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NOTES ADVISEDTESTS ORINTERVENTIONS POSSIBLE ANOMALIES POSSIBLE CAUSE
EDC WARNING LIGHT
BLINK CODE 1.5OffDefectiveclutchswitch. CC/PTOnotfunctioningJudderingongear changeCheckwiring,connections, component 1.6OnBrakeswitchplausibility. NoreactionafterturningCC/PTO switch
Cruisecontrol/PTO notfunctioningCheckwiring,connections, component 1.7OffAcceleratorpedalsensor/brake switchplausibilityNoreactionfromsystem 2.1OffDefectivecoolanttemperature sensor. Excessivestartingtimeincold conditions Greatercombustion noiseduetohigh injectionadvance Activediagnosisofpre-heating element. Parameterreading.Checkwiring, connections,component
Absenceofoverheatingprotection, replacementvalue=0°C 2.2OffTurboairtemperaturesensor defectiveIfsensorindicates lowertemperature thanreal,errornot memorisedandengine achievesbetter performancebutwith blacksmoke
Parameterreading. Checkwiring,connections, component
Replacementvalue=20°C 2.3OffDefectivefueltemperaturesensorParameterreading. Checkwiring,connections, component
Noinjectionflow-ratecorrection,but driverdoesnotnotice. Replacementvalue=970mbar 2.4OnDefectiveturbopressuresensor. ReducedpowerTemporaryblack smokeinsignificant quantities
Modusparameterreading:if replacementvalueappearsatidle,fault isconfirmed
BLINK CODE
EDC WARNING LIGHT
POSSIBLE CAUSEPOSSIBLE ANOMALIESADVISEDTESTS ORINTERVENTIONSNOTES 2.5OffDefectiveambientpressuresensorContactHelpDeskforcontrolunit replacementbecausesensorbuilt-in tothesame
LessaccurateVGTfunctionathigh altitude,butdriverdoesnotnotice. Replacementvalue=970mbar (2.6)(On)Enginebrakingcommandswitchesor selectorswitch. Enginebrakenotfunctioninginall threeselectedmodes
Modusparameterreading. Checkwiring,connections, component (2.6)(On)Enginebrakingswitchblockedclosed. Enginebrakingenabledonlyabove 900rpm
Activediagnosisofenginebraking solenoidvalveFuelinjectioninterruptedbyECU, enginespeeddropsto800rpm,fuel injectionagaininterruptedbyECU (2.6)(On)EnginebrakingswitchblockedopenEnginetestonenginebraking. Activediagnosisofenginebraking solenoidvalve
Enginebrakingfunctionswhen activatedbyModusorbyothertwo selectionmodes(accelerator–brake) 3.5OffBatteryvoltagetooloworfaultin voltagerecognitionPossiblepre-heating andstartingproblemsTestbatteriesEDCoperateswithreplacementvalue of28V 4.1OffFaultyVGTpressuresensorcapsule. Poorperformanceatlowspeedsand onacceleration
Possiblereductionin enginebrakingpowerEnginetest:Checkwiring, connections,component. Checkarrivalofcompressedairto capsule. Checkfunctionofshut-offvalveon chassis.
Ifcapsulepressureincreasesduring VGTtestbut,visually,theactuator doesnotmove,itisseized.
ASTRA HD8
28 ENGINE F3B SECTION 3
BLINK CODE
EDC WARNING LIGHT
POSSIBLE CAUSEPOSSIBLE ANOMALIESADVISEDTESTS ORINTERVENTIONSNOTES 4.1OffRotatingpartsofturbo-compressor totallyseized. Poorperformanceatlowspeedsand onacceleration
Reducedengine brakingpowerEnginetest:enginecheck-upCapsulememorisesturbinerevs sensorerror,evenifitfunctions correctly (4.1)(Off)VGTcommandsolenoidblockedor seizedclosed. Noiseindicatesfaultyturbobehaviour (speeddoesnotfollowaccelerator pedal)
Poorvehicle accelerationEnginetest:VGT. Turbineactuatoractivediagnosis (4.2)(Off)VGTmechanismblockedclosed. Reducedpowerwithenginespeed below1200rpm.
Blacksmokewith normalfunction,after acceleration. Enginebrake disengagedbycontrol unitinbrakingmode withhighengine speeds
Enginetest:enginebrakeandVGT. TurbineactuatoractivediagnosisPowerreducedbycontrolunitdueto excessiveturbinespeed 4.2OnFaultyturbospeedsensor. ReducedpowerandspeedEnginetest:checkwiring,connections, component 4.3OnTurbineoverspeedorexcessiveturbo pressure. Reducedpower
Poorenginebrake efficiencyEnginetestFuelflowreductionduringturbine over-revving 4.4OnVGTmonitoringofcontrolunit. ReducedpowerEnginetestDeviationofVGTvariablegeometry beyondsetthresholds
BLINK CODE
EDC WARNING LIGHT
POSSIBLE CAUSEPOSSIBLE ANOMALIESADVISEDTESTS ORINTERVENTIONSNOTES (4.1) (4.4)(Off) (On)NocompressedairdeliverytoVGT valveorinsufficientpressure. Poorperformanceatlowspeedsand inacceleration Possiblereductionin enginebraking efficiency
Enginetest:activediagnosis:turbine actuator. Checkcompressedairdeliveryto capsule. Checkfunctionofshut-offvalveon chassis Ifnotfunctioningcheckconnections, wiring,componentandpassage. Ifshut-offvalvefunctions,checkairline fromshut-offtocapsuleandline connectiontocapsule. CheckmechanicalefficiencyofVGT commandsolenoidvalve. (4.1) (4.4)(Off) (On)VGTmechanisminturbineblocked halfopen.Poorperformanceatlow andmediumspeedsandin acceleration
Possiblereductionin enginebraking efficiency
Enginetest:VGT,enginebrake. TurbineactuatoractivediagnosisIfexternalVGTcommand mechanismsfunctionbutVGTtest indicatesfault,faultshouldbesought inturbointernalmechanisms. 4.5OnElectricalproblemwithVGTsolenoid valve. Significantpowerreductionatlow speedandinacceleration
Reductioninengine brakingefficiencyEnginetest:Checkwiring,connections andcomponent 4.6BlinkingEnginebrakesolenoidvalve. EnginebrakenotfunctioningEnginetest:checkwiring,connections andcomponentIfenginebrakedoesnotfunctionwith enginetest,solenoidvalveisnot poweredbyvehiclewiring 5.xOnEnginetest(iffaultispresent): Checkwiring,connectionsand component(headercableaswell)
ASTRA HD8
30 ENGINE F3B SECTION 3
BLINK CODE
EDC WARNING LIGHT
POSSIBLE CAUSEPOSSIBLE ANOMALIESADVISEDTESTS ORINTERVENTIONSNOTES 6.1OnFaultyflywheelsensor. ReducedenginespeedandpowerEnginestartmaytake longerthanusualModusfaultmemoryreading. Checkwiring,connectionsand component 6.2OnCamshaftsensor. ReducedenginepowerandspeedEnginestartmaytake longerthanusualModusfaultmemoryreading Checkwiring,connectionsand component (6.1–6.2)(On)Camshaftphonicwheeloffsetdueto loosescrews. Enginedoesnotstartorstops.Restart impossible.
Reducedpowerwith motorrunning(after recommended intervention)
Disconnectcamshaftsensor. Ifenginestarts,takinglongerthat usual,phonicwheelisoffset. 6.4BlinkingEnginehasreached3800rpm (motoring)foranyreasonFaultmemoryreading.Readflight recordertoconfirmengineoverspeed. 7.1OffTwocableABS/ASRinterface problems ASRnotfunctioning
Checkvehiclewiring 7.4OffCANgearboxcommandinterruption. Gearboxcommanddoesnotfunction viaCAN (9.1)(Blinking)FaultyEDCcontrolunit EnginestopsordoesnotstartContactHelpDeskforcontrolunit replacementNodiagnosispossible. Thiserrormaynotbememorised, dependsoncontrolunitcondition.
BLINK CODE
EDC WARNING LIGHT
POSSIBLE CAUSEPOSSIBLE ANOMALIESADVISEDTESTS ORINTERVENTIONSNOTES 9.2OnFaultycontrolunit(EEPROM memory). Reducedenginespeedandpower Faultmemory cancelled,diagnosis possibleonlyfor currentfaults
ContactHelpDeskforpossible replacementofcontrolunit 9.4OnMainrelayfaultyorblockedclosed. EDClampstaysonwhenkeyturned toOFFbutenginestops.
EDCpowerremainson afterturningkeytooff, dangerofflattening battery
Checkwiring,connectionsand componentFaultismemorisedonlyafter subsequentstarting 9.5OnECUpowerfrequentlyinterrupted(5 times):Mainrelayfaultyorenginestop bybatterycut-offswitch.
Checkmainrelay,wiringand component.Investigatepossibledriver habitsregardingstoppingengine withoutturningkey
Problemsolvesonlywithsubsequent switch-offprocedureandcorrectdata memorising. 9.6OnECUstoptestfail. ReducedenginespeedandpowerInternalcontrolunit testprocedureto checkpowerstages. Couldmemoriseother errorsrelatedto variousactuatorpower stages.
ContactHelpDeskforpossible replacementofcontrolunit
ENGINE - F3B
32 SECTION 3 ASTRA HD8Ec
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Main engine operating anomalies:
1 - The engine does not start;
2 - The engine is excessively heated;
3 - The engine lacks efficiency;
4 - The engine has grey smokes (tending to white);
5 - The engine has blue smokes;
6 - Poor engine braking efficiency;
7 - The engine stops;
8 - Excessive fuel consumption;
9 - Excessive or insufficient oil pressure.
1
NO
YES
ENGINE DOES NOT START
NO
Battery efficient Pre-heating element always on
Check alternator efficiency
Check battery terminal connections
Starter motor efficient Carry out checks / replace
Air heater efficient Check power supply and earth connection
Check heater relay by active diagnosis
Main relay efficient Check fuses
Check relay by active diagnosis
Fuel pump efficient Check efficiency checking pressure at filter
Fuel prefilter - filter efficient Check for clogging / replace
(continued)
ENGINE - F3B
34 SECTION 3 ASTRA HD8Ec
NO
0.8 bar valve on fuel return efficient Check efficiency, replace if blocked open
Fuel circuit efficient Check circuit seal and bleed
Coolant level correct Check for leaks and top-up
Water pump and fan belts efficient Check, adjust tension and if necessary replace components
Water pump efficient Overhaul or replace group
Thermostat efficient Check whether remains closed or partially open.
Replace
Thoroughly clean, check for leaks, replace if necessary Radiator efficient
Air filter and circuit piping efficient Check that hoses and pipes are clear Check filter clog indicator, replace filter.
YES
NO
YES
NO
Cylinder head gasket efficient Check water pressure and replace head gasket
Fan efficient Replace
Exhaust gas circuit efficient
NO
YES
Fuel circuit efficient Check whether tank filter, prefilter and fuel filter are clogged. Replace.
Check whether 0.8 bar valve on fuel return from head is blocked open (low pressure) or closed (high temperature). Replace
Check for circuit leaks and fuel pump efficiency
Remove obstruction on circuit and replace air filter if clogged.
Check clogged cartridge indicator Injectors efficient
Engine air intake circuit efficient
Injector pump may seize or fuel leak from O-ring.
Carry out engine test and proceed as per instructions given
Eliminate leaks on exhaust manifold NO
Correct running temperature Check cooling system
ENGINE LACKS POWER
(continued)
ENGINE - F3B
36 SECTION 3 ASTRA HD8Ec
VGT actuator efficient Carry out Engine Test following instructions displayed
by diagnosis tool NO
NO
YES
NO
Turbocompressor efficient Carry out Engine Test on turbine and check integrity of following turbo components
- turbine blades - bearings - modulator valve - Clogged VGT filter - turbine actuator Replace faulty components
Mechanical injection system efficient Check injector rocker wear, check rollers, rocker bushes and camshaft cams
YES
Valve play correct Adjust valve play
NO YES
NO
4 ENGINE EMITS GREY/WHITE SMOKE
Head gasket efficient Grind head and replace gasket
NO
Turbocompressor cooling circuit seal efficient Overhaul turbo NO
Injector sheathes efficient Replace sheathes
YES
YES
NO
5 ENGINE EMITS BLUE SMOKE
Piston rings efficient Overhaul pistons - cylinder
NO
Good quality fuel Check for water in tank and eliminate
YES
NO
Turbo lubrication circuit efficient Overhaul turbo
YES
NO
Valve oil seals efficient Replace valve guide gaskets
YES
ENGINE - F3B
38 SECTION 3 ASTRA HD8Ec
NO
YES
NO
6 POOR ENGINE BRAKING EFFICIENCY
Engine braking components efficient Check correct function of engine brake actuator cylinders and command solenoid
Check cylinder command oil piping seal Check exhaust valve play
Turbocompressor efficient VGT blocked open
Faulty VGT actuator (seepage from tie rod) Faulty modulator valve
Incorrect air supply to modulator valve Replace faulty components
7 ENGINE STOPS
Fuel in tank Bleed group after filling tank
Tank filter, pre-filter and engine fuel filter efficient Clean tank filter and replace filter and prefilter
Tank fuel lines correctly connected Inverting the pipes may cause vehicle to stop
after 200 - 300 km even if tank has fuel because piping that feeds engine has less scavenge.
Invert pipes.
YES
NO
YES
NO
NO
9 OIL PRESSURE INSUFFICIENT OR EXCESSIVE
Pressure regulator valve operates correctly Check and if necessary replace
Oil pump and delivery piping efficient Check and if necessary replace.
Main bearings and big ends efficient Replace bearings and if necessary grind crankshaft
Engine oil SAE viscosity correct Change engine oil with suitable viscosity oil YES
NO
YES
NO
YES
NO
NO
8 EXCESSIVE FUEL CONSUMPTION
Air filter efficient Replace
NO
Tank and fuel lines efficient. Eliminate any leaks and replace worn parts NO
YES
ENGINE - F3B
40 SECTION 3 ASTRA HD8Ec