Deutz-Fahr 1200 – ECU: Engine Fuel Injection Quantity for Multiple Cylinders

The Engine Control Unit (ECU) has detected a deviation in the amount of fuel being delivered to one or more cylinders compared to the expected, calculated quantity. This indicates a deviation from the expected fuel delivery pattern across the engine's cylinders, which can be caused by either an over-fueling or under-fueling condition. The ECU monitors fuel delivery and flags this error when the actual injection quantity correction exceeds predefined limits, pointing to a problem within the fuel injection system.

• Series 3
• Series 5
• Series 5G
• Series 6
• TCD 2.9
• TCD 3.6
• TCD 4.1
• TCD 6.1
• TCD 7.8
• 1011 Series
• 2011 Series
• 1012 Series
• 2012 Series

1. 1

   Verify fuel quality and level, ensuring the tank is filled with clean, correct-specification diesel fuel free from water or contaminants.

2. 2

   Inspect the fuel system for leaks along all fuel lines, filters, and connections from the tank to the injectors.

3. 3

   Check and replace clogged or dirty primary and secondary fuel filters.

4. 4

   Bleed the fuel system to ensure all air is removed, especially if the system was recently serviced or ran out of fuel.

5. 5

   Inspect electrical connections, wiring harnesses, and connectors to the fuel injectors (or individual injection pumps) and the main engine ECU for loose, corroded, or damaged pins.

6. 6

   Read fault codes with a Deutz SerDia diagnostic tool or a generic J1939 scanner to identify the specific SPN and FMI codes (e.g., SPN 5357) for more detailed sub-fault information.

1. 1

   Identify the Faulty Cylinder(s) (Modern Common Rail Systems)

   Use a diagnostic tool to perform a cylinder cutout test or to view live data on injector fuel quantity correction for each cylinder. This will help pinpoint which injector(s) are deviating from the norm.

2. 2

   Remove the Fuel Injector (Modern Common Rail Systems)

   Thoroughly clean the area around the injector to prevent contamination. Disconnect the electrical connector and the high-pressure fuel line. Always cap open fuel ports immediately. Remove the injector retaining clamp and carefully withdraw the injector from the cylinder head. A slide hammer or specialized puller may be necessary if it is seized.

3. 3

   Inspect and Replace (Modern Common Rail Systems)

   Inspect the injector nozzle for carbon buildup or damage. Clean the injector bore in the cylinder head thoroughly. Install a new or remanufactured injector with a new sealing washer.

4. 4

   Reassemble and Recode (Modern Common Rail Systems)

   Torque the injector retaining clamp and high-pressure fuel line to the manufacturer's specifications. It is best practice to use a new high-pressure line. Reconnect the electrical connector. Program the new correction code (often found on the injector body) into the ECU using a diagnostic tool.

5. 5

   Final System Check (Modern Common Rail Systems)

   Clear the fault codes, start the engine, and check for leaks. Monitor live data to ensure fuel trims are within specification.

6. 6

   Identify the Faulty Pump (Older Unit Pump Systems)

   A cylinder cutout test or temperature measurement of the exhaust manifold runners may help identify the malfunctioning cylinder.

7. 7

   Lock the Fuel Rack (Older Unit Pump Systems)

   Before removing an injection pump, the fuel control rack must be locked in the central position using a special pin or screw.

8. 8

   Remove the Injection Pump (Older Unit Pump Systems)

   Rotate the engine so the tappet for the specific pump is at the bottom of its travel (base circle). Disconnect the fuel lines. Unscrew the two nuts holding the pump and remove it, taking note of any shims used for installation height.

9. 9

   Install the New Pump (Older Unit Pump Systems)

   Lock the new injection pump's actuating arm before installation. Ensure the pump's rotating portion aligns with the slot on the fuel rack as you install it. Install the pump with the correct shims and torque the retaining nuts evenly.

10. 10

    Final Checks (Older Unit Pump Systems)

    Unlock the fuel rack and verify it moves freely. Reconnect fuel lines, bleed the system, and check for correct operation.