fumes are properly extracted.

Remain a safe distance from rotating and/or moving compo-nents.

To prevent the risk of fire, the engine and the area surround-ing it must be free of highly inflammable liquids.

If work is carried out on the engine encapsulation, then the engine compartment, the encapsulation and the engine should be cleaned, if necessary, because there is a risk of fire if the encapsulation, engine or engine compartment are dirty.

Comment: The engine stops automatically after a set time if the engine idles and the accelerator pedal is not depressed.1 - 1DD039400

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1.2 AREAS OF RISK

1.2.1 MOVING PARTS

Remain a safe distance from rotating and/or moving compo-nents.

1.2.2 ELECTRICAL SHORT CIRCUIT

In order to prevent people from starting the engine when work is being carried out on the vehicle, always disconnect the batterys earth connection. Place a sign that reads DO NOT OPERATE on the dashboard.

1.2.3 VARIOUS LIQUIDS

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 clutch fluid.

Therefore, avoid internal and external bodily contact with these liquids.

To prevent damage to electrical components, never disconnect the battery terminal clamps whilst the engine is running.

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. If the connection is disconnected too quickly, the AdBlue lines may become blocked.

To prevent skin injury and poisoning, avoid internal and external bodily contact with the various liquids. Always read the safety data sheet.1 - 2 DD039400

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1.2.4 FUEL

A certain quantity of fuel will be released when removing the fuel systems components. To keep this quantity of fuel to a minimum, unscrew the tank cap to allow any excess pres-sure to escape.

Collect any fuel that escapes and remain aware of the fire risk.

Diesel is an extremely flammable liquid. It must not be exposed to a naked flame nor be brought into contact with hot components. The diesel fumes remaining in an empty fuel tank form an extremely explosive mixture.

Diesel is highly inflammable.Avoid a naked flame, heat sources or a lit cigarette close to the fuel system: FIRE RISK!

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 - 3DD039400

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1.2.5 ADBLUE

AdBlue is non-inflammable. If AdBlue is exposed to high tem-peratures, the solution breaks down into ammonia and car-bon dioxide.

Avoid AdBlue coming into contact with painted components. Spilt AdBlue can be easily removed with water. If AdBlue dries, it leaves a white film, which can be removed with water.

If AdBlue comes into contact with the electrical installation (wiring harnesses and contacts), then the components con-cerned must be replaced.

Do not allow AdBlue to come into contact with other chemi-cals.

Carefully check the AdBlue lines for leaks.

Avoid bodily contact with AdBlue. In the event of skin contact: rinse with plenty of water. In the event of contact with the eyes: rinse with plenty of

water for at least 15 minutes and seek medical assistance. If swallowed: rinse your mouth with plenty of water. Do not

induce vomiting. Seek medical assistance. In the event of inhalation: get some fresh air and take a

rest. Seek medical assistance.

If the AdBlue tank cap is opened at a high exterior tempera-ture, then it is possible that ammonia fumes may escape. Ammonia has a strong, irritating smell and affects the eyes, skin and mucous membrane.

Refuelling with liquids other than AdBlue can cause prob-lems with the exhaust gas after-treatment system and may

See the AdBlue safety data sheet for the properties, risks and safety information.Always wear gloves and safety goggles when working on the AdBlue unit/exhaust gas after-treatment system.

Although AdBlue is not poisonous and not harmful to the environment, collect AdBlue separately.

AdBlue corrodes metals, such as copper and aluminium. Alloys, such as brass, can also be damaged.

Therefore, turn your face away when removing the cap from the tank.1 - 4 DD039400

cause the OBD symbol on the dashboard to light up.

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1.2.6 EXHAUST GASES

Do not allow the engine to run in a confined or unventilated space. Make sure the exhaust fumes are properly extracted.

Intake and exhaust systemsThere is a risk of being burnt, because a number of compo-nents, such as the exhaust pipe and the catalytic converter, are hot when the engine is running (or has been running). It can take some time for the hot components to cool down.

A silencer with an integrated catalytic converter remains hot for longer than a silencer without a catalytic converter.

Dust and materials that are released from a silencer when, for example, removing a silencer are harmful and must not be inhaled.

The ceramic element of a silencer with a catalytic converter has a highly poisonous coating.

It is not permitted to avoid the use of the exhaust gas after-treatment system or to strip it of components. It is also not permitted to use a urea solution (AdBlue) that does not meet the required specifications or to use the vehicle or the device without a urea solution (AdBlue).

The vehicle is equipped with a catalytic converter. The cata-lytic converter/exhaust system becomes very hot when the vehicle is being driven.

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.

NEVER park or stop the vehicle on a surface that is easily inflammable. This will cause a fire risk.1 - 5DD039400

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1.2.7 CATALYTIC CONVERTER

The catalytic converter contains vanadium pentoxide (see DNX (Denox catalyst) Safety data sheet).

See the product's safety data sheet for the properties, risks and safety information.The catalytic converter must be removed and disposed of in accordance with Directives 91/689/EC-160802 and the local, regional and national legislation.Always wear gloves and safety goggles when working on the catalytic converter.

If the sleeve is damaged or if the catalytic converter has come loose, chemical dust can come out of the silencer.If this is the case, plug all of the catalytic converter's openings before removing the catalytic converter.

It is not permitted to open the catalytic converter/exhaust silencer!1 - 6 DD039400

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TECHNICAL INFORMATIONGeneral information

2. GENERAL INFORMATION

2.1 LOCATION OF THE COMPONENTS

ILAj08951 Fuel tank2 Fuel delivery unit/level sensor3 AdBlue tank4 High-pressure pump2 - 1DD039400

5 Fuel fine filter6 Preliminary fuel filter/water separator7 Fuel tank bleed valve

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Engine

ILAj08701 Fuel rail pressure sensor 6 High-pressure pump2 Fuel line to the fuel rail 7 Fuel line to the high-pressure pump3 Fuel rail 8 Overflow valve leak-off line4 Return fuel overflow valve 9 Fuel return line5 Overflow valve leak-off line 10 Fuel fine filter2 - 2 DD039400

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2.2 SYSTEM DESCRIPTION

The fuel delivery pump (4a) draws the fuel from the fuel tank (1) through the water separator/coarse filter element (2b).

The fuel delivery pump (4a) is fitted against the high-pres-sure pump (4c) and is driven by the camshaft gear.

Fuel is pressed to the fuel fine filter (5) from the fuel delivery pump.

After passing the filter, the fuel is fed into the high-pressure pump (4c) via the fuel pump regulator's solenoid (4b), which controls the quantity of fuel that flows to the high-pressure pump. Fuel that does not pass through the high-pressure pump returns to the delivery pump's supply via the circulation valve (4d) and some of it is used to lubricate the high-pres-sure pump.

The high-pressure pump presses the fuel to the fuel rail (6) under high pressure. The fuel rail distributes the fuel

ILAj0766

1 Fuel tank2 Water separator/coarse filter2a. Hand pump2b. Water separator/coarse filter element5 Water heater4 Fuel pump4a. Fuel delivery pump4b. Fuel regulator solenoid4c. High-pressure pump4d. Circulation valve5 Fuel fine filter6 Fuel rail6a. Rail pressure sensor6b. Pressure relief valve7 Injection nozzles8 Pressure relief valve9 Quick-release connection10 Quick-release connection11 Check valve2 - 3DD039400

amongst the injectors (7). The fuel rail (6) also functions as an accumulator to prevent large pressure fluctuations as a result of injector openings and pump pressure pulses.

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The pressure in the fuel rail is registered via the rail pressure sensor (6a). The electronic unit uses this information to con-trol the high-pressure pump (by means of the fuel pump reg-ulator's solenoid), so that the rail pressure can be kept at the desired level. The desired pressure is not constant, but depends on the operating conditions.

A pressure relief valve (6b) is fitted at the end of the fuel rail and when the pressure in the fuel rail is too high (only in emergency situations), it allows the excess fuel to flow to the return line. This return line is connected to the fuel tank's (1) return line.

The electronic unit calculates the injector's opening time, which depends on the actual rail pressure, to achieve the desired injection quantity.

The injector leak-off ducts in the cylinder head are connected with the fuel tanks return line (1) via a pressure relief valve (8). This pressure relief valve prevents the injectors from becoming empty when the engine stops.

If the system has been opened, the fuel system can be bled using the hand pump (2a) that is integrated in the water sep-arator/coarse filter (2).

Quick-release connections (9 and 10) are located in the fuel supply and return lines to and from the water heater (3). When the fuel lines are disconnected, they close off the fuel supply and return lines to prevent them from running empty.

For further information about the fuel system, please refer to QuickServe Online. See https://quickserve.cummins.com.2 - 4 DD039400

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TECHNICAL INFORMATIONComponent description

3. COMPONENT DESCRIPTION

3.1 FUEL TANK/ADBLUE TANK CONSTRUCTION

The vehicle has an AdBlue tank (5) and a fuel tank (1).

The fuel tank (1) consists of the following: Fuel level gauge/suction unit. Fuel tank valve. Fuel cap.

ILAf0030

1 Fuel tank2 Attachment strap3 Fuel tank cap4 Cowl water drainage5 AdBlue tank6 AdBlue tank cap7 AdBlue sensor8 Fuel level gauge/suction unit9 Plug10 Fuel tank valve3 - 1DD039400

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There are two different types of fuel tank:

2-door modelThe fuel tank is made from aluminium. The tank has internal partitions to strengthen the tank and to prevent the fuel from splashing.The tank has a volume of 240 litres.The tank is fitted against the tank bracket by means of two attachment straps.

3-door modelThe fuel tank is made from aluminium. The tank has internal partitions to strengthen the tank and to prevent the fuel from splashing.The tank has a volume of 236 litres.

ILAf0031

ILAf00333 - 2 DD039400

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The AdBlue tank is made from plastic has has a volume of 26 litres.

The tank can be equipped with an optional heating system.The AdBlue is then heated by the engines cooling system.

ILAf00321 Tank cap2 AdBlue tank3 AdBlue sensor4 AdBlue heaterA. Coolant INB. Coolant OUTC. AdBlue supplyD. AdBlue return3 - 3DD039400

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3.2 FUEL LEVEL SENSOR/SUCTION UNIT

The combined fuel level sensor/suction unit is located in the fuel tank.

Fuel tanl level sensor (B286)The fuel level sensor measures the fuel level in the fuel tank. The level sensor consists of micro switches (reed switches) that are connected in parallel to the resistors. The number of resistors depends on the type of tank module. These micro switches are influenced by a magnetic field that is located outside of the sensor. A float is fitted around the sensor, which floats on the fuel and which has a permanent magnet. The permanent magnet ensures that one of the switches is closed. Depending on the closed switch, two or more resis-tors are connected in series, which causes the resistance value to change. The resistance value is sent to the VFC via IOU A011. The VFC then activates the display on the ICM on which the fuel level is displayed.

Suction unitFuel is fed to the engine from the fuel tank by the fuel delivery pump via the integrated filter and the delivery tube.

ILAh05363 - 4 DD039400

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3.3 FUEL TANK VALVE

The fuel tank valve has a number of functions: To aerate and bleed the fuel tank. To prevent the spilling of fuel. Thermal bleeding.

The fuel tank valve prevents there being a large positive pressure or negative pressure in the fuel tank.If the valve is blocked, a too large positive pressure or nega-tive pressure will be created in the fuel tank. This will result in deformation of the tank.

The thermal safety device in the fuel tank valve ensures that, if the fuel temperature exceeds 124 C, the fuel tank will be automatically bled.

ILAf0029

No modifications may be made to the fuel tank installation. Altering the fuel tank installation without explicit permission from VDL Bus & Coach will lead to overfilling/fuel leaks. 3 - 5DD039400

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3.4 FUEL TANK CAP

The aluminium tank cap is a push open cap.Pushing the cap allows the locking hook (10) to be moved aside so that the cap can be opened.There is an antislosh plate in the neck of the fuel cowl.

ILAj08461 Tank cap hinge pin2 Tank cap3 O-ring4 Filler pipe5 Seal6 Spring, lock7 Bleed/aeration valve8 Locking spring9 Spring; closing hook10 Locking hook11 Antislosh plate3 - 6 DD039400

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3.5 ADBLUE TANK CAP

The AdBlue tanks cap is of the bayonet type and has an internal bleed valve.

Tank protectionThere is a magnetic adaptor in the AdBlue tanks filler neck.It is only possible to fill the AdBlue tank using the AdBlue fuel nozzle in combination with the magnetic adaptor. The mag-netic switch in the fuel nozzles tube is opened by the mag-netic field in the tank opening.This makes it impossible to fill the tank with another liquid. It is also not possible to fill the AdBlue tank with petrol or diesel because the fuel nozzle does not fit in the adaptor in the tank opening.

ILAf00341 Tank cap2 Adaptor3 Adaptor4 Magnet5 AdBlue tank

ILAf00353 - 7DD039400

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3.6 PRELIMINARY FUEL FILTER/WATER SEPARATOR

The preliminary fuel filter/water separator is a filter with a fil-ter fineness of 10 microns that filters out contamination and separates water from the fuel. Water in the fuel can cause corrosion to the fuel systems components.

The fuel flows from the tank to the preliminary fuel filters inlet (A) and then through the filter element (1). The filter element separates water from the fuel and this then drips to the bot-tom of the filter. Dirt in the fuel is held by the filter element. The fuel flows from outlet (B) to the engine.

After the filter element has been replaced, the system can be bled using the hand pump (4) and the bleed plug (6).

A CAN message is sent by the engine ECU when the water level sensor (3) registers that the water level in the base cover is too high. The ICM ensures that the warning symbol is shown on the main display.

By unscrewing the drain plug (2), the water can flow out of the filter element (1).

3.7 FUEL FINE FILTER

The fuel fine filter is a filter with a filter fineness of 3 microns.

The fuel fine filter filters contamination out of the fuel. Dirt in the fuel system can cause damage and increases wear of the various components.The fuel filter is a disposable filter and must, therefore, never be cleaned and reused. The seal between the filter element and the filter head is made using a rubber ring.When a new fuel fine filter is fitted, the filter must not be filled with fuel. After being fitted, the filter must be pumped full using the hand pump on the preliminary fuel filter/water sep-arator. This considerably reduces the risk of dirt getting into the fuel system.

ILAj0820 If the preliminary fuel filter/water separator is replaced, then the water level sensor must be fitted on to the new filter element.3 - 8 DD039400

ILAj0040

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3.8 HIGH-PRESSURE PUMP

The high-pressure pump is driven by the crankshaft by means of the camshaft gear. The pump shaft operates at a speed that is 1.33 times faster than that of the crankshaft. The pump shaft drives the delivery pump. The fuel that is taken by the gear from the suction side is pushed through the volume constriction by the gear at the outlet port. The deliv-ery pump has two valves. The first valve (1) limits the pump pressure, for example, if the fine filter is blocked. The second valve (2) opens a bypass over the delivery pump when the hand pump is operated.

The high-pressure pump's shaft has an eccentric disc. This eccentric disc drives the eccentric ring (4). The pump pistons (3) are driven by the eccentric ring and pushed back by the spring (2).

The fuel is supplied via the connection (5) and then internally distributed amongst the three pump elements. Before the fuel is distributed amongst the pump elements, the flow of fuel is regulated by the fuel pump regulator's (6) solenoid.

The fuel pump regulator's solenoid is controlled by the elec-tronic unit based on the signal from the rail pressure sensor. In this way, there is a closed control circuit. The fuel pump regulator's solenoid is normally open and is activated by a duty cycle. A fixed value is used when the engine is started. If the measured pressure deviates from the desired (pro-grammed) pressure, the duty cycle value is altered until the measured value and the desired value are the same. If this is not successful, the electronic unit will give a warning and save an error code.

The fuel is supplied via the delivery pump's suction valve (9) during the downward stroke (left-hand diagram). During the delivery stroke (right-hand diagram), the valve is closed by the force of the spring (8) and the built-up fuel pressure. The fuel leaves the pump element via the delivery valve (10). The compressed fuel from the three pump elements is collected in the pump housing and leaves the pump via a joint high-pressure connection.

Fuel that leaks from the pump elements is removed via the return connection.

ILAj0767

ILAj07683 - 9DD039400

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The delivery pump has a higher capacity than the high-pres-sure pump. If only a small amount of fuel is taken from the rail, the fuel pump regulator's solenoid will be almost closed. The excess fuel that is delivered will cause an increase in pressure at the inlet of the fuel pump regulator's solenoid. This pressure is limited by the circulation valve (7). If the valve is open, the excess fuel is returned to the suction side of the delivery pump. A small part of the fuel is led to the high-pressure pump's shaft and eccentric disc via a constriction for lubrication purposes.

Any air bubbles will pass through the low pressure circuit with the fuel when bleeding the system using the hand pump. Fuel is pushed inwards at the port (5). The fuel pump regula-tor's solenoid is fully open when deactivated, so that the fuel can pass. The pump elements form a high resistance for the fuel, so that the fuel will escape via the lubrication constric-tion in the pump. As a result, the fuel and any air bubbles are led to the return line. ILAj07693 - 10 DD039400

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3.9 FUEL PUMP REGULATOR SOLENOID

The capacity of the high-pressure pump is too great for nor-mal operating conditions. This would lead to large quantities of fuel being pushed to the fuel rail under high pressure, which would then be immediately led to the return line via a pressure limiting valve on the fuel rail. This causes unneces-sary heat production and a loss of power, because too much fuel with a large difference in pressure will flow.

It has been decided to only press the quantity of fuel that is actually going to be used to the rail under high pressure. Therefore, a solenoid for the fuel pump regulator has been placed at the inlet port of the high-pressure pump. This sole-noid is open when it is deactivated, so that the high-pressure pump elements can be filled in the normal way.

If the fuel rail pressure becomes too high, for example because the rail uses less fuel, then the solenoid is activated by the electronic unit with a higher duty cycle, so that the pis-ton is pushed against the force of the spring with a larger force and the valve's opening becomes slightly smaller. As a result, the fuel supply to the pump elements is reduced and the pump's delivery will decrease. This will then cause the fuel rail pressure to fall.

If the rail pressure becomes too low, then the opposite applies.

The flow is led to the coil (3) via the connector (1). The flow causes the core (2) and the piston (4) to be pushed away against the force of the spring (5). In this way, the fuel can flow from inlet (A) to outlet (B) in a controlled manner.

Thanks to this valve, under normal circumstances, hardly any fuel flows away from the rail. This is beneficial to the yield and the development of heat. ILAj07703 - 11DD039400

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3.10 INJECTOR

The injectors are opened and closed electronically. An injec-tor is normally closed. This is due to the force of the spring (2) and the fuel rail pressure in chamber (C).The fuel is supplied via (A) from the fuel rail. The return fuel can flow back to the fuel tank via (B).When the coil (7) is activated, the anchor body (5) moves upwards. As a result, the pressure in chamber (C) falls some-what and the injector needle (1) is pushed upwards by the rail pressure in chamber (D), so that the fuel can be injected.

ILAj07713 - 12 DD039400

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Fuel supply pipe

The fuel supply pipe (3) connects the injector line (2) with the injector (4) by means of a steel-on-steel press-in connection. This means that the head of the supply pipe seals on the socket in the injector supply line.There is an edge filter (1) in the fuel supply pipe. In the unlikely event that there is dirt in the fuel system, then the edge filter will break the dirt into very small particles because of the fuel pulses. This prevents the very small holes in the injectors from becoming blocked.

The fuel supply pipe has a locking mechanism.

The fuel supply pipe can only be fitted with the locking mech-anism at the top as the bore in the cylinder head has a groove (1) at the top.

ILAj0772

ILAj0773

ILAj07743 - 13DD039400

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3.11 PRESSURE LIMITING VALVE

A pressure limiting valve has been fitted to the fuel rail to allow the rail pressure to be limited to a safe value in emer-gencies. The pressure limiting valve is located at the end of the fuel rail.The fuel rail's control circuit is usually activated. The control circuit consists of the delivery pump, the fuel pump regula-tor's solenoid, the high-pressure pump, the fuel rail, the rail pressure sensor and the electronic unit. If there is a fault, then the rail pressure can no longer be controlled. It can then increase up to the activation pressure of the fuel rail's pres-sure limiting valve. This pressure is approximately 1,850 bar. In the open position, the pressure falls to a value of approxi-mately 800 bar and all the excess fuel flows pressureless to the fuel tank via the fuel rails fuel return connection.

This activation pressure is approximately 2,050 bar. In the open position, the pressure falls to a value of approximately 850 1,000 bar and all the excess fuel flows pressureless to the fuel tank via the fuel rails fuel return connection.

3.12 FUEL RETURN OVERFLOW VALVE

The injectors are mounted in the cylinder head. The injectors do not have a separate return port. Instead, there is a longi-tudinal bore in the cylinder head which touches all the injec-tor bores in all the cylinders at the same height as the return hole in the injectors.An overflow valve has been fitted at the end of the bore in order to prevent moisture from forming in the bore and to pre-vent the bore from running empty when the engine is turned off.The valve maintains a residual pressure with regard to the return pressure of 1.3 to 2.0 bar.

The return fuel flows back to the fuel tank from the overflow valve.

For further information about the fuel system, please refer to QuickServe Online. See https://quickserve.cummins.com.

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TECHNICAL INFORMATIONInspection and adjustment

4. INSPECTION AND ADJUSTMENT

4.1 BLEEDING THE FUEL SYSTEM

When the hand pump is used, the fuel system is bled auto-matically. Any air will be returned to the tank via the return line.1. Unscrew the hand pumps pressure cap (A) and pull out

the pressure cap.2. Use the hand pump until a higher resistance can be

clearly felt.3. Push the pressure cap back in and tighten it until the

sealing ring touches. Next, rotate the pressure cap by hand a further turn.

For details about checking and adjusting the fuel system, please refer to Quickservice Online. See https://quick-serve.cummins.com.

Stop pumping as soon as a higher resistance is felt. Continuing to pump may cause internal damage to the fuel system.

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TECHNICAL INFORMATIONInspection and adjustment4 - 2 DD039400

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TECHNICAL INFORMATIONRemoval and installation

5. REMOVAL AND INSTALLATION

5.1 REMOVING AND INSTALLING THE BATTERY TERMINAL CLAMPS

The battery terminal clamps must always be disconnected when removing and installing fuel system components.

In order to prevent the tachograph from saving an error code, the driver's card must be replaced by the workshop card before the battery terminal clamp is disconnected from the negative pole.

Do not place any tools or other materials on or near the batteries. This could short-circuit 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.5 - 1DD039400

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See 2 - 5.1 Removing and installing the battery terminal clamps (5 - 1) for the battery terminal clamp tightening tor-ques.

Battery acid is an aggressive liquid.In the event of skin contact: wash the affected area thoroughly with plenty of water. Contact a doctor if the affected area remains red or painful. Remove affected clothing and rinse with water.In the event of eye contact: wash for at least 15 minutes with plenty of water and contact a doctor.If swallowed: DO NOT induce vomiting, rinse your mouth, drink two glasses of water and visit a doctor. If inhaled: get some fresh air, take a rest and contact a doctor.5 - 2 DD039400

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5.2 REMOVING AND INSTALLING THE ADB-LUE TANK

Removing the AdBlue tank1. To prevent dirt from entering, the outside of the AdBlue

tank must first be cleaned.

2. Disconnect the earth cable from the batteries (see 2 - 5.1 Removing and installing the battery terminal clamps (5 - 1)).

3. If the AdBlue tank has a heating system, drain the cool-ing system (see Group 2).

See the AdBlue safety data sheet for the properties, risks and safety information. Always wear gloves and safety goggles when working on the AdBlue unit/exhaust gas after-treatment system.

Do not allow AdBlue to come into contact with other chemicals.

Avoid AdBlue coming into contact with painted components. Immediately rinse off AdBlue with clean water.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.If the connection is disconnected too quickly, then the AdBlue lines may become blocked.5 - 3DD039400

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4. Mark the lines at the rear of the AdBlue tank.

5. Place a suitable container under the AdBlue tank.

6. Drain the AdBlue tank by disconnecting the line con-nected to the "AdBlue OUT" connection.

7. Disconnect the other lines from the AdBlue tank, plug them and tie them against the chassis.

8. Place suitable lifting equipment under the AdBlue tank.

9. Remove the attachment bolts (8) which connect the AdB-lue tank's bracket (3) to the chassis.

10. Remove the attachment bolt (2) which connects the bracket (3) against the tank frame (12).

11. Support the AdBlue tank.Remove the AdBlue tank's attachment bolts (4).

12. Remove the bracket (3), the vibration dampers (5 and 7) and the bush (6).

13. Carefully lower the AdBlue tank.

14. Disconnect the connector (11) on top of the AdBlue tank. Next, lower the tank further.

15. Remove the AdBlue tank (1).

ILAj08991 AdBlue IN2 AdBlue OUT3 Coolant IN4 Coolant OUT

The volume of the AdBlue tank is approx. 25 litres.

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Installing the AdBlue tank1. Check the AdBlue tank for damage.

2. Fit the vibration dampers (5 and 7) and the bush (6) in the AdBlue tank (1).

3. Connect the level sensor's connector (11).

4. Hoist up the AdBlue tank and fit the AdBlue tank and the bracket (3) against the tank frame (12) with the bolts (4).

5. Fit the bracket (3) against the chassis bracket (10) using the attachment bolts (8).

6. Fit the bracket (3) to the tank frame (12) using the attach-ment bolt (2).

7. Reconnect the AdBlue tank's lines.

8. Fill the AdBlue tank.

9. Fill the cooling system (only necessary if the AdBlue tank has a heating system) (see Group 2).

10. Check the tank and the tank connections for leaks.

11. Connect the earth cable to the batteries (see 2 - 5.1 Removing and installing the battery terminal clamps (5 - 1)).

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5.3 REMOVING AND INSTALLING THE FUEL TANK

A quantity of fuel may be released when removing fuel lines/components. Collect the fuel and avoid the risk of fire.Plug the openings immediately.Always read the safety data sheet.

Diesel is an inflammable liquid and must not be exposed to a naked flame or other heat sources. Collect any drained fuel in a suitable container.Diesel fumes that remain in an empty fuel tank form an extremely explosive mixture.

Dirt in the system can cause serious damage to the fuel systems components. Prevent this by cleaning the components before disassembling them and by plugging all the openings.

Diesel fuel is toxic and can, therefore, have a damaging effect on your health. Avoid any direct or indirect physical contact.5 - 6 DD039400

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Removing the fuel tank1. To prevent dirt from entering, the outside of the fuel tank

must first be cleaned.


3. Remove the AdBlue tank (see ).

4. Drain the fuel tank via the plug at the bottom of the tank.

5. Open the fuel cowl and remove the attachment bolts (B2) which secure the fuel cowl to the bodywork.

6. Place suitable lifting equipment under the fuel tank.

7. Remove the attachment bolts (C) from the bracket on the side of the tank frame.

8. Remove the attachment bolts (A2) which secure the tank frame to the chassis.

9. Carefully lower the fuel tank slightly.

10. Make sure the fuel tank's bleed line is not touching any-thing.

11. Make sure the fuel cowl's leak-off line is not touching anything.

12. Disconnect the fuel level sensors connector. Next, lower the tank further.

13. Mark the lines connected to the fuel level sensor.

14. Disconnect the lines from the fuel level sensor or com-pletely remove the fuel level sensor. Plug the lines and tie them against the chassis in a high location.

15. To remove the fuel level sensor, use a tightly fitting adjustable spanner to carefully rotate the fuel level sen-sors housing (2) anticlockwise by 30.Carefully remove the fuel level sensor from the fuel tank.

16. Remove the fuel tank together with the tank frame.

ILAj0834A 2 x M10B 1 x M10C 3 x M10

The total volume of the fuel tank is 240 litres!5 - 7DD039400

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Installing the fuel tank 1. Check the fuel tank for damage.

2. Use suitable lifting equipment to install the fuel tank and the tank frame underneath the vehicle.

3. Connect the lines to the fuel level sensor. See 0 - 2.2 Tightening torques (2 - 3) for the maximum specified tightening torques for the line unions.OrPlace the fuel level sensor in the fuel tank and use a tightly fitting adjustable spanner to rotate the gauge by 30 clockwise whilst applying a vertical force of 30 - 40 kg (maximum torque 50 Nm).

4. Connect the fuel level sensors connector.

5. Check whether none of the lines/hoses are touching any-thing and hoist the tank further upwards until the attach-ment bolts can be fitted.

6. First, fit attachment bolts A2 and C of the fuel tank frame and tighten them by hand.

7. Open the fuel cowl and fit the attachment bolts (B2).

8. Tighten the tank frames attachment bolts.

9. Fit the AdBlue tank (see 2 - 5.2 Removing and installing the AdBlue tank (5 - 3)).

10. Fill the fuel tank.

11. Bleed the fuel system (see 2 - 4.1 Bleeding the fuel system (4 - 1)).

12. Check the fuel tank and the hose connections for leaks.


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5.4 REMOVING AND INSTALLING THE ADBLUE INJECTOR

Removing the AdBlue injector1. Turn OFF the engine and the main switch.


3. Remove the AdBlue hose (1) from the AdBlue injector (2).

4. Unscrew the nut (3) from the AdBlue injector (2) and remove the injector from the exhaust pipe.

RISK OF BEING BURNT: The catalytic converter becomes very hot and cools down more slowly than a standard silencer.

Always wear gloves and safety goggles when working on the AdBlue unit/exhaust gas after-treatment system. See the AdBlue safety data sheet for the properties, risks and safety information.Do not allow AdBlue to come into contact

with other chemicals.

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Handle the AdBlue injector with care. There is a ceramic insulator in the injector. To avoid damage, handle and assemble the AdBlue injector with care. 5 - 9DD039400

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Installing the AdBlue injector1. Refit the AdBlue injector with the nut facing towards the

exhaust pipe. Place the cam (1) on the AdBlue injector in the recess (2) in the exhaust pipe.

2. Tighten the nut (3) to the specified torque (see 0 - 3.2 Tightening torques (3 - 2)).

3. Fit the AdBlue hose (1) to the AdBlue injector (3).


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Handle the AdBlue injector with care. There is a ceramic insulator in the injector. To avoid damage, handle and assemble the AdBlue injector with care.

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5.5 REMOVING AND INSTALLING THE FUEL LEVEL SENSOR

Always read the safety data sheet. A quantity of fuel may be released when removing fuel lines/components. Collect the fuel and avoid the risk of fire.Plug the openings immediately.

Diesel is an inflammable liquid and must not be exposed to a naked flame or other heat sources. Collect any drained fuel in a suitable container.Diesel fumes that remain in an empty fuel tank form an extremely explosive mixture.

Dirt in the system can cause serious damage to the fuel systems components. Prevent this by cleaning the components before disassembling them and by plugging all the openings.

Diesel fuel is toxic and can, therefore, have a damaging effect on your health. Avoid any direct or indirect physical contact.5 - 11DD039400

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Removing the fuel level sensor1. Disconnect the earth cable from the batteries (see

2 - 5.1 Removing and installing the battery terminal clamps (5 - 1)).

2. Remove the fuel tank (see 2 - 5.3 Removing and install-ing the fuel tank (5 - 6)).

3. Disconnect the fuel level sensors connector (1).

4. If necessary, disconnect the fuel lines from the fuel level sensor.

5. Use a tightly fitting adjustable spanner to carefully rotate the fuel level sensors housing (2) anticlockwise by 30.

6. Carefully remove the fuel level sensor from the fuel tank.

7. Rinse the sieve (4) in clean diesel and then blow it clean and dry with compressed air.

8. Replace the O-ring (3).

First, clean the area surrounding the fuel gauge on the fuel tank.

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Installing the fuel level sensor1. Place the fuel level sensor in the fuel tank and use a

tightly fitting adjustable spanner to rotate the gauge by 30 clockwise whilst applying a vertical force of 30 - 40 kg (maximum torque 50 Nm).

2. Reconnect the fuel lines.See 0 - 2.2 Tight

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