Mercedes Benz Truck R 320 BLUETEC Technical LI14-10_P-047525 Date: 090814
Diesel Engine - Low Power/Limp Home Mode/Codes Set
ENGINE SWITCHES TO LIMP-HOME MODE OR HAS INSUFFICIENT OUTPUT, FAULT CODE STORED IN CDI CONTROL UNIT
Topic Number LI14.10-P-047525
Version 1
Design Group 14.10 Exhaust manifold
Date 08-14-2009
Validity Models 164, 203, 204, 207, 209, 211, 212, 219, 221, 251, 461, 463 with engine 642
Reason for change Test method optimized. fault code 2616 entered. Fault codes 2511 and 2355 deleted. Test step 6 deleted. Damage code 14124 Reason for block
COMPLAINT:
Engine switches to limp-home mode or has insufficient output, fault code stored in CDI control unit.
NOTE:
Fault codes P2510, P2359, P2616, P2592 or combinations P2510 + P2359, P2510 + P2616 may be stored in CDI control unit (N3/9).
CAUSE:
Turbocharger may have been damaged or had its function briefly impaired by foreign objects from the exhaust manifold.
Attachments
REMEDY:
NOTE:
The vehicle mileage, the sequence of the test steps and the frequency counter in the fault freeze frame data must be strictly observed!
1. Perform quick test with DAS.
2. Operational check of boost pressure positioner (Y77/1).
After ignition ON, the boost pressure positioner (Y77/1) must move to the upper position.
Mercedes Benz Truck R 320 BLUETEC
Page 286
If fault P2510 is logged in the process, remove turbocharger and perform step 5.
NOTE:
See the EPC parts catalog for turbocharger part number.
3. Check of turbocharger be acquisition of DIAGNOSIS PERFORMANCE DATA in DAS.
NOTE:
Test prerequisites: Engine at idle, transmission stage at N, all electric consumers switched off, air conditioning off, engine at operating temperature
(oil and coolant temperature > 80°C), load condition of diesel particulate filter < 50%. At > 50% a manual regeneration must be performed.
NOTE:
In DAS select: Control units -> Drive -> CDI common rail -> Acquisition of DIAGNOSIS PERFORMANCE DATA.
Launch program.
4. Print out results log.
NOTE:
In the 2nd part of the measurement "Measurement values on rpm increase and exhaust gas recirculation off" check the exhaust back pressure value
"Normname DT_38_EGpCD_pP3Val". (Model series 221: "DT_31_EGPpCD_pP3FItVaIB1/2")
If the exhaust back pressure is greater then 2000 +/- 50hPa, replace turbocharger and both exhaust manifolds.
If the exhaust back pressure is less then 2000 +/- 50hPa, proceed according to the following parameters:
- If the vehicle mileage is less then 20,000 km, the fault frequency counter is higher then 3 times, and the fault setting intervals between the first and
last entries is less then 5000 km, replace the turbocharger.
- If the vehicle mileage is greater then 20,000 km, the fault frequency counter is higher then 3 times, and the fault setting intervals between the first
and the last entries is less then 5000 km, replace both exhaust manifolds and turbocharger.
- With fault setting intervals greater then 5000 km and any fault frequency count, erase fault memory and do not replace any components.
NOTE:
The results log must be enclosed with the faulty parts.
5. Check exhaust manifold in installed condition.
NOTE:
If one of the two exhaust manifolds id damaged externally (Figure 1), replace both exhaust manifolds.
If metal pieces from the turbine housing (Figure 2) fall out of the removed turbocharger, replace both exhaust manifolds.
If there is no visible damage on the outside of the exhaust manifold, perform a sound test with a rubber hammer. If there are rattling noises, replace
both exhaust manifolds.
Tip: Inspect exhaust manifold using an endoscope (if available). If cracks or metal pieces (Figure 2) are found in the exhaust manifold, replace both
exhaust manifolds.
Symptoms
Mercedes Benz Truck R 320 BLUETEC
Page 287
Control unit/fault code
Parts
Mercedes Benz Truck R 320 BLUETEC
Page 288
Work units
Validity
Attachment - Figure 1 Torn inner pipe in exhaust manifold at three-hole flange
Mercedes Benz Truck R 320 BLUETEC
Page 289
Attachment - Figure 2 Metal piece of exhaust manifold
Diesel Engine - Low Power/Limp Home Mode/Codes Set
ENGINE SWITCHES TO LIMP-HOME MODE OR HAS INSUFFICIENT OUTPUT, FAULT CODE STORED IN CDI CONTROL UNIT
Topic Number LI14.10-P-047525
Version 1
Design Group 14.10 Exhaust manifold
Date 08-14-2009
Validity Models 164, 203, 204, 207, 209, 211, 212, 219, 221, 251, 461, 463 with engine 642
Reason for change Test method optimized. fault code 2616 entered. Fault codes 2511 and 2355 deleted. Test step 6 deleted. Damage code 14124 Reason for block
COMPLAINT:
Engine switches to limp-home mode or has insufficient output, fault code stored in CDI control unit.
NOTE:
Fault codes P2510, P2359, P2616, P2592 or combinations P2510 + P2359, P2510 + P2616 may be stored in CDI control unit (N3/9).
CAUSE:
Turbocharger may have been damaged or had its function briefly impaired by foreign objects from the exhaust manifold.
Attachments
REMEDY:
NOTE:
The vehicle mileage, the sequence of the test steps and the frequency counter in the fault freeze frame data must be strictly observed!
1. Perform quick test with DAS.
2. Operational check of boost pressure positioner (Y77/1).
After ignition ON, the boost pressure positioner (Y77/1) must move to the upper position.
Mercedes Benz Truck R 320 BLUETEC
Page 286
If fault P2510 is logged in the process, remove turbocharger and perform step 5.
NOTE:
See the EPC parts catalog for turbocharger part number.
3. Check of turbocharger be acquisition of DIAGNOSIS PERFORMANCE DATA in DAS.
NOTE:
Test prerequisites: Engine at idle, transmission stage at N, all electric consumers switched off, air conditioning off, engine at operating temperature
(oil and coolant temperature > 80°C), load condition of diesel particulate filter < 50%. At > 50% a manual regeneration must be performed.
NOTE:
In DAS select: Control units -> Drive -> CDI common rail -> Acquisition of DIAGNOSIS PERFORMANCE DATA.
Launch program.
4. Print out results log.
NOTE:
In the 2nd part of the measurement "Measurement values on rpm increase and exhaust gas recirculation off" check the exhaust back pressure value
"Normname DT_38_EGpCD_pP3Val". (Model series 221: "DT_31_EGPpCD_pP3FItVaIB1/2")
If the exhaust back pressure is greater then 2000 +/- 50hPa, replace turbocharger and both exhaust manifolds.
If the exhaust back pressure is less then 2000 +/- 50hPa, proceed according to the following parameters:
- If the vehicle mileage is less then 20,000 km, the fault frequency counter is higher then 3 times, and the fault setting intervals between the first and
last entries is less then 5000 km, replace the turbocharger.
- If the vehicle mileage is greater then 20,000 km, the fault frequency counter is higher then 3 times, and the fault setting intervals between the first
and the last entries is less then 5000 km, replace both exhaust manifolds and turbocharger.
- With fault setting intervals greater then 5000 km and any fault frequency count, erase fault memory and do not replace any components.
NOTE:
The results log must be enclosed with the faulty parts.
5. Check exhaust manifold in installed condition.
NOTE:
If one of the two exhaust manifolds id damaged externally (Figure 1), replace both exhaust manifolds.
If metal pieces from the turbine housing (Figure 2) fall out of the removed turbocharger, replace both exhaust manifolds.
If there is no visible damage on the outside of the exhaust manifold, perform a sound test with a rubber hammer. If there are rattling noises, replace
both exhaust manifolds.
Tip: Inspect exhaust manifold using an endoscope (if available). If cracks or metal pieces (Figure 2) are found in the exhaust manifold, replace both
exhaust manifolds.
Symptoms
Mercedes Benz Truck R 320 BLUETEC
Page 287
Control unit/fault code
Parts
Mercedes Benz Truck R 320 BLUETEC
Page 288
Work units
Validity
Attachment - Figure 1 Torn inner pipe in exhaust manifold at three-hole flange
Mercedes Benz Truck R 320 BLUETEC
Page 289
Attachment - Figure 2 Metal piece of exhaust manifold
