Troubleshooting
The Iveco Electronic Diagnostic Tool (IT2000) provides effective diagnostics. When the vehicle arrives at the workshop, the driver’s information is taken into account and then the IT2000 is connected to carry out a comprehensive diagnosis, including
- Reading the fault memory
- Parameter reading
- Engine test
It may be useful to print out the results, particularly if help desk assistance is required. Note that the Help Desk may not accept enquiries based solely on the blink code.
The Blink Code is a useful tool in certain cases (e.g. vehicle has broken down on the road), but it should not replace diagnosis with Iveco tools as it only gives general indications.
Experience is also essential for troubleshooting. In order to compensate for possible lack of experience with the new electronic system, a troubleshooting guide has been developed by Training in collaboration with the MS 6.2 EDC control unit experts.
The guide consists of two sections:
- Mechanical faults with flashing code: This section identifies faults that can be detected directly by the 3 control unit, mainly electrical and electronic faults.
- Mechanical faults by symptoms: This section describes possible faults that cannot be detected by the electronic control unit, mainly mechanical and hydraulic faults.
Troubleshooting is not a substitute for diagnosis using Iveco electronic diagnostic tools, but is intended as a supplement.
Blink code of troubleshooting (Table)
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| 1.1 | On | Defective vehicle speed sensor. Tachigraph not functioning. | Vehicle speed no longer limited, can be surpassed in case of poor resistance to advancement. | Flight recorder detects long time at low speed. | Control unit replacement value: 5 kph |
| Faulty tachigraph needle behaviour | Juddering in high gears | Check wiring, connections, component | |||
| 1.2 | On | Defective multi-state switch. | Check wiring, connections, component | ||
| No reduction in Economy mode | |||||
| (1.2) | (On) | Multi-state switch blocked in one position | Remains in last selected mode | Check wiring, connections, component | |
| No switching between normal and economy operation | |||||
| 1.3 | Off | Defective cruise control. | Cruise Control / PTO not functioning | Check wiring, connections, component | Switch signals not plausible (pressed together) |
| No reaction after turning CC/PTO switches | |||||
| 1.4 | On | Accelerator pedal: defective powering or signal not plausible. Idle at 1000 rpm and faulty engine reaction to accelerator pedal | Can be varied with warm engine by CC switch (Set + / Set -) | ||
| 1.4 | On | Accelerator pedal: defective powering or signal not plausible. Idle at 1000 rpm and faulty engine reaction to accelerator pedal | Can be varied with warm engine by CC switch (Set + / Set -) |
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| 1.5 | Off | Defective clutch switch . CC/PTO not functioning | Juddering on gear change | Check wiring, connections, component | |
| 1.6 | On | Brake switch plausibility. | Cruise control / PTO not functioning | Check wiring, connections, component | |
| No reaction after turning CC/PTO switch | |||||
| 1.7 | Off | Accelerator pedal sensor / brake switch plausibility | No reaction from system | ||
| 1.8 | Off | Defective coolant temperature sensor. | Greater combustion noise due to high injection advance | Active diagnosis of pre-heating element. | Absence of overheating protection, replacement value = 0°C |
| Excessive starting time in cold conditions | Parameter reading. Check wiring, connections, component | ||||
| 2.2 | Off | Turbo air temperature sensor defective | If sensor indicates lower temperature than real, error not memorised and engine achieves better performance but with black smoke | Parameter reading. | Replacement value = 20°C |
| Check wiring, connections, component | |||||
| 2.3 | Off | Defective fuel temperature sensor | Parameter reading. | No injection flow-rate correction, but driver does not notice. | |
| Check wiring, connections, component | Replacement value = 970 mbar | ||||
| 2.4 | On | Defective turbo pressure sensor. Reduced power | Temporary black smoke in significant quantities | Modus parameter reading: if replacement value appears at idle, fault is confirmed |
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| 2.5 | Off | Defective ambient pressure sensor | Contact Help Desk for control unit replacement because sensor built-in to the same | Less accurate VGT function at high altitude, but driver does not notice. | |
| Replacement value = 970 mbar | |||||
| (2.6) | (On) | Engine braking command switches or selector switch. | Modus parameter reading. | ||
| Engine brake not functioning in all three selected modes | Check wiring, connections, component | ||||
| (2.6) | (On) | Engine braking switch blocked closed. | Active diagnosis of engine braking solenoid valve | Fuel injection interrupted by ECU, engine speed drops to 800 rpm, fuel injection again interrupted by ECU | |
| Engine braking enabled only above 900 rpm | |||||
| (2.6) | (On) | Engine braking switch blocked open | Engine test on engine braking. | Engine braking functions when activated by Modus or by other two selection modes (accelerator – brake) | |
| Active diagnosis of engine braking solenoid valve | |||||
| 3.5 | Off | Battery voltage too low or fault in voltage recognition | Possible pre-heating and starting problems | Test batteries | EDC operates with replacement value of 28V |
| 4.1 | Off | Faulty VGT pressure sensor capsule. | Possible reduction in engine braking power | Engine test: Check wiring, connections, component. | If capsule pressure increases during VGT test but , visually, the actuator does not move, it is seized. |
| Poor performance at low speeds and on acceleration | Check arrival of compressed air to capsule. | ||||
| Check function of shut-off valve on chassis. |
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| 4.1 | Off | Rotating parts of turbo-compressor totally seized. | Reduced engine braking power | Engine test: engine check-up | Capsule memorises turbine revs sensor error, even if it functions correctly |
| Poor performance at low speeds and on acceleration | |||||
| (4.1) | (Off) | VGT command solenoid blocked or seized closed. | Poor vehicle acceleration | Engine test: VGT. | |
| Noise indicates faulty turbo behaviour (speed does not follow accelerator pedal) | Turbine actuator active diagnosis | ||||
| (4.2) | (Off) | VGT mechanism blocked closed. Reduced power with engine speed below 1200 rpm. | Black smoke with normal function, after acceleration. | Engine test: engine brake and VGT. Turbine actuator active diagnosis | Power reduced by control unit due to excessive turbine speed |
| Engine brake disengaged by control unit in braking mode with high engine speeds | |||||
| 4.2 | On | Faulty turbo speed sensor. Reduced power and speed | Engine test: check wiring, connections, component | ||
| 4.3 | On | Turbine overspeed or excessive turbo pressure. | Poor engine brake efficiency | Engine test | Fuel flow reduction during turbine over-revving |
| Reduced power | |||||
| 4.4 | On | VGT monitoring of control unit. Reduced power | Engine test | Deviation of VGT variable geometry beyond set thresholds |
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| (4.1) | (Off) | No compressed air delivery to VGT valve or insufficient pressure. | Possible reduction in engine braking efficiency | Engine test: active diagnosis: turbine actuator. | |
| (4.4) | (On) | Poor performance at low speeds and in acceleration | Check compressed air delivery to capsule. | ||
| Check function of shut-off valve on chassis | |||||
| If not functioning check connections, wiring, component and passage. | |||||
| If shut-off valve functions, check air line from shut-off to capsule and line connection to capsule. | |||||
| Check mechanical efficiency of VGT command solenoid valve. | |||||
| (4.1) | (Off) | VGT mechanism in turbine blocked half open. Poor performance at low and medium speeds and in acceleration | Possible reduction in engine braking efficiency | Engine test: VGT, engine brake. Turbine actuator active diagnosis | If external VGT command mechanisms function but VGT test indicates fault, fault should be sought in turbo internal mechanisms. |
| (4.4) | (On) | ||||
| 4.5 | On | Electrical problem with VGT solenoid valve. | Reduction in engine braking efficiency | Engine test: Check wiring, connections and component | |
| Significant power reduction at low speed and in acceleration | |||||
| 4.6 | Blinking | Engine brake solenoid valve. Engine brake not functioning | Engine test: check wiring, connections and component | If engine brake does not function with engine test, solenoid valve is not powered by vehicle wiring | |
| 5.x | On | Engine test (if fault is present): | |||
| Check wiring, connections and component (header cable as well) |
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| 6.1 | On | Faulty flywheel sensor. | Engine start may take longer than usual | Modus fault memory reading. | |
| Reduced engine speed and power | Check wiring, connections and component | ||||
| 6.2 | On | Camshaft sensor. | Engine start may take longer than usual | Modus fault memory reading | |
| Reduced engine power and speed | Check wiring, connections and component | ||||
| (6.1 – 6.2) | (On) | Camshaft phonic wheel offset due to loose screws. | Reduced power with motor running (after recommended | Disconnect camshaft sensor. | |
| Engine does not start or stops. Restart impossible. | intervention) | If engine starts, taking longer that usual, phonic wheel is offset. | |||
| 6.4 | Blinking | Engine has reached 3800 rpm (motoring) for any reason | Fault memory reading. Read flight recorder to confirm engine overspeed. | ||
| 7.1 | Off | Two cable ABS/ASR interface problems | Check vehicle wiring | ||
| ASR not functioning | |||||
| 7.4 | Off | CAN gearbox command interruption. | |||
| Gearbox command does not function via CAN | |||||
| (9.1) | (Blinking) | Faulty EDC control unit Engine stops or does not start | Contact Help Desk for control unit replacement | No diagnosis possible. | |
| This error may not be memorised, depends on control unit condition. |
| BLINK CODE | POSSIBLE CAUSE | POSSIBLE ANOMALIES | ADVISED TESTS OR INTERVENTIONS | NOTES | |
| 9.2 | On | Faulty control unit (EEPROM memory). | Fault memory cancelled, diagnosis possible only for current faults | Contact Help Desk for possible replacement of control unit | |
| Reduced engine speed and power | |||||
| 9.4 | On | Main relay faulty or blocked closed. | EDC power remains on after turning key to off, danger of flattening battery | Check wiring, connections and component | Fault is memorised only after subsequent starting |
| EDC lamp stays on when key turned to OFF but engine stops. | |||||
| 9.5 | On | ECU power frequently interrupted (5 times): Main relay faulty or engine stop by battery cut-off switch. | Check main relay, wiring and component. Investigate possible driver habits regarding stopping engine without turning key | Problem solves only with subsequent switch-off procedure and correct data memorising. | |
| 9.6 | On | ECU stop test fail. | Internal control unit test procedure to check power stages. Could memorise other errors related to various actuator power stages. | Contact Help Desk for possible replacement of control unit |
