Astra HD8 Troubleshooting

By | 16/08/2018

Astra HD8 Troubleshooting (Blinking Codes)

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Astra HD8 troubleshooting

Astra HD8

Troubleshooting

An effective diagnosis can be made above all using the electronic diagnosis tools (IT2000) developed by Iveco.

When the vehicle arrives at the workshop, the information provided by the driver should be given due consideration, although the first thing to do is to connect the IT2000 and carry out a complete diagnosis:

  • Fault memory reading
  • Parameter reading
  • Engine test

It is useful to print out the results, especially if Help Desk assistance is required.

In this case, note that the Help Desk may not accept requests for assistance based only on Blink Code.

The Blink Code is a tool that can be useful in certain cases (vehicle broken down on the road, no Modus/IWT/IT2000), but must not substitute diagnosis with the Iveco tools because the code only offers general indications.

Another factor important in troubleshooting is experience.

To get around a possible lack of experience of the repair mechanic with respect to this new electronic system (there being no previous systems of the kind to use as reference, the following pages offer a TROUBLESHOOTING GUIDE developed by Training in collaboration with the experts who designed and developed the MS 6.2 EDC control unit.

However, it has to be stressed that not even Troubleshooting can replace the IT2000, although it is an extra help in that it concentrates the experience of the people who have a profound knowledge of the system.

The Troubleshooting guide consists of two distinct sections:

  • The first looks for mechanical faults with Blink Code and regards faults that can be directly identified by the 3 control unit. These faults are mainly of an electrical – electronic nature;
  • The second looks for mechanical faults by symptoms, and describes possible faults that cannot be recognised by the electronic control unit. These faults are mainly of a mechanical – hydraulic

Troubleshooting does not substitute diagnosis with Iveco electronic diagnosis tools, but is intended as a supplement to the same.

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
Reduced engine speed and power