EDC 16 ,2

1 Engine and peripherals 13B

DIESEL INJECTION EDC16CP33 Program No.: C4 Vdiag No.: 0C, 10, 14, 16

Fault finding – Introduction Fault finding – Cleanliness guidelines Fault finding – System operation Fault fifinding – Replacement of of co components Fault Fault findi finding ng – Config Configura uratio tions ns and and prog program rammin ming g Fault finding – Fault summary table Fault finding – Interpretation of faults Fault finding – Conformity check Fault finding – Status summary table Fault finding – Interpretation of statuses Fault finding – Parameter summary table Fault ault fin findin ding – Inte Interp rpre reta tati tion on of pa param ramete eters Fault finding – Command summary table Fault ault fin findin ding – Inte Interp rpre reta tati tion on of co comman mands Fault finding – Customer complaints Fault finding – Fault Finding Chart Fault finding – Test

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V5 "The repair procedures given by the manufacturer in this document are based on the technical specifications current when it was prepared. The procedures may be modified as a r esult of changes introduced by the manufacturer manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Edition Anglaise All rights reserved by by Renault s.a.s. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault s.a.s.

© Renault Renault s.a.s. 2009 MR-410-X83-13B000$TOC.mif V5

DIESEL INJECTION

EDC16CP33 Program No.: C4 Vdiag No.: 0C, 10, 14, 16

1.

Fault finding – Introduction

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SCOP SCOPE E OF OF THI THIS S DOC DOCUM UMEN ENT T

This document presents the fault finding procedure applicable to all computers with the following specifications: Vehicle(s): TRAFIC II phase 2 Engine: M9R 780, M9R 782 and M9R 784 Function concerned: Bosch Diesel Injection

2.

Computer name: BOSCH EDC16CP33 Program No.: C4 Vdiag No.: 0C, 10, 14 and 16

PRERE PREREQU QUISI ISITES TES FOR FOR FAUL FAULT T FINDIN FINDING G

Documentation type Fault finding procedures (this document): – Assisted fault finding (integrated (integrated into the diagnostic tool), Dialogys. Wiring Diagrams: – Visu-Schéma (CD-ROM). Type of diagnostic tools – CLIP Special tooling required Special tooling required

Multimeter Elé. 1681

Universal bornier

EDC16CP33_V0C_PRELI / EDC16CP33_V10_PRELI / EDC16CP33_V14_PRELI / EDC16CP33_V16_PRELI

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DIESEL INJECTION Fault finding – Introduction

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REMINDERS

Faults

Faults are declared present or stored (depending on whether they appeared in a certain context and have disappeared since, or whether they remain present but are not diagnosed within the current context). The present or stored status of faults should be taken into consideration when the diagnostic tool is switched on following the + after ignition feed (without any system components being active). For a present fault , apply the procedure described in the Interpretation Interpretation of faults section. For a stored fault , note the faults displayed and apply the Notes section. If the fault is confirmed when the instructions are applied, the fault is present. Deal with the fault. If the fault is not confirmed, check: – the electrical lines which correspond to the fault, fault, – the connectors on these these lines (corrosion, bent bent pins, etc.), – the resistance of the component component detected detected as defective, – the condition of of the wires (melted or split insulation, insulation, wear). Conformity check

The aim of the conformity check is to check data that does not produce a fault on the diagnostic tool because the data is inconsistent. Therefore, this stage is used to: – carry out fault finding finding on faults that that do not have have a fault display display,, and which may may correspond to a customer complaint. – check that the system is operating operating correctly and that that there is no risk of a fault recurring after repairs. This section gives the fault finding procedures for statuses and parameters and the conditions for checking them. If a status is not behaving normally or a parameter is outside the permitted tolerance values, consult the corresponding fault finding page. Customer complaints - Fault finding chart

If the test with the diagnostic tool is OK but the customer complaint is still present, the fault should be processed by customer complaints . A summary of the overall procedure to follow is provided on the following page in the form of a flow chart.

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DIESEL INJECTION


4.

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Fault finding – Introduction Introduction

FAUL FAULT T FIND FINDIN ING G PROC PROCED EDUR URE E

Perform a pre-diagnostic on the system

Print the system fault finding log (available on CLIP and in the Workshop Repair Manual or Technical Note)

Connect CLIP

Dialogue with computer?

NO

See ALP no. 1

YES Read the faults

Faults present

NO Conformity check

YES Deal with present faults

The cause is still present

NO

Fault solved

Deal with stored faults Use fault finding charts (ALPs) The cause is still present

NO

Fault solved

The cause is still present

YES

NO

Contact the Techline with the completed fault finding log

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Fault solved


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FAUL FAULT T FIND FINDING ING PROCE PROCEDU DURE RE (con (contin tinued ued))

Wiring check Fault finding problems Disconnecting the connectors and/or handling handling the wiring harness may temporarily remove, the cause of a fault. Electrical measurements of voltage, resistance and insulation are generally correct, especially if the fault is not present when the analysis is made (stored fault). Visual inspection Look for damage under the bonnet and in the passenger compartment. Carefully check the fuses, insulators and wiring harness routing. Look for signs of oxidation. Physical inspection While manipulating the wiring harness, use the t he diagnostic tool to note any change in fault status from stored to present. Make sure that the connectors are properly locked. Apply light pressure to the connectors. Twist the wiring harness. If there is a change in status, try to locate the source of the fault. Inspection of each component Disconnect the connectors and check the appearance of the clips and tabs, as well as the crimping (no cr imping on the insulating section). Make sure that the clips and tabs are properly locked in the sockets. Check that no clips or tabs have been dislodged during connection. Check the clip contact pressure using an appropriate model of tab. Resistance check Check the continuity of entire lines, then section by section. Look for a short circuit to earth, to + 12 V or with another wire.

If a fault is detected, repair or replace the wiring harness.

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FAULT FINDING LOG

IMPORTANT

IMPORTANT Any fault on a complex system requires thorough fault finding with the appropriate tools. The FAULT FINDING LOG, which should be completed during the procedure, enables you to keep track of the procedure which is carried out. It is an essential document when consulting the manufacturer.

IT IS THEREFORE COMPULSORY TO COMPLETE A FAULT FINDING LOG EACH TIME IT IS REQUESTED BY TECHLINE OR THE WARRANTY RETURNS DEPARTMENT

You will always be asked for this log: ● when requesting technical assistance from Techline, ● for approval requests when replacing parts for which approval is mandatory, ● to be attached to monitored parts for which reimbursement is requested. The log is needed for warranty reimbursement, and enables better analysis of the parts removed. 6.

SAFETY INSTRUCTIONS

Safety rules must be observed during any work on a component to prevent any damage or injury: – check the battery voltage to avoid incorrect operation of computer functions, – use the proper tools.

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EDC16CP33 Program No: C4 Vdiag No.: 0C, 10, 14, 16

I.

DIESEL INJECTION Fault finding – Cleanliness guidelines

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HAZARDS ASSOCIATED WITH CONTAMINATION

The high pressure direct injection system is highly sensitive to contamination. The risks associated with contamination are: – damage to or destruction of the high pressure injection system, – components jamming, – components losing seal integrity. All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) should have entered the system during dismantling. The cleanliness principle must be applied from the filter to the injectors. What are the sources of contamination? – metal or plastic swarf, – paint, – fibres: – from cardboard, – from brushes, – from paper, – from clothing, – from cloths, – foreign bodies such as hair, – ambient air – etc. IMPORTANT Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection faults. II.

INSTRUCTIONS TO BE FOLLOWED PRIOR TO ALL OPERATIONS

IMPORTANT Before any work is carried out on the high pressure injection system, protect: – the accessories belts, – the electrical accessories, (starter, alternator, electric power-assisted steering pump), – the flywheel face, to prevent any diesel fuel spilling onto the clutch disc, – timing chain.

Check that you have plugs for the unions to be opened (set of plugs available from the Parts Department). The plugs are single-use only. After use, they must be discarded (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be discarded.

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EDC16CP33 Program No: C4 Vdiag No.: 0C, 10, 14, 16

DIESEL INJECTION Fault finding – Cleanliness guidelines

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Check that you have hermetically resealable plastic bags for storing removed parts. Parts stored in this way will be less susceptible to the risk of contamination. The bags are to be used once only, and discarded after use. Use lint-free cleaning cloths (cloth part number 77 11 211 707). Using normal cloth or paper is prohibited. They are not lint-free and could contaminate the fuel circuit. Each cloth should only be used once. Use fresh cleaning agent for each operation (used cleaning agent is contaminated). Pour it into an uncontaminated container. For each operation, use a clean brush in good condition (the brush must not shed its bristles). Use a brush and cleaning agent to clean the unions to be opened. Blast compressed air over the cleaned parts (tools, workbench, the parts, unions and injection system zones). Check that no bristles remain. Wash your hands before and during the operation if necessary. When wearing leather protective gloves cover them with latex gloves to prevent contamination. III. INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Department. The plugs must not be reused under any circumstances. Seal the pouch shut, even if it has to be opened shortly afterwards. Ambient air carries contamination. All components removed from the injection system must be stored in a hermetically sealed plastic bag once they have been plugged. Using a brush, cleaning agent, air gun, sponge or normal cloth is strictly prohibited once the circuit has been opened. These items could allow contamination to enter the system. A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.

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DIESEL INJECTION Fault finding – System operation

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System outline

The high pressure injection system is designed to deliver a precise quantity of diesel fuel to the engine at a set moment. It is fitted with a BOSCH 128-track computer, type EDC16CP33. The system comprises: – a priming bulb, – a diesel filter, – a high pressure pump, – a fuel pressure regulator (or actuator) on the high pressure pump (MPROP), – a fuel pressure regulator (or actuator) mounted on the injector rail (DRV), – an injector rail, – a fuel pressure sensor, – four piezoelectric injectors, – a diesel temperature sensor, – a coolant temperature sensor, – an upstream air temperature sensor, – a cylinder reference sensor, – an engine speed sensor, – a turbocharger pressure sensor, – an exhaust gas recirculation valve, – a recycled gas cooling solenoid valve, – an accelerator pedal potentiometer, – an atmospheric pressure sensor integrated into the injection computer, – a flow sensor, – a turbocharging limiter solenoid valve, – a damper valve. The Common rail direct high pressure injection system works sequentially (based on the petrol engine multipoint injection function). This system uses piezoelectric injectors which enable a more precise injection since opening and closing times are shorter compared to conventional solenoid injectors. This injection system reduces operating noise, reduces the volume of pollutant gases and particles and produces high engine torque at low engine speeds thanks to a pre-injection procedure. The high pressure pump generates the high pressure and transmits it to the injector rail. The actuator located on the pump controls the quantity of diesel fuel supplied, according to the requirement determined by the computer. The rail supplies each injector through a steel pipe. The actuator located on the injector rail controls the pressure of diesel fuel in the rail according to the demand determined by the computer.

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a)


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The computer:

Determines the injection pressure necessary for the correct operation of the engine; the pressure can reach 1600 bar in the rail and it must be constantly regulated. Checks that the pressure value is correct by analysing the value transmitted by the pressure sensor located on the rail. It determines the injection timing required to deliver the right quantity of diesel fuel and the moment when injection should start. Controls each injector electrically and individually after determining these two values. The quantity of fuel injected is determined by: – Engine speed (Crankshaft + Cam for synchronisation). – Accelerator pedal – Turbocharger pressure – Coolant temperature – Inlet air temperature – Air flow – Rail pressure – Vehicle speed The computer manages: – idling regulation, – exhaust gas flow reinjection to the inlet, – fuel supply check (advance, flow and rail pressure), – the fan assembly control, – fan assembly activation request, – the air conditioning (cold loop function), – cruise control/speed limiter function, – pre-post heating control, – indicator lights control via the multiplex network, – turbocharging pressure. The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump). It supplies the rail, the pressure in which is regulated by: – the pressure regulator on the rail (DRV) for starting phases, starting the engine when cold (increase in temperature to heat the diesel circuit) and when under no load. – the pressure regulator on the pump (MPROP) for all other phases (90 % of cases). As natural leaks in piezoelectric injectors are very low, opening the pressure regulator (DRV) is the only quick method of dumping the rail pressure, and it prevents overpressure when injection is restarted. The pressure regulator on the pump (MPROP) enables the high pressure pump to supply just the exact quantity of diesel fuel required to maintain the rail pressure. This component minimises the heat generated and improves engine output. Note: Each piezoelectric injector is connected to the return rail. The injector r eturn rail is kept pressurised by a mechanical valve at the end of the return rail with a 10 bar calibration (while solenoid injectors used to return directly into the common fuel return circuit). This feature is linked to the operation of piezoelectric injectors. Fuel surplus from the pump, injector return rail or rail is collected in a low pressure "octopus manifold" and is then sent to the fuel filter, providing that the fuel is cold (recirculation), and then to the tank.

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Multiplex connection between the vehicle's various computers

The electronic system fitted in this vehicle is multiplexed. This enables dialogue between the various vehicle computers. As a result: – the fault warning lights on the instrument panel are lit by the multiplex network, – vehicle faults are displayed by the multiplex network, – the vehicle speed sensor on the gearbox is not needed. The vehicle speed signal on the instrument panel is transmitted by the ABS computer (or by the sensor on the gearbox, if the vehicle is not equipped with ABS) via a wire connection. This signal is then transmitted via the multiplex network, to the main users such as the injection computer, airbag computer and automatic transmission computer when the vehicle is fitted with this. Some vehicles have a presence sensor mounted in the filter for detecting water in the diesel. If there is water in the diesel fuel, the orange "Injection and pre-post heating" warning light will come on. WARNING The engine must not operate with: – diesel fuel containing more than 10 % diester, – petrol even in minute quantities

The system can inject diesel fuel into the engine at a pressure of up to 1600 bar . Before each operation, check that the injector rail is depressurised and that the fuel temperature is not too high. You must respect the cleanliness guidelines and safety advice specified in this document for any work on the high pressure injection system. Removal of the internal parts of the pump and injectors is prohibited. Only the fuel pressure regulator (or actuator) on the high pressure pump (MPROP), the fuel pressure regulator (or actuator) on the injector rail (DRV) or the diesel temperature sensor can be replaced. For safety reasons, it is strictly prohibited to undo a high pressure pipe union when the engine is running. It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit contamination faults. If the pressure sensor fails, replace the pressure sensor, the rail and the high pressure pipes. Supplying + 12 V directly to any component in the system is prohibited. Ultrasonic decoking and cleaning are prohibited. Never start the engine unless the battery is connected correctly. Disconnect the injection computer when carrying out any welding work on the vehicle.

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Functions hosted:

Air conditioning management assistance:

For models with air conditioning, the EDC16CP33 system can deactivate the air conditioning under certain conditions of use: – when requested by the driver, – when starting the engine, – if the engine overheats (in order to reduce the power the engine has to supply), – when the engine speed is kept at a very high level (to protect the compressor), – during transition phases (e.g. high acceleration demand for overtaking, anti-stalling and moving off). These conditions are only taken into account if they do not occur repeatedly, so as to prevent system instabilities (erratic deactivation), – when certain faults appear. Cold loop air conditioning management:

The air conditioning is the cold loop type and its management shared between several computers. The injection computer is responsible for: – authorising requests for cold air depending on the engine coolant temperature and the engine speed, – calculating the power absorbed by the compressor from the refrigerant pressure – requesting activation of the fan assembly, controlling the activation of the fan assembly, according to the vehicle speed, refrigerant pressure and engine coolant temperature. The driver requests the air conditioning to be switched on by means of the ventilation selector coupled to a switch. The cold air request is authorised or denied depending on the pressure measured. If this pressure is outside the operating limits, the cold loop program is not activated. The air conditioning system is authorised by the injection computer 2 to 8 seconds after the engine is started. Heating element management:

To improve cold starting, the vehicle is fitted with heating elements. To check for them, use configuration reading LC056 Heating elements (WITH OR WITHOUT) and status ET780 Number of heating elements (0 or 4) (except Vdiag 0C) using the diagnostic tool. These heating elements are managed and controlled by the injection computer, according to the operating phases, primarily to accelerate the increase in engine coolant temperature. The maximum number of heating elements that can be actuated is three, and their actuation depends essentially on the coolant temperature and the air temperature.

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Cruise control/speed limiter management: The vehicle cruise control function, when activated, allows you to keep the vehicle speed at a selected value regardless of the driving conditions encountered. Using the control buttons, the driver can increase or reduce the speed of the vehicle.

If the driver wishes to exceed the cruising speed, he may: – depress the accelerator pedal and exceed the cruising speed (the vehicle will return to the initial cruising speed once the driver takes his foot off the pedal), – press the system control buttons. The cruise control function can be deselected either by: – the system control buttons, – deactivating the cruise control switch, – when system events are detected, such as the brake pedal or clutch being depressed, – when system errors are detected such as an inconsistent vehicle speed. The cruise function can also be temporarily disabled when the driver wants to increase speed by depressing the accelerator pedal. The cruising speed is resumed when the driver releases the accelerator pedal. The vehicle will then attempt to reach the cruising speed at a controlled acceleration rate. It is possible to reactivate cruise control and resume the last cruising speed after deactivation (computer supply voltage not switched off). When activated (using the selection switch) the vehicle speed limiter function limits the vehicle speed to a preselected value. The driver controls the vehicle in the normal way using the accelerator pedal until the limit speed is reached. If the driver attempts to exceed this speed, the system ignores the pedal request and controls the vehicle speed in the same way as the cruise control function, as long as the accelerator pedal is kept sufficiently depressed. As with the cruise control function, the cruising speed can be altered using the control buttons by pressing briefly or keeping the switch pressed. For safety reasons, the limit speed can be exceeded by depressing the accelerator pedal beyond the pedal position limit value. The vehicle speed is fully controlled through pedal position, until the vehicle speed falls back below the limit speed when the speed limiter function will once again be reactivated. If the driver wishes to exceed the cruising speed, he may: – exceed the accelerator pedal's kickdown point, – increase it by pressing or pressing and holding the switch. The speed limiter function can be deselected either: – the system control buttons, – by switching off the speed limiter switch, – when system events are detected, such as the brake pedal or clutch being depressed, – when system errors are detected such as an inconsistent vehicle speed.

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Management of the damper valve

The damper valve is now responsible for two functions: – Damping: when the engine is switched off, the flap closes in order to block the passage of air towards the cylinders. The aim of this is to stop the engine as quickly as possible and to reduce instabilities as the engine is switched off. – "Valving": according to the engine's operating points, the damper valve closes by a few % to create a "venturi" effect in the EGR valve flow section. The aim of this is to accelerate the air flow of EGR gases and to reduce the emission of pollutants. Exhaust gas recirculation management

The EGR (Exhaust Gas Recirculation) system involves removing exhaust gases and reintroducing them at the inlet. The exhaust gases are collected in the exhaust manifold (before the turbocharger), then directed to the EGR cooler and then the EGR valve. – EGR cooler The EGR cooler bypass function consists of cooling, via a gas-water exchanger, the gases extracted from the exhaust and then reintroducing them at the inlet. This cooler is equipped with an all or nothing solenoid valve, which enables gases to be cooled or not, depending on emission control requirements. – EGR valve The system comprises a direct current EGR valve and a potentiometer which reports the position of the valve.

Its opening is controlled by a positive control (0 → 100 %). The potentiometer serves to control and run fault finding on the valve. The very first time the engine is started, then each subsequent engine start, the "valve closed" position is programmed (offset). This value is compared to the very first offset or last programmed offset, for the purposes of fault finding. It is also used to readjust the valve control function. It is important to associate the EGR valve with the computer that controls it.

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Warning light management: Instrument panel display

The computer manages the data display on the instrument panel relating to engine operation. This concerns five functions: – the pre-postheating warning light, – the coolant temperature warning light, – the fault level 1 warning light (non-critical fault), – the fault level 2 warning light (emergency stop), – the OBD warning light (European On Board Diagnostic). These five functions are represented by 3 warning lights and/or messages transmitted by the trip computer. Orange pre-post heating/non-critical fault SERVICE warning light (severity 1) This light is used both as an in-operation indicator light and as a system fault indicator: – Continuously lit when the ignition is switched on: Indicates preheating of the spark plugs. – Continuously lit with the injection fault message: Indicates a level 1 fault (implies operation of the injection system in defect mode). The driver should carry out repairs as soon as possible. Temperature warning light/red EMERGENCY STOP (level 2) This indicator light is used both as an in-operation indicator light and as a system fault warning light. Lights up for 3 seconds when the ignition is switched on (automatic test procedure managed by the instrument panel): – Continuously lit: Indicates engine overheating (the driver is free to choose whether or not to stop the vehicle). – Continuously lit with the stop engine message: Indicates a severity 2 fault (In this case, injection is automatically cut after a few seconds). The driver should carry out repairs as soon as possible. ORANGE OBD excess pollution warning light

Symbolised by an engine, it lights up for approximately 3 seconds when the ignition is switched on. This warning light comes on if the system has one or more OBD faults. This warning light is used to alert the driver to injection faults that could lead to excessive pollution, or if the EOBD system (European On Board Diagnostic) has been deactivated. The injection computer requests activation of the OBD warning light for a present fault only after three successive driving cycles. The 3 second visual inspection when the ignition is switched on (automatic test procedure managed by the instrument panel) is carried out by the injection computer.

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EOBD management (European On Board Diagnostic):

The OBD (On Board Diagnostic) system enables the detection of any faults relating to the vehicle emission control system (OBD EURO IV emission control standards exceeded). This system should be active for the entire life of the vehicle.

1. obd fault display conditions

An OBD fault will be detected after 3 driving cycles. It allows the driver to know if the vehicle has a fault directly linked to pollution. 2. System faults displayed by the OBD

Only a few faults are indicated by the OBD system: – – – – – – – – – – – – – – – – –

DF004 DF011 DF012 DF013 DF026 DF027 DF028 DF029 DF054 DF056 DF099 DF107 DF200 DF209 DF272 DF569 DF647

Turbocharging pressure sensor circuit Sensor feed voltage no. 1 Sensor feed voltage no. 2 Sensor feed voltage no. 3 Cylinder 1 injector control circuit Cylinder 2 injector control circuit Cylinder 3 injector control circuit Cylinder 4 injector control circuit Turbocharging solenoid valve control circuit Air flow sensor circuit ''TA* or sequential gearbox connection via the multiplex network'' Computer memory Atmospheric pressure sensor EGR valve position sensor circuit EGR valve control circuit Turbocharging circuit EGR valve position regulation

Some repair operations require programming to ensure that certain engine components function correctly. Follow the programming procedures (see Replacement of components), if replacing the exhaust gas recirculation valve or an injector. 3. obd fault clearing conditions

An OBD fault is cleared in several steps. The fault present in the diagnostic tool is not stored (following repair) until after 3 journeys with the vehicle. The OBD warning light will only light up after these 3 driving cycles. The warning light coming on does not always mean that there is a fault on the system. In order that the OBD fault and the display parameters are cleared from the computer, the system needs to go through 40 engine heating cycles. An engine heating cycle is a driving cycle during which: – the engine coolant temperature reaches at least 71.1 ˚C, – the engine coolant temperature varies by 22.2 ˚C in relation to the engine starting temperature. If one of these conditions is not fulfilled, the OBD fault will still be present or stored in the injection computer. * TA: automatic transmission (automatic gearbox)

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DIESEL INJECTION Fault finding – Replacement of components

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COMPUTER REPLACEMENT OR REPROGRAMMING

Four procedures must be performed when replacing or reprogramming the computer: SC003 "Backup computer data", SC001 "Write stored data", SC036 "Reinitialise programming" and SC040 "Speed limiter". PROCEDURE: – Use SC003 before the computer is replaced or reprogrammed . This enables certain data to be saved in the diagnostic tool so that the new computer* can be reconfigured like the old one. The saved data are: injector codes, EGR programming, vehicle options. – Carry out reprogramming or replace the computer. – Run SC001 after the computer is replaced or reprogrammed . It enables you to rewrite the data (saved by command SC003) to the new computer*. – Only for Vdiag14: use SC036 "Reinitialise programming" after replacing or reprogramming the computer. It makes it possible to configure the correct heater plug type fitted to the vehicle. – If necessary, use SC040 after the computer is replaced or reprogrammed . This is used to configure the float limiter depending on the restriction applied to the vehicle (label affixed to the instrument panel). – Switch off the ignition, wait for the loss of dialogue message on the Clip diagnostic tool (this may take several minutes). – Switch on the ignition again, establish dialogue with the computer and clear the fault memory. If you cannot establish dialogue with the computer being replaced: nothing will be saved. After replacing the

computer, reconfigure it manually according to its equipment level or parameters, using the special commands. – SC002: Enter the injector codes, – SC036: ''Reinitialise programming", select ''heater plugs" and follow the procedure (only with Vdiag 14).

IMPORTANT Vdiag 14 only: There are two types of heater plug: "SLOW" and "FAST": SLOW plugs are identified by a black ring. QUICK plugs are identified by a white ring . It is prohibited to replace "SLOW" heater plugs with "FAST" ones. If the plugs are being partially replaced, all the heater plugs fitted on the vehicle must be replaced by plugs of the same type; if not, there is a risk that the heater plugs may deteriorate, leading to irreparable engine damage. Use command SC036 ''Reinitialise programming" and select ''heater plugs", to configure the correct heater plug type.

– CF030: ''Heating elements" (except Vdiag 0C), – VP010: ''Write VIN'' – SC040 ''Speed limiter'' (if necessary)

Exhaust gas recirculation valve data is programmed automatically the 1st time the new computer is switched on*. * New computer or reprogrammed computer.

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DIESEL INJECTION Fault finding – Replacement of components

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REPLACING THE EXHAUST GAS RECIRCULATION VALVE (EGR valve)

After the EGR valve has been replaced, the computer must store the new valve offset, and the offset measured from the last time the ignition was switched off (in 1 min phase), which corresponds to the valve closing. Using this data, the computer can detect whether the valve is clogged or seized. If the valve is replaced, clear the stored offsets SC036 Reinitialise programming so that the program works with the new valve's offset value. The data linked to this strategy is compiled in the Emission control/OBD sub-function. – PR128: FIRST EGR VALVE OFFSET. – PR129: LAST EGR VALVE OFFSET ≥ PR128 if the valve is new . Programming PR128 and PR129 must be cleared every time the exhaust gas recirculation valve is replaced. Procedure to be followed after replacing the exhaust gas recirculation valve: Run command SC036 Reinitialise programming. Select EGR valve as the operation type, then follow the instructions given by the diagnostic tool. Note: When the reinitialisation is complete, the Emission control/OBD sub-function displays: PR128 = PR 129 = 0 % When the command is finished. Switch off the ignition. Wait 1 min before switching on the ignition again. As soon as the ignition is switched on again the new EGR valve offset is automatically reprogrammed. Note: When the new EGR valve offset has been reprogrammed, the Emission control/OBD sub-function displays: 10 % < PR128 < 40 % PR129 < 0 % Start the vehicle to enable the latest EGR valve offset to be programmed. Switch off the ignition. Wait 1 min before switching on the ignition again. The last EGR valve offset reprogrammed is stored on the computer. Note: When the reprogramming of the last EGR valve offset has been done, the Emission control/OBD sub-function displays: 10 % < PR128 < 40 % 10 % < PR129 < 40 % Then check the system faults, and clear any stored faults. If there are faults, deal with the present faults. Clear the faults from the computer memory. Carry out a road test followed by a complete check with the diagnostic tool.

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DIESEL INJECTION Fault finding – Configurations and programming

13B

REPLACING THE INJECTORS

Note: The "IMA" code (individual correction of the injector) is a calibration with corrective values unique to each injector, and is used to adjust their flow accurately (injector classification). This correction takes into account mechanical variations and the variations of the piezo actuator. An injector's class is determined by measurements taken at different pressures on a test bench. The IMA class identification (7-character alphanumeric code) is then engraved on the collar of the injector. These individual correction classes are then written to the computer EEPROM*, which can then control the injectors, taking into account their manufacturing variance. After one or more injectors have been changed, enter the IMA codes again and then run command SC036 Reset programming.

To do this, note the IMA code(s) engraved on the injector bodies, and save the codes in the computer using command SC002 Enter injector codes , and follow the instructions given by the diagnostic tool. Use SC036 Reinitialise programming and select injectors then follow the procedure. IMPORTANT Engines can only operate correctly if the correct IMA codes have been entered. If no code has been entered, or if an invalid code has been entered, fault DF066 Injector code(s) will be present and the engine will run in defect mode (engine speed limited significantly). If another injector's code has been entered, the system will accept it but will make an incorrect correction. This could lead to engine damage, loss of performance and pollution. Always use the correct injector codes for the engine cylinder/computer.

Note: On the M9R engine (Renault - Nissan partnership engine), cylinder no. 1 is located at the timing end.

IMPORTANT – When the command is complete, switch off the ignition and exit fault finding mode. – Wait for 1 minute and switch on the ignition again. – Return to fault finding mode. – Select the Identify computer function from the main screen. – Check that the injector codes entered into the computer correspond to those on the injector bodies. – If the codes do not match, restart the command SC002 Enter injector codes procedure. – Then check the system faults, and clear any stored faults. – If the computer does not have any faults, the operation is complete. If there are faults, deal with the present faults. REPLACING THE DAMPER VALVE

After replacing the damper valve, run command SC036 Reinitialise programming and select damper valve. When the command is complete, switch off the ignition and exit fault finding mode. Wait 1 min before switching on the ignition again. *EEPROM: erasable storage memory.

MR-410-X83-13B000$240.mif V5

13B-19


DIESEL INJECTION Fault finding – Configurations and programming

13B

Summary of available configuration readings

NOTES

Configuration readings are used to check the status of configurations performed. The configuration readings cannot be changed.

LC009

Air conditioning WITH OR WITHOUT

LC056

Heating elements WITH OR WITHOUT This configuration reading is directly linked to the configuration CF030 Heating elements *.

LC065

Water in diesel fuel sensor WITH OR WITHOUT

LC120

Cruise control WITH OR WITHOUT

LC121

Speed limiter WITH OR WITHOUT

* The CF030 "Heating elements" (except Vdiag 0C)

MR-410-X83-13B000$240.mif V5

13B-20


DIESEL INJECTION

13B

Fault finding – Fault summary table

WARNING LIGHT MANAGEMENT

Management of instrument panel warning lights according to the faults notified.

DTC code in hexadecimal

Severity 1 fault warning light (Orange warning light)

Severity 2 fault warning light (Red warning light) STOP

No warning light on

EOBD* warning light on

DF001 Coolant temperature sensor circuit

115

CC.0/CO.1

-

-

-

DF002 Air temperature sensor circuit

110

-

-

CC.0/CO.1

-

DF004 Turbocharging pressure sensor circuit

235

CO.0/CC.1/ 1.DEF

-

-

CO.0/CC.1/ 1.DEF

DF007 Rail pressure sensor circuit

190

CC.0/CO.1/ 1.DEF/2.DEF

-

-

-

DF011 Sensor feed voltage no. 1

641

1.DEF/2.DEF

-

-

1.DEF/ 2.DEF

DF012 Sensor feed voltage no. 2

651

1.DEF/2.DEF

-

-

1.DEF/ 2.DEF

DF013 Sensor supply voltage no. 3

697

1.DEF/2.DEF

-

-

1.DEF/ 2.DEF

DF017 Pre-postheating unit control circuit

670

-

-

CC.0/CO/ CC.1/1.DEF

-

DF018 Low-speed fan assembly control circuit

480

CC.0/CO/CC.1/ 1.DEF

-

-

DF019 High-speed fan assembly control circuit

481

CC.0/CO/CC.1/ 1.DEF

-

-

-

DF025 Pre-postheating unit fault finding connection

380

-

-

CC.0/CO.1

-

DF026 Cylinder 1 injector control circuit

201

CO

CC.1/1.DEF

-

CO/CC.1/ 1.DEF


202

CO

CC.1/1.DEF

-

CO/CC.1/ 1.DEF


203

CO

CC.1/1.DEF

-

CO/CC.1/ 1.DEF


204

CO

CC.1/1.DEF

-

CO/CC.1/ 1.DEF

DF032 Heating element 1 relay control circuit

1641

-

-

CC.1/CC.0/ CO/1.DEF

-


1642

-

-

CC.1/CC.0/ CO/1.DEF

-

Fault

*EOBD: European On Board Diagnostics

MR-410-X83-13B000$288.mif V5

13B-21


DIESEL INJECTION

13B







No warning light on



1643

-

-

CC.1/CC.0/ CO/1.DEF

-

DF038 Computer

606

1.DEF/2.DEF

1.DEF/3.DEF

-

-

560

-

-

1.DEF/2.DEF/ 3.DEF

-

2505

-

-

1.DEF

-

DF051 Cruise control/speed limiter function

575

-

-

1.DEF

-

DF052 Injector control circuit

200

-

CC.0/CC.1/ CC

-

-

DF054 Turbocharging solenoid valve control circuit

45

CC.1/CC.0/CO/ 1.DEF

-

-

CC.1/CC.0/ CO/1.DEF

100

1.DEF/CO.0/ CC.1

-

-

1.DEF CO.0/CC.1

DF059 Combustion misfire on cylinder 1

301

-

-

X

-


302

-

-

X

-


303

-

-

X

-


304

-

-

X

-

DF065 Combustion misfire

300

-

-

1.DEF

-

DF066 Injector code(s)

611

1.DEF/2.DEF

-

-

-

500

-

-

1.DEF/2.DEF/ 3.DEF

-

180

-

-

CC.0/CO.1

-

C101

-

-

-

1.DEF

Fault

DF046 Battery voltage DF047 Computer feed voltage

DF056 Air flowmeter circuit

DF091 Vehicle speed signal DF098 Fuel temperature sensor circuit DF099 TA* or sequential gearbox connection via the multiplex network (only with Vdiag 16)

*EOBD: European On Board Diagnostic *TA: automatic transmission (automatic gearbox).

MR-410-X83-13B000$288.mif V5

13B-22


DIESEL INJECTION

13B







No warning light on


DF107 Computer memory

62F

1.DEF

-

-

1.DEF

DF119 Camshaft sensor signal

340

-

-

1.DEF/2.DEF

-

DF120 Engine speed sensor signal

335

-

1.DEF/2.DEF

-

-

DF151 Main relay circuit

685

CO.1/CC.0

-

-

-

DF165 Accelerator pedal position sensor circuit

2299

1.DEF/3.DEF

-

2.DEF

-

DF195 Engine speed/ camshaft sensor consistency

16

-

-

1.DEF

-

DF196 Pedal sensor circuit gang 1

225

CO.0/CC.1

1.DEF

-

-

DF198 Pedal sensor circuit gang 2

2120

CO.0/CC.1

1.DEF

-

-

DF200 Atmospheric pressure sensor

2226

-

-

-

1.DEF/2.DEF

DF209 EGR valve position sensor circuit

409

-

-

-

CC.1/CO.0

DF221 Clutch contact signal

830

-

-

1.DEF

-

DF228 Brake signal

571

-

-

1.DEF

-

DF230 Air conditioning cold loop relay control circuit

645

CC.1/CC.0/ CO/1.DEF

DF232 Coolant pressure sensor circuit

530

1.DEF/2.DEF

DF249 Injector control

62B

-

1.DEF

-

-

DF265 Injector no. 1

1201

-

-

1.DEF

-


1202

-

-

1.DEF

-


1203

-

-

1.DEF

-


1204

-

-

1.DEF

-

-

CO/CC.1/ CC.0/CC/ 1.DEF

Fault

DF272 EGR valve control circuit

487

-

*EOBD: European On Board Diagnostics

MR-410-X83-13B000$288.mif V5

13B-23

-


DIESEL INJECTION

13B




Fault




No warning light on


DF293 Water in diesel fuel detector

2269

-

-

1.DEF

-

DF304 EGR by-pass circuit

2425

-

-

CO/CC.0/CC.1/ 1.DEF

-

2100

-

-

CO/CC.0/CC.1/ 1.DEF/CC

-

DF502 Cruise control or speed limiter button

565

-

-

1.DEF

-

DF532 Alternator charge signal (except Vdiag 0C).

2502

-

-

1.DEF/2.DEF

-

DF569 Turbocharging circuit

2263

1.DEF/2.DEF

-

-

1.DEF/2.DEF

DF645 Damper valve position regulation

2101

-

-

1.DEF/2.DEF/ 3.DEF

-

DF646 Damper valve position sensor

120

-

-

CC/CO.0

-

DF647 EGR valve position regulation

488

1.DEF/2.DEF/ 3.DEF

-

-

1.DEF/2.DEF 3.DEF/4.DEF

DF891 Group 1 injectors feed

2146

-

CC.0/1.DEF

-

-

DF892 Group 2 injectors feed

2149

-

CC.0/1.DEF

-

-

DF895 Pressure regulation on rail

2293

2.DEF/3.DEF

1.DEF/4.DEF

-

-

DF896 Pressure regulation on pump

89

2.DEF/3.DEF/ 4.DEF

1.DEF

-

-

DF897 Pressure regulation circuit on pump

90

CO/CC.1/ 1.DEF

CC.0

-

-

2294

-

CO/CC.1/ CC.0.DEF1. DEF

-

-

1670

1.DEF

-

-

-

DF323 Damper valve

DF898 Pressure regulation circuit on rail DF1069 Heater plugs not configured (only with Vdiag 14)

*EOBD: European On Board Diagnostics MR-410-X83-13B000$288.mif V5

13B-24


DF001 PRESENT OR STORED

DIESEL INJECTION Fault finding – Interpretation of faults

13B

COOLANT TEMPERATURE SENSOR CIRCUIT CC.0 : Short circuit to earth CO.1 : Open circuit or short circuit to + 12 V

Priorities when dealing with a number of faults: Deal with fault DF046 Battery voltage first if it is present or stored. Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test. NOTES

Special notes: If the fault is present: – the heating elements are no longer controlled, – the coolant temperature: PR064 Coolant temperature is fixed at 119 ˚C, – the preheating time lasts longer than 4 seconds, – the low speed fan assembly is continuously supplied. The level 1 warning light is lit. Use bornier Elé. 1681 for any work on the computer connectors.

See Wiring Diagrams Technical Note Trafic II phase 2.

CC.0

NOTES

None

Check the condition of the coolant temperature sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3C and 3JK of component 244. Replace the sensor if the resistance is less than 67 Ω (see MR 408, Mechanical, 19A, Cooling, Coolant temperature sensor, Removal - Refitting). Check insulation against earth of the following connection: – 3C between components 120 and 244. If the connection is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Switch off the ignition, wait 1 minute and carry out a road test followed by another check with the diagnostic tool.

EDC16CP33_V0C_DF001 / EDC16CP33_V10_DF001/ EDC16CP33_V14_DF001 / EDC16CP33_V16_DF001 MR-410-X83-13B000$336.mif V5

13B-25



13B

DF001 CONTINUED

CO.1

NOTES

None

Check the condition of the coolant temperature sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3C and 3JK of component 244. Replace the sensor if the resistance is greater than 83 kΩ (see MR 408, Mechanical, 19A, Cooling, Coolant temperature sensor, Removal - Refitting). Check the insulation from the + 12 V feed of the following connection: – 3C between components 120 and 244. Check the continuity of the following connections: – 3C between components 120 and 244, – 3JK between components 120 and 244. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-26




13B

AIR TEMPERATURE SENSOR CIRCUIT CC.0 : Short circuit to earth CO.1 : Open circuit or short circuit to + 12 V

Priorities when dealing with a number of faults: Deal with fault DF046: Battery voltage first if it is present or stored Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test. NOTES

Special notes: If the fault is present: – the heating elements are disabled, – the inlet air temperature is in defect mode, PR059 Inlet air temperature = 20 ˚C. The air temperature sensor is integrated into the air flowmeter. Use bornier Elé. 1681 for all operations on the engine management computer connectors.


CC.0

NOTES

None

Check the condition of the air flowmeter connector Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3ABQ and 3DU of component 799. Replace the air flowmeter if the resistance is less than 87 Ω (see MR 408, Mechanical, 12A, Fuel mixture, Air flowmeter, Removal - Refitting). With the flow sensor disconnected, check the insulation from earth of the following connection: – 3ABQ between components 120 and 799. If the connection is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-27



13B

DF002 CONTINUED

CO.1

NOTES

None

Check the condition of the air flowmeter connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3ABQ and 3DU of component 799. Replace the air flowmeter if the resistance is greater than 50 kΩ (see MR 408, Mechanical, 12A, Fuel mixture, Air flowmeter, Removal - Refitting). Check the insulation from + 12 V of the following connections: – 3ABQ between components 120 and 799, – 3DU between components 120 and 799. Check the continuity of the following connections: – 3ABQ between components 120 and 799, – 3DU between components 120 and 799. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-28




13B

TURBOCHARGING PRESSURE SENSOR CIRCUIT CO.0 : Open circuit or short circuit to earth CC.1 : Short circuit to + 12 V 1.DEF: Consistency between turbocharging pressure and atmospheric pressure.

Priorities when dealing with a number of faults: Deal with faults DF011 "Sensor feed voltage no. 1", DF046 "Battery voltage"first, if they are present or stored. Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test. NOTES

Special notes: Use bornier Elé. 1681 for all operations on the injection computer connectors. If the fault is present: – engine torque limited, – turbocharging pressure is in defect mode, PR041 Turbocharging pressure = 0.75 bar , – the level 1 and EOBD* warning lights are lit.


CO.0

NOTES

None

Check the condition of the turbocharging pressure sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check insulation against earth of the following connection: – 3LP between components 120 and 1071. Check the continuity of the following connections: – 3LQ between components 120 and 1071, – 3LP between components 120 and 1071. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, replace the turbocharger pressure sensor. * EOBD: European On Board Diagnostics

AFTER REPAIR



13B-29



13B

DF004 CONTINUED

CC.1

NOTES

None

Check the condition of the turbocharging pressure sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation from + 12 V and + 5 V (computer feed) of the following connection: – 3LP between components 120 and 1071. Check the continuity of the following connection: – 3LN between components 120 and 1071 . If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, replace the turbocharger pressure sensor.

1.DEF

NOTES

None

Check the condition of the turbocharging pressure sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Perform fault finding procedure on parameter PR041 Turbocharging pressure.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-30




13B

RAIL PRESSURE SENSOR CIRCUIT CC.0 : CO.1 : 1.DEF : 2.DEF :

Short circuit to earth Short circuit or open circuit to + 12 V Below minimum threshold Above maximum threshold

Priorities when dealing with a number of faults: Deal with fault DF013 Sensor feed voltage no. 3 first, if it is present or stored.

NOTES

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test. Special notes: If the fault is present, – the rail pressure is in defect mode, PR038 Rail pressure ≤ 1150 bar , – the level 1 warning light is lit, Use bornier Elé. 1681 for all operations on the injection computer connectors.

See Wiring Diagrams Technical Note Trafic II phase 2 .

CC.0

NOTES

None

Check the condition of the rail pressure sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connection: – 3LX between components 120 and 1032. Check insulation against earth of the following connection: – 3LY between components 120 and 1032. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-31



13B

DF007 CONTINUED 1

CO.1

NOTES

None

Check the condition of the rail pressure sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3LX between components 120 and 1032, – 3LY between components 120 and 1032. Check the insulation from + 12 V and + 5 V (computer feed) of the following connection: – 3LY between components 120 and 1032. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-32



13B

DF007 CONTINUED 2

1.DEF 2.DEF

NOTES

The fault is declared present or stored after an attempt to start or after starting from cold, several hours after the last trip (the difference in the coolant temperature from the last engine stop and this start must be at least 60 ˚C).

Check the condition of the rail pressure sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check that there are no external diesel leaks from the high pressure fuel circuit. Check for continuity and absence of interference resistance of the following connections: – 3LX between components 120 and 1032, – 3LY between components 120 and 1032, – 3LZ between components 120 and 1032. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. With the ignition on and the engine stopped for over 1 minute: View parameter PR038 Rail pressure. – If the pressure is below 90 bar , the sensor is in order. – If the pressure is above 90 bar , contact the Techline. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-33




13B

SENSOR FEED VOLTAGE NO. 1 1.DEF : Above maximum threshold 2.DEF : Below minimum threshold

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on. – starting the engine, – a road test.

NOTES

Special notes: If the fault is present, – air conditioning is switched off, – engine torque limited, – the cruise control/speed limiter function is switched off, – the heating elements are switched off, – the EGR function is disabled by the engine management computer. Safe mode on the accelerator pedal sensor: gang 2 value used instead of gang 1. The level 1 and EOBD* warning lights are lit. Use bornier Elé. 1681 for all operations on the engine management computer connectors.


1.DEF

NOTES

None

Note: Feed no. 1 is for the following components: – accelerator pedal sensor (gang 1), – turbocharger pressure sensor. Measure the feed voltage on the following connections: – 3LR of component 921, – 3LQ of component 1071. If at least one of the two voltages is greater than + 5.1 V, disconnect the sensor connectors one by one. If, after disconnecting the turbocharger pressure sensor, the voltage returns to normal, Check the insulation from + 12 V on the following connection: – 3LQ between components 120 and 1071. If after disconnecting the accelerator pedal sensor the voltage returns to normal, Check the insulation from + 12 V on the following connection: – 3LR between components 120 and 921. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Clear the faults created by the multiple disconnections. * EOBD: European On Board Diagnostics

AFTER REPAIR



13B-34



13B

DF011 CONTINUED

Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline.

2.DEF

NOTES

None

Note: Feed no. 1 is for the following components: – accelerator pedal sensor (gang 1), – turbocharger pressure sensor. Measure the feed voltage on the following connections: – 3LR of component 921, – 3LQ of component 1071. If at least one of the two voltages is less than + 4.9 V, disconnect the sensor connectors one by one. If, after disconnecting the turbocharger pressure sensor, the voltage returns to normal, Check insulation against earth of the following connection: – 3LQ between components 120 and 1071. If after disconnecting the accelerator pedal sensor the voltage returns to normal, Check insulation against earth of the following connection: – 3LR between components 120 and 921. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Clear the faults created by the multiple disconnections. Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-35




13B


Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on. – starting the engine, – a road test.

NOTES

Special notes: If the fault is present: – engine torque limited, – the cruise control/speed limiter function is switched off, – the heating elements are switched off, – air conditioning is switched off, – the low speed fan assembly is continuously supplied. Safe mode on the accelerator pedal sensor: gang 1 value used. The level 1 and EOBD* warning lights are lit. Use bornier Elé. 1681 for all operations on the engine management computer connectors.


1.DEF

NOTES

None

Note: Supply no. 2 serves the following components: – accelerator pedal sensor (gang 2), – EGR valve position sensor, – damper valve position sensor, – cruise control/speed limiter button (on steering wheel). Measure the feed voltage on the following connections: – 3LU of component 921, – 38KQ of component 1461, – 3GC of component 169. If at least one of the voltages is greater than + 5.1 V, disconnect these connectors one by one. If, after disconnecting the damper valve, the voltage returns to normal. Check the insulation from + 12 V on the following connection: – 38KQ between components 120 and 1461. If after disconnecting the accelerator pedal sensor the voltage returns to normal, Check the insulation from + 12 V on the following connection: – 3LU between components 120 and 921. * EOBD: European On Board Diagnostics

AFTER REPAIR



13B-36



13B

DF012 CONTINUED 1

1.DEF

NOTES

None

If, after disconnecting the EGR valve, the voltage returns to normal, Check the insulation from + 12 V on the following connection: – 3GC between components 120 and 169. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Clear the faults created by the multiple disconnections. Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-37



13B

DF012 CONTINUED 2

2.DEF

NOTES

None

Note: Supply no. 2 serves the following components: – accelerator pedal sensor (gang 2), – EGR valve position sensor, – damper valve position sensor. Measure the feed voltage on the following connections: – 3LU of component 921, – 38KQ of component 1461, – 3GC of component 169. If at least one of the voltages is less than 4.9 V, disconnect these connectors one by one. If, after disconnecting the damper valve, the voltage returns to normal. Check insulation against earth of the following connection: – 38KQ between components 120 and 1461. If after disconnecting the accelerator pedal sensor the voltage returns to normal, Check insulation against earth of the following connection: – 3LU between components 120 and 921. If, after disconnecting the EGR valve, the voltage returns to normal, Check insulation against earth of the following connection: – 3GC between components 120 and 169. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Clear the faults created by the multiple disconnections. Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-38




13B


Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on. – starting the engine, – a road test. NOTES

Special notes: If the fault is present: – engine torque limited, – test SC031 Operational fault finding of cylinders inhibited. The level 1 and EOBD* warning lights are lit. Use bornier Elé. 1681 for all operations on the engine management computer connectors.

See Trafic II phase 2 Wiring Diagrams Technical Note.

1.DEF

NOTES

None

Note: Feed no. 3 is for the following components: – air flow sensor, – rail pressure sensor. Measure the feed voltage on the following connections: – 3KJ of component 799, – 3LX of component 1032. If at least one of the voltages is greater than + 5.1 V, disconnect the sensor connectors one by one. If, after disconnecting component 799, the voltage returns to normal. Check the insulation from + 12 V on the following connection: – 3KJ between components 120 and 799. If, after disconnecting component 1032, the voltage returns to normal. Check the insulation from + 12 V on the following connection: – 3LX between components 120 and 1032. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the wiring, otherwise replace it. Clear the faults created by the multiple disconnections. Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline. * EOBD: European On Board Diagnostics

AFTER REPAIR



13B-39



13B

DF013 CONTINUED

2.DEF

NOTES

None

Note: Feed no. 3 is for the following components: – flow sensor, – rail pressure sensor. Measure the feed voltage on the following connections: – 3KJ of component 799, – 3LX of component 1032. If at least one of the voltages is less than 4.9 V, disconnect the sensor connectors one by one. If, after disconnecting the air flowmeter, the voltage returns to normal, Check insulation against earth of the following connection: – 3KJ between components 120 and 799. If, after disconnecting the rail pressure sensor, the voltage returns t o normal, Check insulation against earth of the following connection: – 3LX between components 120 and 1032. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Clear the faults created by the multiple disconnections. Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-40



NOTES


13B

PRE-POSTHEATING UNIT CONTROL CIRCUIT CO : Open circuit CC.1 : Short circuit to + 12 V CC.0 : Short circuit to earth 1.DEF : Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on. – starting the engine, – a road test, – relay actuation using command AC037 Preheating relay . Special notes: – preheating inhibited. Use bornier Elé. 1681 for all operations on the engine management computer connectors.


CO

NOTES

None

Check the condition of the pre-postheating unit connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connection: – connection code 3FF between components 120 and 257. Check the + AVC feed on the following connection: – BP17 of component 257. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, replace the pre-postheating unit (see MR 408, Mechanical, 13C, Preheating, PrePostheating unit, Removal - Refitting).

AFTER REPAIR



13B-41



13B

DF017 CONTINUED 1

CC.1

NOTES

None

Check the condition of the pre-postheating unit connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation from the + 12 V feed of the following connection: – 3FF between components 120 and 257. If the connection is faulty and there is a repair method ( see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, replace the pre-postheating unit (see MR 408, Mechanical, 13C, Preheating, PrePostheating unit, Removal - Refitting).

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-42



13B

DF017 CONTINUED 2

CC.0

NOTES

None

Check the condition of the pre-postheating unit connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check insulation against earth of the following connection: – 3FF between components 120 and 257. Check the + AVC feed on the following connection: – BP17 of component 257. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, replace the pre-postheating unit (see MR 408, Mechanical, 13C, Preheating, PrePostheating unit, Removal - Refitting).

1.DEF

NOTES

Special note: This fault appears when the computer control section overheats or when command AC037 Preheating relay is run.

Check the condition of the pre-postheating unit connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance on the following connection: – 3FF between components 120 and 257. Check the + AVC feed on the following connection: – BP17 of component 257. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-43




13B

LOW SPEED FAN ASSEMBLY CONTROL CIRCUIT CO : CC.1 : CC.0 : 1.DEF :

Open circuit Short circuit to + 12 V Short circuit to earth Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – the ignition is switched on. – clearing the fault from the memory, – the relay is controlled using command AC154 Low-speed fan unit. NOTES

Special notes: – high-speed fan assembly constantly actuated, – the level 1 warning light is lit.

Use bornier Elé. 1681 for all operations on the engine management computer connectors. See Wiring Diagrams Technical Note Trafic II phase 2 .

CO

NOTES

No low speed fan assembly control.

Check the condition of the low-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the low-speed fan assembly relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Remove the low speed relay and check the continuity of the following connection: – 49J between components 120 and 335. Check the + 12 V after relay feed on the following connection: – 37X of component 335. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Carry out a control via actuator AC154 LOW-SPEED FAN ASSEMBLY using the diagnostic tool. Switch off the ignition, wait 1 minute and carry out a road test followed by another check with the diagnostic tool.


13B-44



13B

DF018 CONTINUED 1

CC.1

NOTES

No low-speed fan assembly control.

Check the condition of the low-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the low-speed fan unit relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Remove the low speed relay and check the insulation from + 12 V of the following connection: – 49J between components 120 and 335. If the connection is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

CC.0

NOTES

Low speed fan assembly constantly activated.

Check the condition of the low-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the low-speed fan unit relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Remove the low speed relay and check the insulation from earth of the following connection: – 49J between components 120 and 335. Check the + 12 V after relay feed of the following connection: – 37X of component 335. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-45



13B

DF018 CONTINUED 2

1.DEF

NOTES

Special note: This fault appears when the computer control section overheats or when command AC154 Low speed fan assembly is run.

Check the condition of the low-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the low-speed fan unit relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if the resistance is more than 200 Ω or less than 20 Ω. Remove the low speed relay and check the insulation and continuity of the following connection: – 49J between components 120 and 335. Check the + 12 V after relay feed on the following connection: – 37X of component 335. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-46




13B

HIGH SPEED FAN ASSEMBLY CONTROL CIRCUIT CO : CC.1 : CC.0 : 1.DEF :

Open circuit Short circuit to + 12 V Short circuit to earth Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – the ignition is switched on. – clearing the fault from the memory, – relay actuated using command AC153 High speed fan assembly . NOTES

Special notes: – The level 1 warning light is lit. This fault is only applicable on vehicles equipped with air conditioning.

Use bornier Elé. 1681 for all operations on the engine management computer connector. See Wiring Diagrams Technical Note Trafic II phase 2 .

CO

NOTES

No the high-speed fan assembly control.

Check the condition of the high-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the "high-speed fan assembly" relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Remove the high-speed relay and check the continuity of the following connection: – 49K between components 120 and 336. Check the + 12 V after relay feed on the following connection: – 37X of component 336. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Carry out a control via actuator AC153 HIGH-SPEED FAN ASSEMBLY using the diagnostic tool. Switch off the ignition, wait 1 minute and carry out a road test followed by another check with the diagnostic tool.


13B-47



13B

DF019 CONTINUED 1

CC.1

NOTES

No the high-speed fan assembly control.

Check the condition of the high-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the "high-speed fan assembly" relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Remove the high-speed relay and check the insulation from + 12 V of the following connection: – 49K between components 120 and 336. If the connection is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

CO.0

NOTES

High-speed fan assembly constantly activated.

Check the condition of the high-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the "high-speed fan assembly" relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Remove the high-speed relay and check the insulation from earth of the following connection: – 49K between components 120 and 336. Check the + 12 V after relay feed on the following connection: – 37X of component 336. If the connection or connections are faulty and there is a repair method ( see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-48



13B

DF019 CONTINUED 2

1.DEF

NOTES

Special note: This fault appears when the computer control section overheats or when command AC153 High speed fan assembly is run.

Check the condition of the high-speed fan assembly relay mounting connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance of the "high-speed fan assembly" relay coil. Take care to measure the right way round; there is a protective diode. Replace the relay if the resistance is more than 200 Ω or less than 20 Ω. Remove the high-speed relay and check the insulation and continuity of the following connection: – 49K between components 120 and 336. Check the + 12 V after relay feed on the following connection: – 37X of component 336. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-49




13B

PRE-POSTHEATING UNIT DIAGNOSTIC LINE CO.1 : Open circuit or short circuit to + 12 V CC.0 : Short circuit to earth

Priorities when dealing with a number of faults: Deal with fault DF017 Pre-postheating control circuit first if it is present or stored.

NOTES

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – the ignition is switched on in the preheating phase, – engine running in postheating phase, – controlling the heater plugs using command AC037 Preheating relay . IMPORTANT Please observe the cleanliness guidelines and safety advice.

Use bornier Elé. 1681 for all operations on the engine management computer connectors. See Wiring Diagrams Technical Note Trafic II phase 2 . Check the condition of the pre-postheating unit connector. Check the condition of the connectors of all the heater plugs If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. During a phase where the heater plugs are activated by command AC037 Preheating relay , measure the current across the heater plugs Replace heater plugs with currents which are less than 1A or greater than 6A after 5 seconds' actuation. Check the continuity of the following connections: – 37AB between components 257 and 682, – 37AA between components 257 and 681, – 37Z between components 257 and 680, – 37AC between components 257 and 683. Check the + AVC feed on the following connection: – BP17 of component 257. Check the engine earthing. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Interpret command AC037 Preheating relay.

AFTER REPAIR



13B-50



13B

DF025 CONTINUED

Check the condition of the engine management computer connector. If the connector is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and absence of interference resistance on the following connection (preheating relay unit diagnostic line): – 3FY between components 120 and 257. If the connection is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, replace the pre-postheating unit (see MR 408, Mechanical, 13C, Preheating, PrePostheating unit, Removal - Refitting).

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-51




13B

CYLINDER 1 INJECTOR CONTROL CIRCUIT CO : Open circuit CC.1 : Short circuit to + 12 volts 1.DEF : Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault recurs as present after: – the ignition is switched on – starting the engine, – a road test

NOTES

Special notes: If the fault is present: – the EOBD warning light comes on, – the level 2 warning light comes on for CC.1 and 1.DEF, – the level 1 warning light is lit for CO. Use bornier Elé. 1681 for all operations on the engine management computer connectors. After an injector has been replaced, run command SC002 Enter injector codes and command SC036 Reinitialise programming and follow the procedure. IMPORTANT: – Cylinder no. 1 is located at the timing end. – Please observe the cleanliness guidelines and safety advice. – Do not disconnect the injector connections with the engine running as this may damage the engine.


CO

NOTES

None

Check the condition of the connector for injector no. 1. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3CR and 3KW of component 193. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR



13B-52



13B

DF026 CONTINUED

CC.1

NOTES

Special note: The engine stops when the fault appears.

Check the condition of the connector for injector no. 1. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation between the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3CR and 3KW of component 193. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

1.DEF

NOTES


Check the condition of the connector for injector no. 1. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and the absence of interference resistance of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3CR and 3KW of component 193. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-53




13B

CYLINDER 2 INJECTOR CONTROL CIRCUIT CO : Open circuit CC.1 : Short circuit to + 12 volts 1.DEF : Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault recurs as present after: – the ignition is switched on. – starting the engine, – a road test.

NOTES



CO

NOTES

None

Check the condition of the connector for injector no. 2. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3KX between components 120 and 194, – 3CS between components 120 and 194. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3KX and 3CS of component 194. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR



13B-54



13B

DF027 CONTINUED 1

CC.1

NOTES


Check the condition of the connector for injector no. 2. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation between the following two connections: – 3KX between components 120 and 194, – 3CS between components 120 and 194. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3KX and 3CS of component 194. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

1.DEF

NOTES


Check the condition of the connector for injector no. 2. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and the absence of interference resistance of the following connections: – 3KX between components 120 and 194, – 3CS between components 120 and 194. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3KX and 3CS of component 194. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-55




13B

INJECTOR CYLINDER 3 CONTROL CIRCUIT CO : Open circuit CC.1 : Short circuit to + 12 volts 1.DEF : Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault recurs as present after: – the ignition is switched on. – starting the engine, – a road test.

NOTES



CO

NOTES

None

Check the condition of the connector for injector no. 3. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3KY between components 120 and 195, – 3CT between components 120 and 195. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3KY and 3CT of component 195. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR



13B-56



13B

DF028 CONTINUED 1

CC.1

NOTES


Check the condition of the connector for injector no. 3. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation between the following two connections: – 3KY between components 120 and 195, – 3CT between components 120 and 195. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3KY and 3CT of component 195. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

1.DEF

NOTES


Check the condition of the connector for injector no. 3. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and the absence of interference resistance of the following connections: – 3KY between components 120 and 195, – 3CT between components 120 and 195. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connection codes 3KY and 3CT of component 195. Replace the injector if the resistance is not within: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$336.mif V5


13B-57




13B

CYLINDER 4 INJECTOR CONTROL CIRCUIT CO: Open circuit CC.1: Short circuit to + 12 volts 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – the ignition is switched on, – starting the engine, – a road test.

NOTES

Special notes: If the fault is present: – the EOBD warning light comes on, – the level 2 warning light comes on for CC.1 and 1.DEF, – the level 1 warning light comes on for CO. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. After an injector has been replaced, run command SC002 Enter injector codes and command SC036 Reinitialise programming and follow the procedure. IMPORTANT: – Cylinder no. 1 is located at the timing end. – Please observe the cleanliness guidelines and safety advice. – Do not disconnect the injector connections with the engine running as this may damage the engine.

See Wiring Diagrams Technical Note, Trafic II phase 2.

CO

NOTES

None.

Check the condition of the connector for injector no. 4. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connections codes 3KZ and 3CU of component 196. Replace the injector if the resistance is not within range: 150 kΩ < X < 210 kΩ. If the fault is still present, contact the Techline.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Switch off the ignition, wait 1 minute and carry out a road test followed by another check with the diagnostic tool .

EDC16CP33_V0C_DF029 / EDC16CP33_V10_DF029 /EDC16CP33_V14_DF029 / EDC16CP33_V16_DF029 MR-410-X83-13B000$384.mif V5

13B-58



13B

DF029 CONTINUED

CC.1

NOTES

Special notes: The engine stops when the fault appears.

Check the condition of the connector for injector no. 4. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation between the following two connections: – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connections codes 3KZ and 3CU of component 196. Replace the injector if the resistance is not within range: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

1.DEF

NOTES

Special notes: The engine stops when the fault appears.

Check the condition of the connector for injector no. 4. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and the absence of interference resistance of the following connections: – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between the following connections: – connections codes 3KZ and 3CU of component 196. Replace the injector if the resistance is not within range: 150 kΩ < X < 210 kΩ If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-59




13B

THERMOPLUNGER 1 RELAY CONTROL CIRCUIT CO: Open circuit CC.1: Short circuit to + 12V CC.0: Short circuit to earth 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – actuator command AC063 Thermoplunger no. 1 relay. NOTES

Special notes: Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2.

CO

NOTES

None.

Check the conformity of fuse: F1C, and replace it if necessary. Check the condition of the thermoplunger 1 relay mounting connector on the engine fuse box. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the thermoplunger 1 relay (relay removed): – Insulation between connections BP91 and 3JS of component 1773. – Measure the resistance between connections 37X and 3JA of component 1773. Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Check the continuity of the following connection: – 3JA between components 120 and 1773. Check the + 12 V after relay feed on the following connection: – 37X of component 1773. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR


EDC16CP33_V0C_DF032 / EDC16CP33_V10_DF032 / EDC16CP33_V14_DF032 / EDC16CP33_V16_DF032 MR-410-X83-13B000$384.mif V5

13B-60



13B

DF032 CONTINUED 1

CC.1

NOTES

None.

Check the conformity of fuse: F1C, and replace it if necessary. Check the condition of the thermoplunger 1 relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the thermoplunger 1 relay (relay removed): – Insulation between connections BP91 and 3JS of component 1773. – Measure the resistance between connections 37X and 3JA of component 1773. Replace the relay if its resistance is greater than 1 kΩ or less than 6Ω. Check the insulation from the + 12 V feed of the following connection: – 3JA between components 120 and 1773. If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

CC.0

NOTES

None.

Check the conformity of fuse: F1C, and replace it if necessary. Check the condition of the thermoplunger 1 relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the thermoplunger 1 relay (relay removed): – Insulation between connections BP91 and 3JS of component 1773. – Measure the resistance between connections 37X and 3JA of component 1773. Replace the relay if its resistance is greater than 1kΩ or less than 6 Ω. Check insulation against earth of the following connection: – 3JA between components 120 and 1773. Check the + 12 V after relay feed on the following connection: – 37X of component 1773. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-61



13B

DF032 CONTINUED 2

1.DEF

NOTES

Special note: This fault appears when the computer control section overheats or when command AC063 Thermoplunger no. 1 relay is run.

Check the conformity of fuse: FM14 , and replace it if necessary. Check the condition of the thermoplunger 1 relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the thermoplunger 1 relay (relay removed): – Insulation between connections BP91 and 3JS of component 1773. – Measure the resistance between connections 37X and 3JA of component 1773. Replace the relay if the resistance is greater than 200 Ω or less than 20 Ω. Check the absence of interference resistance of the following connection: – 3JA between components 120 and 1773. Check the + 12 V after relay supply on the following connection: – 37X of component 1773. Check the + AVC feed on the following connection: – BP91 of component 1773. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-62




13B

THERMOPLUNGER 2 RELAY CONTROL CIRCUIT CO: Open circuit CC.1: Short circuit to + 12V CC.0: Short circuit to earth 1.DEF: Internal electronic fault



CO

NOTES

None.

Check the conformity of fuse: F1D, and replace it if necessary. Check the condition of the "thermoplunger 2" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 2" relay (relay removed): – Insulation between connections BP92 and 3JC of component 1774. – Measure the resistance between connections 37X and 3AFA of component 1774 . Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Check the continuity of the following connection: – 3AFA between components 120 and 1774 . Check the + 12 V after relay feed on the following connection: – 37X of component 1774. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-63



13B

DF033 CONTINUED 1

CC.1

NOTES

None.

Check the conformity of fuse: F1D, and replace it if necessary. Check the condition of the "thermoplunger 2" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 2" relay (relay removed): – Insulation between connections BP92 and 3JC of component 1774. – Measure the resistance between connections 37X and 3AFA of component 1774 . Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Check the insulation against + 12 V of the connection between: – 3AFA between components 120 and 1774 . If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-64



13B

DF033 CONTINUED 2

CC.0

NOTES

None.

Check the conformity of fuse: F1D, and replace it if necessary. Check the condition of the "thermoplunger 2" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 2" relay (relay removed): – Insulation between connections BP92 and 3JC of component 1774. – Measure the resistance between connections 37X and 3AFA of component 1774 . Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Check insulation against earth of the following connection: – 3AFA between components 120 and 1774 . Check the + 12 V after relay feed on the following connection: – 37X of component 1774. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-65



13B

DF033 CONTINUED 3

1.DEF

NOTES

Special note: This fault appears when the computer control section overheats or when command AC064 "Thermoplunger no. 2 relay" is run.

Check the conformity of fuse F1D, and replace it if necessary. Check the condition of the "thermoplunger 2" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 2" relay (relay removed): – Insulation between connections BP92 and 3JC of component 1774. – Measure the resistance between connections 37X and 3AFA of component 1774 . Replace the relay if the resistance is greater than 200 Ω or less than 20 Ω. Check the absence of interference resistance of the following connection: – 3AFA between components 120 and 1774 . Also check the insulation on the following connections: Check the + 12 V after relay supply on the following connection: – 37X of component 1774. Check the + before ignition feed on the following connection: – BP92 of component 1774. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-66




13B

THERMOPLUNGER 3 RELAY CONTROL CIRCUIT CO: Open circuit CC.1: Short circuit to + 12 V CC.0: Short circuit to earth 1.DEF: Internal electronic fault



CO

NOTES

None.

Check the conformity of fuse F1C, and replace it if necessary. Check the condition of the "thermoplunger 3" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 3" relay (relay removed): – Insulation between connections BP91 and 3JD of component 1775. – Measure the resistance between connections 37X and 3AFB of component 1775 . Replace the relay if its resistance is greater than 1 kΩ or less than 6Ω. Check the continuity of the following connection: – 3AFB between components 120 and 1775. Check the + 12 V after relay feed on the following connection: – 37X of component 1775. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-67



13B

DF034 CONTINUED 1

CC.1

NOTES

None.

Check the conformity of fuse F1C, and replace it if necessary. Check the condition of the "thermoplunger 3" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 3" relay (relay removed): – Insulation between connections BP91 and 3JD of component 1775. – Measure the resistance between connections 37X and 3AFB of component 1775 . Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Check the insulation from the + 12 V feed of the following connection: – 3AFB between components 120 and 1775. If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-68



13B

DF034 CONTINUED 2

CC.0

NOTES

None.

Check the conformity of fuse F1C, and replace it if necessary. Check the condition of the "thermoplunger 3" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 3" relay (relay removed): – Insulation between connections BP91 and 3JD of component 1775. – Measure the resistance between connections 37X and 3AFB of component 1775 . Replace the relay if its resistance is greater than 1 kΩ or less than 6 Ω. Check insulation against earth of the following connection: – 3AFB between components 120 and 1775. Check the + 12 V after relay feed on the following connection: – 37X of component 1775. If the connections are faulty and there is a repair method ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-69



13B

DF034 CONTINUED 3

1.DEF

NOTES

Special note: This fault appears when the computer control section overheats or when command AC031 "Thermoplunger no. 3 relay" is run.

Check the conformity of fuse F1C, and replace it if necessary. Check the condition of the "thermoplunger 3" relay mounting connector on the engine fuse box. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the "thermoplunger 3" relay (relay removed): – Insulation between connections BP91 and 3JD of component 1775. – Measure the resistance between connections 37X and 3AFB of component 1775 . Replace the relay if the resistance is greater than 200 Ω or less than 20 Ω. Check the absence of interference resistance of the following connection: – 3AFB between components 120 and 1775. Also check the insulation on the following connections: Check the + 12 V after relay feed on the following connection: – 37X of component 1775. Check the + before ignition feed on the following connection: – BP91 of component 1775. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-70




13B

COMPUTER 1.DEF: Internal electronic fault 2.DEF: Data inconsistency 3.DEF: Computer feed voltage

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – starting the engine, – a road test.

NOTES

1.DEF

Special notes: If the fault is present: – depending on the situation, the level 1 or level 2 warning light is lit for 1.DEF, – the level 1 warning light is illuminated for 2.DEF, – the level 2 warning light is illuminated for 3.DEF, – engine torque limited, – the engine stops.

NOTES

None.

If the fault is stored, clear the fault from the computer memory. Switch off the ignition and wait 1 min before switching on the ignition again. Start the engine and re-establish dialogue. If the fault recurs, contact the Techline.

2.DEF

NOTES

None.

NOTES

Priorities when dealing with a number of faults: Deal with faults DF047 Computer supply voltage or DF046 Battery voltage first, if they are present or stored.

Contact Techline.

3.DEF

If either of faults DF047 Computer feed voltage or DF046 Battery voltage is present or stored, clear the fault after dealing with DF046 or DF047. If the fault recurs, contact the Techline.

AFTER REPAIR



13B-71




13B

BATTERY VOLTAGE 1.DEF: Above maximum threshold. 2.DEF: Below minimum threshold 3.DEF: Abnormal voltage

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – starting the engine, – a road test. NOTES

Special notes: Computer operating voltage: 6 V < operating voltage < 16.5 V . It is then not possible to start the engine. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.

See Wiring Diagrams Technical Note, Trafic II phase 2. 1.DEF

NOTES

None.

Check the charging circuit, apply Technical Note 6014A Checking the charging circuit. Carry out the necessary repairs. 2.DEF

NOTES

None.

Using a voltmeter , take a reading of the battery voltage. – Compare this value with the value displayed by the diagnostic tool PR074 Battery voltage . If there is no difference (less than 1 V): Recharge and test the battery. If it is faulty, replace it. Then check the charging circuit: Technical Note 6014A Checking the charging circuit . If there is a difference (greater than 1 V): – Check the tightness and the condition of the battery terminals. – Using the appropriate wiring diagram: Check for continuity and absence of interference resistance on the following connection: – 3FAC between components 120 and 983. Check the conformity of the earths on connections NF of component 120. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. 3.DEF

NOTES

Only deal with this fault when it is present.

Switch off the ignition, wait 1 minute, then switch on the ignition again after the power -latch*, check to see if the fault is still present. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-72




13B

COMPUTER SUPPLY VOLTAGE 1.DEF: Voltage outside permitted range of values


Special notes: Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.

See Wiring Diagrams Technical Note, Trafic II phase 2. – Check the tightness and the condition of the battery terminals. – Using the appropriate wiring diagram: Check for continuity and absence of interference resistance on the following connection: – 3FAC between components 120 and 983. Check the conformity of the earths on connections NF of component 120. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-73




13B

CRUISE CONTROL/SPEED LIMITER 1.DEF: Cruise control/Speed limiter steering wheel control

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – a road test with activation of the cruise control/speed limiter function, – the engine is started. NOTES

Special notes: If the fault is present: – Cruise control/speed limiter cut off Use bornier Elé. 1681 for all operation at the level of the injection computer connectors.


1.DEF

NOTES

Priority when dealing with a number of faults: Deal with faults DF196 Pedal sensor circuit gang 1, DF198 Pedal sensor circuit gang 2 first, if either of the two is present or stored.

Check the conformity of the steering wheel controls as follows: disconnect the connector from component 689 under the central cover of the steering wheel (connect the ohmmeter on the steering wheel switch side). The measurement should be: ● 900 Ω (± 10 Ω ) when the Resume switch is pressed. (or the one-touch switch R on the right-hand side of the steering wheel) ● 0 Ω (0.8 Ω max. ) when the Suspend switch is pressed. (or the one-touch switch O on the right-hand side of the steering wheel) ● 300 Ω (± 10 Ω ) when the Set + button is pressed. (or the one-touch switch on the left of the steering wheel) ● 100 Ω (± 10 Ω ) when the Set - button is pressed. (or the one-touch switch on the left of the steering wheel) ● Infinite resistance in rest position. – If the values are not correct , replace the steering wheel switches. – If the values are correct , take the same measurements on connections 86G and 86M from component 120 (steering wheel control connector connected). If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. – If the values are correct, clear the fault, switch off the ignition, wait 1 min and switch on the ignition again. If the fault is still present (after pressing the steering wheel controls), contact the Techline.

AFTER REPAIR



13B-74




13B

INJECTORS CONTROL CIRCUIT CC.0: Short circuit to earth CC.1: Short circuit to + 12 V CC: Short circuit

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – the ignition is switched on, – starting the engine, – a road test.

NOTES

Special notes: If the fault is present: – the level 2 warning light will be lit, – the engine stops. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2. IMPORTANT: – Cylinder no. 1 is located at the timing end. – Do not disconnect the injectors when the engine is running. – Please observe the cleanliness guidelines and safety advice.

1.DEF

NOTES

None.

Check the condition of the injector connectors. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the continuity and insulation from earth of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193, – 3KX between components 120 and 194, – 3CS between components 120 and 194, – 3KY between components 120 and 195, – 3CT between components 120 and 195, – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-75



13B

DF052 CONTINUED 1

CC.1

NOTES

None.

Check the condition of the injector connectors. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation from + 12 V of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193, – 3KX between components 120 and 194, – 3CS between components 120 and 194, – 3KY between components 120 and 195, – 3CT between components 120 and 195, – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-76



13B

DF052 CONTINUED 2

CC

NOTES

None.

Check the condition of the injector connectors. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193, – 3KX between components 120 and 194, – 3CS between components 120 and 194, – 3KY between components 120 and 195, – 3CT between components 120 and 195, – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-77




13B

TURBOCHARGING SOLENOID VALVE CONTROL CIRCUIT CO: Open circuit CC.1: Short circuit to + 12V CC.0: Short circuit to earth 1.DEF: Internal electronic fault

Priorities when dealing with a number of faults: Deal with fault DF046: Battery voltage first if it is present or stored.

NOTES

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test, – actuator command AC004 Turbocharging solenoid valve. Special notes: If the fault is present: – turbocharging is no longer authorised, – the EGR function is inhibited, – the level 1 and EOBD warning lights are lit. Use bornier Elé. 1681 for all operation at the level of the injection computer connectors. See Wiring Diagrams Technical Note, Trafic II phase 2.

CO

NOTES

None.

Check the condition of the turbocharging solenoid valve connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connection: – 3MG between the components 120 and 1475. Check the + 12 V after relay supply on the following connection: – 37X of component 1475. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. See Test 6 Turbocharger control solenoid valve check . If the fault is still present, replace the turbocharging solenoid valve.

AFTER REPAIR



13B-78



13B

DF054 CONTINUED 1

CC.1

NOTES

None.

Check the condition of the turbocharging solenoid valve connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation from the + 12 V feed of the following connection: – 3MG between the components 120 and 1475. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the turbocharging solenoid valve.

CC.0

NOTES

None.

Check the condition of the turbocharging solenoid valve connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check insulation against earth of the following connection: – 3MG between the components 120 and 1475. Check the + 12 V after relay feed on the following connection: – 37X of component 1475. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. See Test 6 Turbocharger control solenoid valve check . If the fault is still present, replace the turbocharging solenoid valve.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-79



13B

DF054 CONTINUED 2

1.DEF

NOTES

Special features: this fault appears when the computer control section overheats or when command AC004 Turbocharging solenoid valve is run.

Check the condition of the turbocharging solenoid valve connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check continuity and make sure there is no interference resistance on the following connection: – 3MG between the components 120 and 1475.

Check the + 12 V after relay feed on the following connection: – 37X of component 1475. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. See Test 6 Turbocharger control solenoid valve check . – If the fault is stored, clear the fault and run command AC004 Turbocharging solenoid valve. – If, when running command AC004 Turbocharging solenoid valve, DF054 1.DEF is present or stored, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-80




13B

AIR FLOWMETER CIRCUIT CO.0: Open circuit or short circuit to earth. CC.1: Short circuit to +12 V 1.DEF : Values outside the permitted tolerance values

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test, – the ignition is switched off: 1.DEF.

NOTES

Special notes: If the fault is present: – the EOBD warning light comes on, – the level 1 warning light comes on and turbocharging is no longer authorised for CO.0 and CC.1, – the EGR function is inhibited by the engine management computer, – engine torque limited, – safe value PR132 Air flow 90 kg/h at idling speed. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.


CC.0

NOTES

Priorities when dealing with a number of faults: In the event of the simultaneous presence of fault DF002 Air temperature sensor circuit, check that the air flow sensor connector is connected correctly. Deal with fault DF013 Sensor supply voltage no. 3 1.DEF first, if it is present or stored.

Check the condition of the air flowmeter connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation from earth of the following connections: – 3DV between components 120 and 799, – 3KJ between components 120 and 799, – 3DU between components 120 and 799. Check the + 5 V feed on the following connection: – 3KJ of component 799. Check the + 12 V after relay supply on the following connection: – 37X of component 799. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Apply test 5 Air flowmeter .

AFTER REPAIR



13B-81



13B

DF056 CONTINUED 1

with the flow meter connected, the vehicle ignition on and engine stopped: check the voltage between connections 3DW and 3DV of component 799. – Replace the air flowmeter if the voltage is not between 0.3 V < X < 0.7 V. If the fault is still present, replace the air flowmeter.

CC.1

NOTES

Priorities when dealing with a number of faults: Deal with fault DF013 Sensor supply voltage no. 3 1.DEF first, if it is present or stored.

Check the condition of the air flowmeter connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation from + 12 V of the following connections: – 3DV between components 120 and 799, – 3KJ between components 120 and 799, – 3DU between components 120 and 799. Check the + 5 V feed on the following connection: – 3KJ of component 799. Check the + 12 V after relay supply on the following connection: – 37X of component 799. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. With the flow meter connected, the vehicle ignition on and engine stopped: check the voltage between connections 3DW and 3DV of component 799. – If the voltage is not approximately 0.3 V ± 0.1 V, replace the air flowmeter. If the fault is still present, replace the air flowmeter.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-82



13B

DF056 CONTINUED 2

1.DEF

NOTES

Priorities when dealing with a number of faults: Deal with fault DF013 Sensor supply voltage no. 3 1.DEF first, if it is present or stored.

Check the condition of the air flowmeter connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and absence of interference resistance of the following connections: – 3DV between components 120 and 799, – 3KJ between components 120 and 799, – 3DU between components 120 and 799. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check the condition of the flow sensor: no visible damage to the sensing element of the flow sensor. If the fault is still present, replace the air flowmeter.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-83




13B

COMBUSTION MISFIRES ON CYLINDER 1

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – engine speed is between idling speed and 1050 rpm, PR055 Engine speed , – a coolant temperature ≥ 20˚C PR064 Coolant temperature . Priorities when dealing with a number of faults: Apply the interpretation of faults: DF026 Cylinder 1 injector control circuit and DF052 Injector control circuit first, if they are present or stored. NOTES

Special notes: – Check that the stored injector codes are consistent with those engraved on each injector. If not, run command SC002 Enter injector codes and follow the procedure. – After an injector has been replaced, run command SC002 Enter injector codes and command SC036 Reinitialise programming and follow the procedure. IMPORTANT Cylinder no. 1 is located at the timing end. Do not disconnect the injectors when the engine is running. When removing or refitting an injector, observe the cleanliness guidelines and safety advice (see MR 408 Mechanical, 13B Diesel injection, Diesel injectors: Removal - Refitting ).

DF059 appears on the diagnostic tool when the engine management computer has detected a fault during the combustion phase several times in succession. Several components may be responsible: – the piston rings, – the piston, – the valves, – the injector, – the heater plug sealing.

Check engine compression, use a compression gauge, the flexible end piece M9R part no. Mot. 1772 and run command VP036 Fuel supply Inhibited.

AFTER REPAIR



13B-84



13B

DF059 CONTINUED

If the fault is stored, start the engine and leave to run at idle engine for more than 1 min with a temperature PR064 '' Coolant temperature''> 30˚C. If the fault becomes present , dismantle the injector concerned in accordance with the methods and the safety advice (see MR 408 Mechanical, 13B, Diesel injection, Diesel injectors: Removal - Refitting ). If no injector fitting fault (in particular injector thrust washer): – change the injector concerned, – modify the IMA code of the injector with command SC002 '' Enter injector codes'' (the IMA codes are read from left to right). – Use command SC036 Reinitialise programming, select injector , select yes only for the injector replaced and follow the procedure. If the fitting of the injector is not correct, refit the injector in accordance with the fitting instructions specified in the MR Mechanical systems, while taking care to install a new washer. Clear the fault and carry out a road test. Check that the fault is not still present. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-85




13B

MISFIRING ON CYLINDER 2

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – engine speed is between idling speed and 1050 rpm, PR055 Engine speed, – a coolant temperature ≥ 20˚C PR064 Coolant temperature . Priorities when dealing with a number of faults: Apply the interpretation of faults: DF027 Cylinder 2 injector control circuit and DF052 Injector control circuit first, if they are present or stored.

NOTES

Special notes: – Check that the stored injector codes are consistent with those engraved on each injector. If not, run command SC002 Enter injector codes and follow the procedure. – After replacing an injector, run commands SC002 Enter injector codes and SC036 Reinitialise programming, follow the procedure. IMPORTANT Cylinder no. 1 is located at the timing end. Do not disconnect the injectors when the engine is running. When removing or refitting an injector, observe the cleanliness guidelines and safety advice (see MR 408 Mechanical, 13B Diesel injection, Diesel injectors: Removal Refitting).



AFTER REPAIR



13B-86



13B

DF060 CONTINUED

If the fault is stored, start the engine and leave to run at idle engine for more than 1 min with a temperature PR064 Coolant temperature > 30˚C . If the fault becomes present , dismantle the injector concerned in accordance with the methods and the safety advice (see MR 408 Mechanical, 13B, Diesel injection, Diesel injectors: Removal - Refitting ). If no injector fitting fault (in particular injector thrust washer): – change the injector concerned, – modify the IMA code of the injector with command SC002 Enter injector codes (the IMA codes are read from left to right). – Use command SC036 Reinitialise programming, select injector , select yes only for the injector replaced and follow the procedure. If the fitting of the injector is not correct, refit the injector in accordance with the fitting instructions specified in the MR Mechanical systems, while taking care to install a new washer. Clear the fault and carry out a road test. Check that the fault is not still present. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-87




13B


Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – engine speed is between idling speed and 1050 rpm, PR055 Engine speed , – a coolant temperature ≥ 20˚C PR064 Coolant temperature . Priorities when dealing with a number of faults: Apply the interpretation of faults: DF028 Cylinder 3 injector control circuit and DF052 Injectors control circuit first, if they are present or stored.

NOTES

Special notes: – Check that the stored injector codes are consistent with those engraved on each injector. If not, run command SC002 Enter injector codes and follow the procedure. – After replacing an injector, run commands SC002 Enter injector codes and SC036 Reinitialise programming, follow the procedure. IMPORTANT Cylinder no. 1 is located at the timing end. Do not disconnect the injectors when the engine is running. When removing or refitting an injector, observe the cleanliness guidelines and safety advice (see MR 408 Mechanical, 13B Diesel injection, Diesel injectors: Removal Refitting).



AFTER REPAIR



13B-88



13B

DF061 CONTINUED

If the fault is stored, start the engine and leave to run at idle engine for more than 1 min with a temperature PR064 Coolant temperature> 30˚C . If the fault becomes present , dismantle the injector concerned in accordance with the methods and the safety advice (see MR 408 Mechanical, 13B, Diesel injection, Diesel injectors: Removal - Refitting ). If no injector fitting fault (in particular injector thrust washer): – change the injector concerned, – modify the IMA code of the injector with command SC002 'Enter injector codes (the IMA codes are read from left to right). – Use command SC036 Reinitialise programming, select injector , select yes only for the injector replaced and follow the procedure. If the fitting of the injector is not correct, refit the injector in accordance with the fitting instructions specified in the MR Mechanical systems, while taking care to install a new washer. Clear the fault and carry out a road test. Check that the fault is not still present. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-89




13B


Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – engine speed is between idling speed and 1050 rpm, PR055 Engine speed , – a coolant temperature ≥ 20˚C PR064 Coolant temperature . Priorities when dealing with a number of faults: Apply the interpretation of faults: DF029 Cylinder 4 injector control circuit and DF052 Injector control circuit first, if they are present or stored. NOTES

Special notes: – Check that the stored injector codes are consistent with those engraved on each injector. If not, run command SC002 Enter injector codes and follow the procedure – After replacing an injector, run commands SC002 Enter injector codes and SC036 Reinitialise programming, follow the procedure. IMPORTANT Cylinder no. 1 is located at the timing end. Do not disconnect the injectors when the engine is running. When removing or refitting an injector, observe the cleanliness guidelines and safety advice (see MR 408 Mechanical, 13B Diesel injection, Diesel injectors: Removal Refitting).



AFTER REPAIR



13B-90




13B


If the fault is stored, start the engine and leave to run at idle engine for more than 1 min with a temperature PR064 ''Coolant temperature'' > 30˚C . If the fault becomes present , dismantle the injector concerned in accordance with the methods and the safety advice (see MR 408 Mechanical, 13B, Diesel injection, Diesel injectors: Removal - Refitting ). If no injector fitting fault (in particular injector thrust washer): – change the injector concerned, – modify the IMA code of the injector with command SC002 'Enter injector codes (the IMA codes are read from left to right). – Use command SC036 Reinitialise programming, select injector , select yes only for the injector replaced and follow the procedure. If the fitting of the injector is not correct, refit the injector in accordance with the fitting instructions specified in the MR Mechanical systems, while taking care to install a new washer. Clear the fault and carry out a road test. Check that the fault is not still present. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-91




13B

COMBUSTION MISFIRES 1.DEF: Combustion misfires detected on several cylinders

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – engine speed is between idling speed and 1050 rpm, PR055 Engine speed , – a coolant temperature ≥ 20˚C PR064 Coolant temperature .

NOTES

Priorities when dealing with a number of faults: Apply the interpretation of these faults first: DF052 Injectors control circuit , present or stored. DF026 Cylinder 1 injector control circuit , present or stored. DF027 Cylinder 2 injector control circuit , present or stored. DF028 Cylinder 3 injector control circuit , present or stored. DF029 Cylinder 4 injector control circuit , present or stored. Special notes: – Check that the stored injector codes are consistent with those engraved on each injector. If not, run command SC002 Enter injector codes and follow the procedure. IMPORTANT When removing or refitting an injector, observe the cleanliness guidelines and safety advice (see MR 408 Mechanical, 13B Diesel injection, Diesel injectors: Removal Refitting).


Check engine compression, use a compression gauge, the flexible end piece M9R part no. Mot. 1772 and run command VP036 Fuel supply Inhibited. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-92



NOTES

1.DEF


13B

INJECTOR CODE(S) 1.DEF: No code stored 2.DEF: Configuration/Initialisation

Special notes: If the fault is present, – the injection flow will be limited, – engine torque limited, resulting in a maximum engine speed of 1500 rpm, – the level 1 warning light is illuminated.

NOTES

This fault appears when an incorrect injector code is entered from command SC002 Enter injector codes .

Check the injector codes and reprogram the correct codes using command SC002 Enter injector codes . (Consult the procedures defined in the Interpretation of commands section). – After the codes have been written: – Switch off the ignition. – Wait for 1 minute and switch on the ignition again. – Establish dialogue and clear the fault memory. – End of operation. Important: if fault DF066 Injector code(s) is still present after the injector codes have been entered, check that the power-latch* runs each time the ignition is switched off.

– Switch off the ignition. – Wait for 1 minute then switch on the ignition again. – Establish dialogue. If the fault has become stored , clear the fault memory and end the operation. If the fault is present , contact the Techline. * The immobiliser warning light will flash a few seconds after the ignition is switched off.

AFTER REPAIR



13B-93



13B

DF066 CONTINUED

2.DEF

NOTES

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the injection computer computer is replaced, – reprogramming.

This fault is present on all blank computers (new or after reprogramming). – Program the injector codes codes using: either command SC001 Enter saved data , or command SC002 Enter injector codes . (Consult the procedures defined in the Interpretation of commands section). – After the codes have been been written: – Switch off the ignition. – Wait for 1 minute and switch switch on the ignition again. again. – Establish dialogue dialogue and clear the fault fault memory. memory. – End of operation. Important: if fault DF066 Injector code(s) is still present after the injector codes have been entered, check that the power-latch* runs each time the ignition is switched off. If the fault is still present, contact the Techline. * The immobiliser warning light will flash f lash a few seconds after the ignition is switched off.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-94



13B

VEHICLE SPEED SIGNAL DF091 STORED

1.DEF: Vehicle speed too high 2.DEF: Inconsistent vehicle speed 3.DEF: Invalid vehicle speed

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – a road test. NOTES

Special notes: – the vehicle speed signal sent by the ABS computer to the injection injection computer is greater than the threshold defined in the calibration. Use bornier Elé. 1681 for all operation at the level of the injection computer connectors.

See Wiring Diagrams Technical Note, Trafic II phase 2. Check the condition of the ABS computer connector (or of the speed sensor if the vehicle is not equipped with ABS). Check the condition of the engine management computer connector. Check the condition of the instrument cluster connector. If one of the connectors is faulty and there is a r epair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation of the following connections: – 47F between components 247 and 1094 (or 250). Run full fault finding on the ABS computer (see 38C, Anti-lock braking system ). Run complete fault finding on the multiplex network (see 88B, Multiplexing). If the fault is still present, contact the Techline.

AFTER REPAIR


EDC16CP33_V0C_DF091M / EDC16CP33_V10_DF091M / EDC16CP33_V14_DF091M / EDC16CP33_V16_DF091M MR-410-X83-13B000$384.mif V5

13B-95




13B

FUEL TEMPERATURE SENSOR CIRCUIT CC.0: Short circuit to earth CO.1: Open circuit or short circuit to +12 V

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present when the ignition is switched on.

NOTES

Special notes: If the fault is present, – the fuel temperature temperature safe value PR063 Fuel temperature = 100˚C . Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.


CC.0

NOTES

None.

Check the condition of the fuel temperature sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a r epair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3FAB and 3LD of component 1066. Replace the sensor if its resistance is less than 85 Ω or greater than 50 k Ω (see MR 408, Mechanical, 13B, Diesel injection, Diesel temperature sensor, Removal - Refitting). Check insulation against earth of the following connection: – 3FAB between components 120 and 1066. If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, ), repair the wiring, otherwise replace it. Wiring: Precautions for repair ),

AFTER REPAIR



13B-96



13B

DF098 CONTINUED

CO.1

NOTES

None.

Check the condition of the fuel temperature sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a r epair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3FAB and 3LD of component 1066. Replace the sensor if its resistance is less than 85 Ω or greater than 50 kΩ (see MR 408, Mechanical, 13B, Diesel injection, Diesel temperature sensor, Removal - Refitting). Check the continuity of the following connections: – 3FAB between components 120 and 1066, – 3LD between components 120 and 1066 . Check the insulation from the + 12 V feed of the following connection: – 3FAB between components 120 and 1066. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$384.mif V5


13B-97

EDC16CP33 Program No.: C4 Vdiag No.: 16


NOTES


13B

AUTOMATIC OR SEQUENTIAL GEARBOX CONNECTION VIA THE MULTIPLEX NETWORK 1.DEF: Multiplex network

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – a road test. Special note: If the fault is present, the European On Board Diagnostic warning light is on.

See Wiring Diagrams Technical Note, Trafic II phase 2. Check the multiplex network (see 88B, Multiplexing). If communication is not established, see 23A, Automatic transmission.

*AT: Automatic transmission (automatic gearbox)

AFTER REPAIR


EDC16CP33_V16_DF099 MR-410-X83-13B000$384.mif V5

13B-98



NOTES


13B

COMPUTER MEMORY 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, – a road test.

Special notes: Level 1 and EOBD warning lights are illuminated.

If the fault is stored, clear the fault from the computer memory. Switch off the ignition and wait 1 min before switching on the ignition again. Start the engine and re-establish dialogue. This fault may be linked a write error following disconnection of the battery when the computer was in a write to EEPROM phase. If this is the case, loading a new calibration will clear the fault. If a more recent calibration is available, load this calibration on to the computer. If the fault is still present: – use scenario SC003 Save computer data , – use the command RZ034 Computer memory, – switch off the ignition and wait for the message loss of communication with the computer, – switch on the ignition again, – use scenario SC001 Enter saved data . If the fault recurs, contact the Techline.

*EOBD: European On Board Diagnostic.

AFTER REPAIR



13B-99




13B

CAMSHAFT SENSOR SIGNAL 1.DEF: No camshaft signal or timing fault (tension or setting) 2.DEF: Feed fault, signal interference, camshaft sensor internal fault


Special notes: Use bornier Elé. 1681 for all operation at the level of the injection computer connectors. See Wiring Diagrams Technical Note, Trafic II phase 2.

1.DEF

NOTES

None.

Check the condition of the camshaft sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Warning: If the fault is stored: Visually check the condition of the surrounding area. If, on detection of the fault, the engine speed is well below idling speed (less than 400 rpm) and no customer complaint is declared (warning light indicated by the customer not illuminated, and vehicle can be started), the fault was detected because the engine had stalled. Clear the fault and carry out a road test.

Check the electrical specifications of the sensor: Note: Measure the resistance between the indicated tracks without producing a short circuit between the tracks. 1. Disconnect the sensor before measuring the resistance with an Ohmmeter or multimeter. 2. Resistance between connections 3SV and 37X of component 1265 (signal and supply) must be between 7.2 k Ω and 13.4 kΩ (10.2 kΩ nominal). 3. Resistance between connections 3SX and 37X of component 1265 (earth and supply) must be greater then 100 kΩ. 4. Resistance between connections 3SX and 3SV of component 1265 (earth and signal) must be greater then 100 kΩ. If the values are incorrect, replace the camshaft sensor.

AFTER REPAIR



13B-100

DIESEL INJECTION


Fault finding – Interpretation of faults

13B

DF119 CONTINUED

Check the continuity of the following connections: – 3SX between components 120 and 1265 , – 3SV between components 120 and 1265 . Check the + 12 V after relay supply on the following connection: – 37X of component 1265. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the camshaft sensor.

2.DEF

NOTES

Priorities when dealing with a number of faults: Deal with fault DF120 Engine speed sensor signal first if it is present or stored.

Check the condition of the camshaft sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3SX between components 120 and 1265 , – 3SV between components 120 and 1265 . Check the + 12 V after relay supply on the following connection: – 37X of component 1265. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. – Check the conformity of the assembly: camshaft sprocket/camshaft. – Check the timing adjustment. Carry out the necessary repairs. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-101




13B

ENGINE SPEED SENSOR SIGNAL 1.DEF: Engine speed signal interference, broken tooth on flywheel or engine speed sensor internal fault 2.DEF: No engine speed signal, or interference affecting engine speed signal

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – starting the engine, – a road test, – attempting to start the engine. NOTES

Special notes: The engine speed sensor is consistent with the camshaft sensor. If the fault is present, the level 2 warning light are lit. Use bornier Elé. 1681 for all operation at the level of the injection computer connectors.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the condition of the engine speed sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check that the sensor is securely attached. Measure the resistance between connections 3BG and 3BL of component 149. If the winding resistance is not between 600 Ω and 1000 Ω, replace the engine speed sensor. Check the continuity, insulation from + 12 V and absence of interference resistance on the following connections: – 3BG between the components 120 and 149, – 3BL between components 120 and 149. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the engine speed sensor.

AFTER REPAIR



13B-102



13B

MAIN RELAY CIRCUIT DF151 STORED

NOTES

CO.1: Open circuit or short circuit to +12 V CC.0: Short circuit to earth

Special notes: The level 1 warning light is on.

See Wiring Diagrams Technical Note, Trafic II phase 2 .

CO.1

NOTES

None.

Note: this fault specification may be due to a premature relay cut-off. Check the condition of the injection supply relay mounting connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check that the battery terminals are in good condition and properly tightened. Check the conformity of the main relay (relay removed): – Insulation between connections 3FB1 and BP38 of component 983. – Measure the resistance between connections 3FAC and BP10 of component 983. Replace the relay if its resistance is less than 6Ω or greater than 1 k Ω. Check the + before ignition feed on the following connection: – BP38 of component 983. Check the + 12 V after relay feed on the following connection: – 3FB1 of component 983. Check the continuity and insulation from + 12 V of the following connection: – 3FAC between components 120 and 983. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR


EDC16CP33_V0C_DF151M / EDC16CP33_V10_DF151M /EDC16CP33_V14_DF151M / EDC16CP33_V16_DF151M MR-410-X83-13B000$432.mif V5

13B-103



13B

DF151 CONTINUED

Check the + 12 V after relay feed on the following connections: – 37X of component 120, – 3FB1 of component 120, – 3FB2 of component 120. Check the conformity of the earths on connections NF of component 120. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the injection feed relay.

CC.0

NOTES

None.

Note: this fault specification may be due to a late relay cut-off. Check the condition of the injection supply relay mounting connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the main relay (relay removed): – Insulation between connections 3FB1 and BP38 of component 983. – Measure the resistance between connections 3FAC and BP10 of the component. Replace the relay if its resistance is less than 6 Ω or greater than 1 kΩ. Check the insulation to earth of the following connection: – 3FAC between components 120 and 983. If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the injection feed relay.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-104




13B

ACCELERATOR PEDAL POSITION SENSOR CIRCUIT 1.DEF: Inconsistent signal 2.DEF: Accelerator pedal sensor locked 3.DEF: Pedal error

Priorities when dealing with a number of faults: Deal with fault DF012 Sensor feed voltage no. 2 first if it is present or stored. Conditions for applying the fault finding procedure to stored faults: The fault is declared present when the brake pedal and accelerator pedal are depressed simultaneously. NOTES

Special notes: Turbocharging and cruise control are not authorised. Engine speed is fixed at 1400 rpm. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the condition of the pedal sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LT and 3LR of component 921. Replace the sensor if the resistance is not: 1.2 kΩ ± 0.50 kΩ. Measure the resistance between connections 3LU and 3LV of component 921. Replace the sensor if the resistance is not: 1.7 kΩ ± 0.70 k Ω. Check the continuity and absence of interference resistance of the following connections: – 3LR between components 120 and 921, – 3LS between components 120 and 921, – 3LT between components 120 and 921, – 3LU between components 120 and 921, – 3LW between components 120 and 921, – 3LV between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-105

DIESEL INJECTION




13B

CAMSHAFT SENSOR / ENGINE SPEED CONSISTENCY 1.DEF: No engine speed signal, or engine speed signal interference

Priorities when dealing with a number of faults: Deal with fault DF119 Camshaft sensor signal and DF120 engine speed sensor signal first if they are present or stored.

NOTES

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after the starter has been running for 10 seconds or a 1 min delay with the engine running. Special notes: Use bornier Elé. 1681 bornier for all operations on the connector of the engine management computer.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the sensor mounting and the conformity of the camshaft target. Check the condition of the engine speed sensor connector. Check the condition of the camshaft sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. – Check the conformity of the camshaft sprocket/camshaft assembly. – Check the timing adjustment. Carry out the necessary repairs. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-106




13B

PEDAL SENSOR CIRCUIT GANG 1 CC.0: Open circuit or short circuit to earth CC.1: Short circuit to + 12 V 1.DEF: Inconsistency between pedal gang 1 and gang 2

Priorities when dealing with a number of faults: Deal with fault first if it is DF011 Sensor feed voltage no. 1 first if it is present or stored. Conditions for applying the fault finding procedure to stored faults: The fault is declared present after a series of full load/no load actions on the accelerator pedal. NOTES

CO.0

Special notes: – engine torque limited, – cruise control disabled, – the level 1 warning light is illuminated, – idling speed is 1400 rpm, – use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2.

NOTES

Dealing with a number of faults: If there is a simultaneous occurrence of fault DF198 Pedal sensor circuit gang 2, check that the pedal sensor connector is connected correctly.

Check the condition of the pedal sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LT and 3LR of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 2 k Ω. Measure the resistance between connections 3LU and 3LV of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Check the continuity of the following connections: – 3LS between components 120 and 921. – 3LR between components 120 and 921. Check the insulation against earth on the following connection: – 3LS between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-107



13B

DF196 CONTINUED 1

CC.1

NOTES

Special notes: see Wiring Diagrams Technical Note, Trafic II phase 2 .

Check the condition of the pedal sensor connector. Check the condition of the engine management computer connector. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LT and 3LR of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 2 kΩ. Measure the resistance between connections 3LU and 3LV of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Check the insulation from + 12 V and + 5 V (computer feeds) of the following connection: – 3LS between components 120 and 921. Check the continuity of the following connection: – 3LT between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-108



13B

DF196 CONTINUED 2

1.DEF

NOTES

Special notes: see Wiring Diagrams Technical Note, Trafic II phase 2 .

Check the condition of the pedal sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LT and 3LR of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 2 kΩ. Measure the resistance between connections 3LT and 3LS of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Measure the resistance between connections 3LU and 3LV of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 3 k Ω. Measure the resistance between connections 3LV and 3LW of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Check for continuity and absence of interference resistance of the following connections: – 3LR between components 120 and 921, – 3LS between components 120 and 921, – 3LT between components 120 and 921, – 3LU between components 120 and 921, – 3LW between components 120 and 921, – 3LV between components 120 and 921. Check the insulation between the following connections: – 3LS between components 120 and 921, – 3LW between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, vary the pedal position and refer to conformity check, sub-function Driver parameters to check the operating values of the accelerator pedal sensor. If the values displayed are inconsistent, replace the accelerator pedal sensor.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-109




13B

PEDAL SENSOR CIRCUIT GANG 2 CO.0: Open circuit or short circuit to earth CC.1: Short circuit to + 12 V 1.DEF: Inconsistency between pedal gang 1 and gang 2

Priorities when dealing with a number of faults: Deal with fault DF012 Sensor feed voltage no. 2 first if it is present or stored. Conditions for applying the fault finding procedure to stored faults: The fault is declared present after a series of full load/no load actions on the accelerator pedal. NOTES

CO.0

Special notes: – engine torque limited, – cruise control disabled, – the level 1 warning light is illuminated, – idling speed is 1400 rpm, – Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2.

NOTES

Dealing with a number of faults: If there is a simultaneous occurrence of fault DF196 Pedal sensor circuit gang 1, check that the pedal sensor connector is connected correctly.

Check the condition of the pedal sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LV and 3LU of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 3 k Ω. Measure the resistance between connections 3LV and 3LW of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Check the continuity of the following connections: – 3LU between components 120 and 921. – 3LW between components 120 and 921. Check the insulation against earth on the following connection: – 3LW between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR


EDC16CP33_V0C_DF198 / EDC16CP33_V0C_DF198 / EDC16CP33_V14_DF198 / EDC16CP33_V16_DF198 MR-410-X83-13B000$432.mif V5

13B-110



13B

DF198 CONTINUED 1

CC.1

NOTES

None.

Check the condition of the pedal sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LV and 3LU of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 3 k Ω. Measure the resistance between connections 3LV and 3LW of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Check the insulation from + 12 V and + 5 V (computer feeds) of the following connection: – 3LW between components 120 and 921. Check the continuity of the following connection: – 3LV between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-111



13B

DF198 CONTINUED 2

1.DEF

NOTES

None.

Check the condition of the pedal sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3LR and 3LT of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 2 k Ω. Measure the resistance between connections 3LS and 3LT of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Measure the resistance between connections 3LV and 3LU of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 3 k Ω. Measure the resistance between connections 3LV and 3LW of component 921. Replace the sensor if the resistance is less than 500 Ω or greater than 10 kΩ. Check for continuity and absence of interference resistance of the following connections: – connection code 3LR, – Connection code 3LS, – connection code 3LT, – connection code 3LU, – connection code 3LW, – Connection code 3LV, between components 120 and 921. Check the insulation between the following connections: – connection code 3LW, – Connection code 3LS, between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, vary the pedal position and refer to conformity check, sub-function Driver parameters to check the operating values of the accelerator pedal sensor. If the values displayed are inconsistent, replace the accelerator pedal sensor.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-112




13B

ATMOSPHERIC PRESSURE SENSOR 1.DEF: Above maximum threshold 2.DEF: Below minimum threshold

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the ignition is switched on, – the engine is started, – a road test.

NOTES

Special notes: The EOBD warning light comes on. The atmospheric pressure sensor is integrated into the injection computer, and cannot be separated. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. If the fault is present: – there is light smoke, – the atmospheric pressure value changes to safe mode, PR035 Atmospheric pressure = 750 mbar .

See Wiring Diagrams Technical Note, Trafic II phase 2 . Disconnect the injection computer and check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the value of PR035 Atmospheric pressure by comparing it with the reading on a conforming vehicle in the workshop. If the PR035 Atmospheric pressure value is not correct (difference greater than 0.1 bar between the 2 vehicles), contact the Techline.

AFTER REPAIR



13B-113




13B

EGR VALVE POSITION SENSOR CIRCUIT CC.1: Open circuit or short circuit to + 12 V CO.0: Short circuit to earth

Priorities when dealing with a number of faults: – DF046 Battery voltage. – DF012 Sensor supply voltage no. 2.

NOTES

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the ignition is switched on, – the engine is started, – a road test. Special notes: If the fault is present: – the EOBD warning light comes on. – EGR programming cut-off: valve in the closed position. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.


CC.1

NOTES

None.

Check the condition of the EGR valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

AFTER REPAIR



13B-114



13B

DF209 CONTINUED 1

Check the insulation from + 12 V and + 5 V (computer feeds) of the following connection: – 3EL between components 120 and 169. Check the continuity of the following connection: – 3JM between components 120 and 169. Check the insulation between the following connections: – 3EL between components 120 and 169, – 3VP between components 120 and 169. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3GC and 3JM (sensor feed and sensor earth), and between connections 3EL and 3JM (sensor signal and sensor earth) of component 169. Replace the valve if the resistances are less than 1 kΩ. After replacement, run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-115



13B

DF209 CONTINUED 2

CO.0

NOTES

None.

Check the condition of the EGR valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3EL between components 120 and 169, – 3GC between components 120 and 169. Check insulation against earth of the following connection: – 3EL between components 120 and 169. Check the insulation between the following connections: – 3EL between components 120 and 169, – 3VQ between components 120 and 169. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3GC and 3JM (sensor feed and sensor earth), and between connections 3EL and 3JM (sensor signal and sensor earth) of component 169. Replace the valve if the resistances are greater than 15 kΩ. After replacement, run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-116



13B

CLUTCH CONTACT SIGNAL DF221 STORED

1.DEF: Clutch inconsistency upon gear change

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present during a road test at speeds higher than 21 mph (35 km/h). NOTES

Special notes: – the cruise control/speed limiter function is switched off. This fault is only applicable on vehicles with a manual gearbox. Use bornier Elé. 1681 bornier for all operations on the connector of the engine management computer.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the condition of the clutch switch connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. – View status ET233 CLUTCH PEDAL , which should be RELEASED when the pedal is not depressed. – Depress the clutch pedal and note whether this status becomes DEPRESSED. If status ET233 "Clutch pedal" becomes DEPRESSED, clear the fault, switch off the ignition, wait for the end of the power latch* and switch on the ignition again. Carry out a road test and then take a fault reading. If the fault recurs, contact the Techline. If status ET233 "Clutch pedal" does not become DEPRESSED. – Remove the clutch switch, and without activating the switch, check the insulation between the following connections: – MJ and 145X of component 675, – MK and 145X of component 675. – Press the clutch switch and check the continuity between the following connections: – MJ and 145X of component 675, – MK and 145X of component 675. If both these checks are not correct, replace the clutch switch. Then check the continuity and absence of interference resistance of the connection: – 145X between components 120 and 675. – Check that the earth is in order on connection MJ or MK of component 675. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. * The immobiliser warning light will flash a few seconds after switching the ignition off.

AFTER REPAIR


EDC16CP33_V0C_DF221M / EDC16CP33_V10_DF221M / EDC16CP33_V14_DF221M / EDC16CP33_V16_DF221M MR-410-X83-13B000$432.mif V5

13B-117




13B

BRAKE SIGNAL 1.DEF: Consistency with redundant brakes

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after the brake pedal is depressed.

1.DEF

NOTES

Special notes: If the fault is present: – Cruise control/speed limiter cut off Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.


AFTER REPAIR



13B-118

DIESEL INJECTION



13B

DF228 CONTINUED 1

From the List of statuses menu, check ET704 Brake switch no. 1 and ET705 Brake switch no. 2 and check: – brake pedal at rest ET704 = INACTIVE and ET705 = INACTIVE – brake pedal depressed and ET704 = ACTIVE ET705 = ACTIVE

Has ET705 been correctly recognised?

NO

YES YES Has ET704 been correctly recognised ?

NO

Clear the fault End of fault finding procedure

Check the condition of the brake pedal switch connector. Check the condition of the ABS computer connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the connector, otherwise replace the wiring. Check the + 12 V after relay feed on the following connection: – AP26 of component 160. Disconnect component 1094 and check the continuity and insulation against + 12 V and against earth on the following connection: – 65A between components 1094 and 160. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Remove the brake pedal switch and check that it is working correctly: – in rest position: continuity between connections AP26 and 5A of component 160, – pressed: continuity between connections AP26 and 65A of component 160. Replace the brake switch if necessary. If the fault is still present, run fault finding on the Anti-lock Braking System - electronic stability program; if no irregularity is detected, then run multiplexed network fault finding.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-119



13B

DF228 CONTINUED 2

Check the condition of the brake pedal switch connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the connector, otherwise replace the wiring. Remove and check the condition and setting of the brake pedal switch. Check the + 12 V after relay feed to the brake pedal switch: – AP26 of component 160. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Disconnect the ABS computer and check the continuity and insulation against + 12 V and against earth on the following connection: – 5A between components 120 and 160. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check that the brake pedal switch is working correctly: – in rest position: continuity between connections AP26 and 5A of component 160, – pressed: continuity between connections AP26 and 65A of component 160. Replace the brake switch if necessary.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-120



NOTES


13B

COLD LOOP AIR CONDITIONING RELAY CONTROL CIRCUIT CO: Open circuit CC.0: Short circuit to earth CC.1: short-circuit to + 12 V 1.DEF: Internal electronic fault

Special notes: Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2 .

Check the condition of the air conditioning relay connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the conformity of the air conditioning fuse. Check the insulation, continuity and the absence of interference resistance of the following connection: – 38K between the components 120 and 584. Check the + 12 V feed on the following connection: – 37X of component 584. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Replace the relay if the fault is still present.

AFTER REPAIR



13B-121



NOTES


13B

REFRIGERANT PRESSURE SENSOR CIRCUIT 1.DEF: Short circuit to earth 2.DEF: Open circuit or short circuit to + 12 V

Special notes: Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2 .

Check the air conditioning circuit. Check the condition of the refrigerant pressure sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Disconnect the battery and the engine management computer. Check the insulation and the continuity of the following connections: – 38Y between components 120 and 1202, – 38X between components 120 and 1202, – 38U between components 120 and 1202. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the refrigerant pressure sensor.

AFTER REPAIR



13B-122




13B

INJECTOR CONTROL 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – the ignition is switched on, – the engine is started.

NOTES

Priority when dealing with a number of faults: Deal with faults DF046 Battery voltage, DF026 Injector cylinder 1 control circuit, DF027 Injector cylinder 2 control circuit, DF028 Injector cylinder 3 control circuit and DF029 Injector cylinder 4 control circuit first if they are present or stored. Special notes: If the fault is present: – in certain cases, the level 2 warning light is lit and the engine is stopped. Use bornier Elé. 1681 for all operations on the connectors of the engine management computer.

See Wiring Diagrams Technical Note, Trafic II phase 2. This fault appears when the computer detects a fault on the injector c ontrol section. Check the condition of the injector connectors. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193, – 3KX between components 120 and 194, – 3CS between components 120 and 194, – 3KY between components 120 and 195, – 3CT between components 120 and 195, – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-123




13B

INJECTOR NO. 1 1.DEF: Internal electronic fault

Priority when dealing with a number of faults: Deal with fault DF026 Injector 1 control circuit first, if it is present or stored. Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – the engine is started, – a road test. NOTES

IMPORTANT – Cylinder no. 1 is located at the timing end. – Please observe the cleanliness guidelines and safety advice. – Do not disconnect the injector connections with the engine running as this may damage the engine.

Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2. Run test 10 Incorrect injector operation . Check the condition of the connector for injector no. 1. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-124




13B

INJECTOR N˚ 2 1.DEF: Internal electronic fault



Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2. Run test 10 Incorrect injector operation . Check the condition of the connector for injector no. 2. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance of the following connections: – 3KX between components 120 and 194, – 3CS between components 120 and 194. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-125




13B

INJECTOR NO. 3 1.DEF: Internal electronic fault



Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2. Run test 10 Incorrect injector operation . Check the condition of the connector for injector no. 3. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance of the following connections: – 3KY between components 120 and 195, – 3CT between components 120 and 195. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-126




13B

INJECTEUR N˚ 4 1.DEF: Internal electronic fault



Use bornier Elé. 1681 for all operations on the connectors of the engine management computer. See Wiring Diagrams Technical Note, Trafic II phase 2. Run test 10 Incorrect injector operation . Check the condition of the connector for injector no. 4. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance of the following connections: – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-127



13B

EGR VALVE CONTROL CIRCUIT DF272 PRESENT OR STORED

CO: Open circuit CC.0: Short circuit to earth CC.1: Short circuit to + 12 V CC: Short circuit 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the ignition is switched on, – the engine is started, – a road test. NOTES

Special notes: If the fault is present: – the EOBD warning light comes on, – the EGR function is inhibited, Use bornier Elé. 1681 bornier for all operations on the connector of the engine management computer.


CO

NOTES

None.

Check the condition of the EGR valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity of the following connections: – 3VP between components 120 and 169, – 3VQ between components 120 and 169. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3VP and 3VQ of component 169. Replace the EGR valve if the resistance is greater than 400 Ω (see MR 408, Mechanical, 14A, Emission control, Exhaust gas recirculation solenoid valve, Removal - Refitting). After replacement, run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-128



13B

DF272 CONTINUED 1

CC.0 CC.1 CC

NOTES

None.

Check the condition of the EGR valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the insulation against + 12 V and against the earth and between the following connections: – 3VP between components 120 and 169, – 3VQ between components 120 and 169. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3VP and 3VQ of component 169. Replace the EGR valve if the resistance is less than 1 Ω or greater than 400 Ω (see MR 408, Mechanical, 14A, Emission control, Exhaust gas recirculation solenoid valve, Removal - Refitting). After replacement, run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-129



13B

DF272 CONTINUED 2

1.DEF

NOTES

Special notes: This fault appears when the computer control section has overheated.

If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$432.mif V5


13B-130



NOTES


13B

WATER IN DIESEL FUEL DETECTOR 1.DEF: Open circuit on the line or water present in the diesel fuel

Fault finding procedure application conditions: Present or stored fault. IMPORTANT Please observe the cleanliness guidelines and safety advice.


Make sure there is no water in the fuel filter. Bleed the fuel filter and the low pressure diesel circuit if necessary. Start the engine and wait at least 1 minute to confirm the repair. If the fault was stored but not present, carry out a road test (see Note). If the fault does not recur, end the fault finding procedure. Check continuity and make sure there is no interference resistance on the following connection: – 3WT between the components 120 and 414. Check the + 12 V after relay feed on the following connection: – 37X of component 414. Check for complete earthing on connection ML of component 414. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. – Start the engine and wait at least 1 minute to confirm the repair. Ensure that the correct fuel is being used: Run test 8 Diesel fuel conformity check. If – – –

none of these checks reveal any faults: replace the water detection sensor, clear the fault, start the engine and wait at least 1 minute to confirm the repair.

Note: When the water level in the fuel filter unit is below the sensor's electrodes, some driving conditions (cornering, gradients) may result in water being detected (in fact, the sensor's off-centre position in the fuel filter unit, combined with the driving conditions, causes water t o be detected).

AFTER REPAIR



13B-131




13B

EGR BY-PASS CIRCUIT CO: Open circuit CC.0: Short circuit to earth CC.1: Short circuit to + 12V 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault reappears when the ignition is switched on. NOTES

CO

Special notes: Use bornier Ele. 1681 for all operations on the engine management computer connectors. See Wiring Diagrams Technical Note, Trafic II phase 2.

NOTES

None.

Check the condition of the EGR bypass solenoid valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3TP of component 1301. If the resistance measured is greater than 1 kΩ or less than 6 Ω, replace the EGR bypass solenoid valve. Check the continuity of the following connection: – 3TP between components 120 and 1301. Check the + 12 V after relay feed on the following connection: – 37X of component 1301. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the EGR by-pass solenoid valve.

CC.0

NOTES

None.

Check the condition of the EGR bypass solenoid valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

AFTER REPAIR



13B-132



13B

DF304 CONTINUED 1

Measure the resistance between connections 37X and 3TP of component 1301. If the resistance measured is greater than 1 kΩ or less than 6 Ω, replace the EGR bypass solenoid valve. Check the continuity, and insulation from earth of the following connection: – 3TP between components 120 and 1301. Check the + 12 V after relay feed on the following connection: – 37X of component 1301. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the EGR by-pass solenoid valve.

CC.1

NOTES

None.

Check the condition of the EGR bypass solenoid valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3TP of component 1301. If the resistance measured is greater than 1 kΩ or less than 6 Ω, replace the EGR bypass solenoid valve. Check the continuity and insulation from + 12 V of the following connection: – 3TP between components 120 and 1301. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the EGR by-pass solenoid valve.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-133



13B

DF304 CONTINUED 2

1.DEF

NOTES

Special notes: This fault appears when the computer control section has overheated. A road test may be necessary to reveal this fault.

Check the condition of the EGR bypass solenoid valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3TP of component 1301. If the resistance measured is not 46 Ω ± 14 Ω, replace the EGR bypass solenoid valve. Check continuity and make sure there is no interference resistance on the following connection: – 3TP between components 120 and 1301. Check the + 12 V after relay feed on the following connection: – 37X of component 1301. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-134


DIESEL INJECTION

13B


DAMPER VALVE DF323 PRESENT OR STORED

CO: Open circuit CC.0: Short circuit to earth CC.1: Short circuit to + 12 V CC: Short circuit 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after the ignition has been switched on. NOTES

CC.0 CC.1

Special notes: Use bornier Ele. 1681 for all operations on the engine management computer connector. See Wiring Diagrams Technical Note, Trafic II phase 2 .

NOTES

None.

Check the condition of the damper valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3AAX and 3AAY of component 1461. Replace the damper valve if the resistance is less than 0.5 Ω or greater than 400 Mechanical,12A, Fuel mixture, Damper valve, Removal - Refitting) .

Ω (see

MR 408,

Then run command SC036 Reinitialise programming and select damper valve to reinitialise the valve's opening and closing stops. Check the insulation from the earth of the following connections: – 3AAX between the components 120 and 1461, – 3AAY between the components 120 and 1461. Check the insulation from + 12 V of the following connections: – 3AAX between the components 120 and 1461, – 3AAY between the components 120 and 1461. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-135



13B

DF323 CONTINUED 1

CC CO

NOTES

None.

Check the condition of the damper valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3AAX and 3AAY of component 1461. Replace the damper valve if the resistance is less than 0.5 Ω or greater than 400 Ω (see MR 408, Mechanical,12A, Fuel mixture, Damper valve, Removal - Refitting). Then run command SC036 Reinitialise programming and select damper valve to reinitialise the valve's opening and closing stops. Check the insulation between the following connections: – 3AAX between the components 120 and 1461, – 3AAY between the components 120 and 1461. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-136



13B

DF323 CONTINUED 2

1.DEF

NOTES

Special notes: This fault appears when the computer control section has overheated. A road test may be necessary. See Wiring Diagrams Technical Note, Trafic II phase 2 .

Check the condition of the damper valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3AAX and 3AAY of component 1461. Replace the damper valve if the resistance is less than 0.5 Ω or greater than 400 Ω (see MR 408, Mechanical,12A, Fuel mixture, Damper valve, Removal - Refitting). Then run command SC036 Reinitialise programming and select damper valve to reinitialise the valve's opening and closing stops. Check the continuity of the following connections: – 3AAX between the components 120 and 1461, – 3AAY between the components 120 and 1461. Check the insulation from + 5 V (computer supplies) of the following connections: – 3AAX between the components 120 and 1461, – 3AAY between the components 120 and 1461. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-137




13B

CRUISE CONTROL OR SPEED LIMITER BUTTON 1.DEF : Cruise control/Speed limiter on/off button inconsistency

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – a road test with activation of the cruise control/speed limiter function, – the engine is started. NOTES

Special notes: If the fault is present: – Cruise control/speed limiter cut off Use bornier Elé. 1681 for all operations on the engine management computer connectors.

See Wiring Diagrams Technical Note, Trafic II phase 2. Check the condition of the cruise control/speed limiter on-off button connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. With the button released, check the insulation between the following connections: – AP3 and 3FX of component 1081, – AP3 and 3PD of component 1081. – Check the continuity between AP3 and 3FX of component 1081 in cruise control position. – Check the continuity between AP3 and 3PD of component 1081 in the speed limiter position. Replace the Cruise control/Speed limiter on/ off button if necessary. Check the continuity and absence of interference resistance of the following connections: – 3FX between components 120 and 1081, – 3PD between components 120 and 1081. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-138

EDC16CP33 Program No.: C4 Vdiag No.: 10, 14, 16



13B

ALTERNATOR CHARGE SIGNAL 1.DEF: Internal electronic fault 2.DEF: Inconsistent signal

Priorities when dealing with a number of faults: Deal with fault DF046 Battery voltage first if it is present or stored.

NOTES

Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – a road test, – the engine is started. Special notes: Computer operating voltage: between 6 V and 16.5 V. Use bornier Elé. 1681 for all operations on the engine management computer connectors.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the condition of the alternator connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the following connection for continuity and for the absence of interference resistance: – 2K between components 120 and 103. If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check the charging circuit, see Technical Note 6014A Checking the charging circuit . Carry out the necessary repairs. If the fault is still present, contact the Techline.

AFTER REPAIR


EDC16CP33_V10_DF532 / EDC16CP33_V14_DF532 / EDC16CP33_V16_DF532 MR-410-X83-13B000$480.mif V5

13B-139




13B

TURBOCHARGING CIRCUIT 1.DEF:Turbocharging 1.DEF:Turbocharging pressure too high 2.DEF: Turbocharging pressure too low

Priorities when dealing with a number of faults: Deal with faults DF054 Turbocharging solenoid valve control circuit, and DF004 Turbocharging pressure sensor circuit first, if they are present or stored. Conditions for applying the fault finding procedure to stored faults: If the fault is declared present after: – the ignition is switched on, – starting the engine, engine, – a road test. NOTES

Special notes: Use bornier Ele. 1681 for all operations on the engine management computer connectors. If the fault is present: – engine torque limited, – turbocharging regulation regulation is inhibited, inhibited, – the EGR function is inhibited, inhibited, – the level 1 and EOBD warning lights are lit.

See Wiring Diagrams Technical Note, Trafic II phase 2 . 1.DEF 2.DEF

NOTES

None.

Perform the following road test (looking for a loss of power when accelerating under full load): – in the highest gear gear ratio, accelerate fully, – lift your foot off the accelerator pedal pedal completely for at least least 2 seconds, – accelerate fully again, again, – release the accelerator accelerator pedal completely, completely, – accelerate slightly. If loss of power was not noted during slight acceleration and if there was a loss of engine power during each acceleration at full load, replace the diesel injector fuel return rail and its overpressure valve (see MR 408 Mechanical, 13B, Diesel injection, Diesel injector fuel return rail: Removal - Refitting ). Check the condition of the turbocharging pressure sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a r epair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

AFTER REPAIR



13B-140

DIESEL INJECTION



13B

DF569 CONTINUED

Check the continuity and absence of interference resistance of the following connections: – 3LQ between components 120 and 1071, – 3LP between components 120 and 1071, – 3LN between components 120 and 1071 . If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Run test SC035 High pressure fuel circuit fault finding . With the engine switched off and ignition on, view parameters PR035 Atmospheric pressure and PR041 Turbocharging pressure. If there is a difference of > 100 mbar , check that the atmospheric pressure reading is consistent (by comparison with another vehicle for example). If atmospheric pressure is consistent, replace the turbocharging sensor. If not, contact the Techline. Apply test 4: Turbocharged air inlet circuit check Apply ALP8 Engine stalling. If the fault is still present, refer to the interpretation of parameter PR041 Turbocharging pressure .

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-141

DIESEL INJECTION




13B

DAMPER VALVE POSITION REGULATION 1.DEF: Value outside permitted tolerance values 2.DEF: Damper valve jammed open 3.DEF: Data inconsistency

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after the engine has been started.

NOTES

Priorities when dealing with a number of faults: Deal with faults DF323 Damper valve, DF012 Sensor feed voltage no. 2 and DF046 first, if they are present or stored. Damper valve position sensor first, Special notes: Use the Elé. 1681 bornier for all operations on the engine management computer connector. See Wiring Diagrams Technical Note, Trafic II phase 2 .

1.DEF 2.DEF 3.DEF

NOTES

None.

Check that the valve is not mechanically jammed: With the engine switched off, disconnect the air inlet hose from the damper valve. Check that the valve is in the open position. Start, then switch off the engine. Check that the valve closes when the engine is switched off and then opens again when the engine has stopped. If this does not happen, replace the damper valve. Then run command SC036 Reinitialise programming and select Damper valve to reinitialise the valve's opening and closing stops. Ensure that the valve is clean. Clean if necessary. Check the condition of the damper valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a r epair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

AFTER REPAIR



13B-142



13B

DF645 CONTINUED

Measure the resistances between connections 38KQ and 38KP (potentiometer feed and potentiometer earth) and between 38KS and 38KP (potentiometer signal and potentiometer earth) of component 1461 . Replace the damper valve if the resistances are not between 290 Ω and 6 kΩ (see MR 408, Mechanical, 12A, Fuel mixture, Damper valve, Removal - Refitting) . Then run command SC036 Reinitialise programming and select Damper valve to reinitialise the valve's opening and closing stops. Check for the absence of interference resistance on the following connections: – 38KQ between components 120 and 1461, – 38KS between components 120 and 1461 , – 38KP between components 120 and 1461 . Check the insulation from + 12 V (computer supplies) of the following connections: – 3AAX between the components 120 and 1461, – 3AAY between the components 120 and 1461. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-143




13B

DAMPER VALVE POSITION SENSOR CC: Short circuit CO.0: Open circuit or short circuit to earth.

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the engine is started, started, – a road test. NOTES

Priorities when dealing with a number of faults: Deal with fault DF012 Sensor feed voltage no. 2 first if it is present or stored. Special notes: Use the Elé. 1681 bornier for all operations on the engine management computer connector. See Wiring Diagrams Technical Note, Trafic II phase 2 .

CC

NOTES

None.

Check the condition of the damper valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a r epair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistances between connections 38KQ and and 38KP (potentiometer feed and potentiometer earth) and even 38KS and 38KP (potentiometer signal and potentiometer earth) of component 1461. Replace the damper valve if the resistances are not between 290 Ω and 6 k Ω (see MR 408, Mechanical, 12A, Fuel mixture, Damper valve, Removal - Refitting) . Then run command SC036 Reinitialise programming and select Damper valve to reinitialise the valve's opening and closing stops. Check the insulation from + 12 V and + 5 V (computer feeds) of the following connection: – 38KS between components 120 and 1461 . Check the insulation between the following f ollowing connections: – 38KP between components 120 and 1461 , – 38KQ between components 120 and 1461, – 38KS between components 120 and 1461 . If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical ), repair the wiring, otherwise replace it. wiring repair, Wiring: Precautions for repair ), If the fault is still present, contact the Techline.

AFTER REPAIR



13B-144



13B

DF646 CONTINUED

CO.0

NOTES

None.

Check the condition of the damper valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistances between connections 38KQ and 38KP (potentiometer feed and potentiometer earth) and between 38KS and 38KP (potentiometer signal and potentiometer earth) of component 1461. Replace the damper valve if the resistances are not between 290 Ω and 6 kΩ (see MR 408, Mechanical, 12A, Fuel mixture, Damper valve, Removal - Refitting) . Then run command SC036 Reinitialise programming and select Damper valve to reinitialise the valve's opening and closing stops. Check the insulation against earth on the following connection: – 38KS between components 120 and 1461 . Check the continuity of the following connections: – 38KS between components 120 and 1461 , – 38KQ between components 120 and 1461. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-145




13B

EGR VALVE POSITION REGULATION 1.DEF: Inconsistent EGR 1 offset 2.DEF: Inconsistent EGR 2 offset 3.DEF: Valve jammed closed 4.DEF: Valve jammed open

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the engine is started, – a road test. NOTES

Special notes: – the level 1 and EOBD warning lights are lit for 1.DEF, 2.DEF and 3.DEF, – only the EOBD warning light comes on for 4.DEF, – the EGR function is inhibited by the engine management computer, – use bornier Ele. 1681 for all operations on the engine management computer connector.


1.DEF 2.DEF

NOTES

Priorities when dealing with a number of faults: – DF209 EGR valve position sensor circuit, – DF046 Battery voltage, – DF012 Sensor feed voltage no. 2, – DF272 EGR valve control circuit.

Check the condition of the EGR valve connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance of the following connections: – 3GC between components 120 and 169, – 3EL between components 120 and 169, – 3JM between components 120 and 169. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. *EOBD: European On Board Diagnostics

AFTER REPAIR



13B-146



13B

DF647 CONTINUED 1

Measure the resistance between connections 3VP and 3VQ of component 169. Replace the valve if the resistance is not between 0.5 Ω < X < 1 kΩ. Measure the resistance between connections 3GC and 3JM of component 169. Replace the valve if the resistance is not between 10 Ω < X < 100 kΩ. Measure the resistance between connections 3GC and 3EL of component 169. Replace the valve if the resistance is not between 10 kΩ < X < 100 kΩ. After replacement, run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets. If the fault is still present, remove and clean the EGR valve, then refit it (see MR 408, Mechanical, 14A Emission control, Exhaust gas recirculation solenoid valve: Removal - Refitting). Run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets If the fault is still present, replace the EGR valve then run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-147



13B

DF647 CONTINUED 2

3.DEF 4.DEF

NOTES

Priorities when dealing with a number of faults: – DF209 EGR valve position sensor circuit – DF046 Battery voltage. – DF012 Sensor feed voltage no. 2 – DF272 EGR valve control circuit

Remove and clean the EGR valve, then refit it (see MR 408, Mechanical, 14A Emission control, Exhaust gas recirculation solenoid valve: Removal - Refitting ). Run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets. If the fault is still present, replace the EGR valve then run command SC036 Reinitialise programming and select EGR valve to reinitialise the EGR valve offsets.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-148




13B

GROUP 1 INJECTORS FEED CC.O : Short circuit to earth 1.DEF : Faulty connections

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – the ignition is switched on, – the engine is started. Priority when dealing with a number of faults: Deal with faults DF026 Cylinder 1 injector control circuit, DF027 Cylinder 2 injector control circuit first if they are present or stored. NOTES

Special notes: If the fault is present: – the level 2 warning light will be lit, – the engine stops. Use bornier Elé. 1681 for all operations on the engine management computer connectors.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the condition of the injector connectors. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation of the following connections: – 3KW between components 120 and 193, – 3CR between components 120 and 193, – 3KX between components 120 and 194, – 3CS between components 120 and 194, If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-149




13B

GROUP 2 INJECTORS FEED CC.O : Short circuit to earth 1.DEF : Faulty connections

Conditions for applying the fault finding procedure to stored faults: If the fault becomes present after: – the ignition is switched on, – the engine is started. Priority when dealing with a number of faults: Deal with faults DF028 Cylinder 3 injector control circuit , DF029 Cylinder 4 injector control circuit first if they are present or stored. NOTES

Special notes: If the fault is present: – the level 2 warning light will be lit, – the engine stops. Use bornier Elé. 1681 for all operations on the engine management computer connectors.

See Wiring Diagrams Technical Note, Trafic II phase 2 . Check the condition of the injector connectors. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the continuity and insulation of the following connections: – 3KY between components 120 and 195, – 3CT between components 120 and 195, – 3KZ between components 120 and 196, – 3CU between components 120 and 196. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Switch off the ignition, wait 1 minute and carry out a road test followed by a check with the diagnostic tool.


13B-150




13B

PRESSURE REGULATION ON RAIL 1.DEF: Below minimum threshold 2.DEF: Above maximum threshold 3.DEF: Negative loop deviation 4.DEF: Positive loop deviation

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the ignition is switched on. – the engine is started, – a road test.

NOTES

Special notes: Fault DF895 Pressure regulation on rail depends on the pressure regulator on the rail (DRV). Fault DF896 Pressure regulation on pump depends on the pressure regulator integrated in the pump (MPROP) . The fuel pressure regulator built into the rail (DRV) and the fuel pressure regulator built into the pump (MPROP) are never actuated at the same time. If the fault is present: – the engine stops and the level 2 warning light comes on: 1.DEF, 4.DEF, – the level 1 warning light is lit: 2.DEF, 3.DEF, – engine torque limited 2.DEF, 3.DEF, 4.DEF, – the rail pressure is regulated by a regulator built into the pump (MPROP): 2.DEF, 3.DEF, 4.DEF.

Use bornier Elé. 1681 for all operations on the engine management computer connectors. See Wiring Diagrams Technical Note, Trafic II phase 2 .

1.DEF 2.DEF 3.DEF 4.DEF

NOTES

Priorities when dealing with a number of faults: Deal with fault DF898 Rail pressure regulator circuit, DF897 Pump pressure regulator circuit, DF896 Pressure regulator on pump first, if they are present or stored.

Check that there are no leaks on the high pressure diesel fuel circuit. Repair if necessary. Check the fuel level in the tank: If there is a fault with the fuel sender sensor, deal with this first. Check the low pressure circuit by running test 3 low pressure circuit test and check that there are no exterior leaks or air leaks in the low pressure fuel circuit. Run test SC035 High pressure fuel circuit fault finding . If the fault is still present, check the rail pressure regulator connections (DRV). check the engine management computer connections. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Switch off the ignition, wait 1 minute and carry out a road test followed by a check with the diagnostic tool.


13B-151



13B

DF895 CONTINUED

Check the seal on the rail pressure regulator (DRV): Disconnect the low-pressure return pipe from the rail pressure regulator (DRV). In its place, connect a transparent pipe, with the other end leading to a container of some sort in order to collect the drained diesel fuel. Start the engine and let the engine idle. When the engine is started, no diesel should flow into the transparent pipe as the rail pressure regulator (DRV) is closed so that the pressure in the hydraulic system can rise. Diesel fuel should flow into the transparent pipe a few seconds after the engine is started, provided that the diesel is cold (less than 15˚C), as the regulation is provided by the rail pressure regulator (DRV) . If the diesel is warm (above 15˚C), regulation is controlled by the pump pressure regulator (MPROP). No diesel should flow into the pipe. If the diesel does not behave in accordance with this description, replace the rail (removing the rail pressure regulator (DRV) is not permitted). Note: the above description no longer applies if faults DF898 Rail pressure regulator circuit, DF897 Pump pressure regulator circuit and DF896 Pump pressure regulation are present. Check the condition of the pressure regulator connector on the pump (MPROP). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 3FB and 3HI of component 1105. Contact Techline if the resistance is not between: 2 Ω and 6 Ω at 20˚C. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-152




13B

PRESSURE REGULATOR ON PUMP 1.DEF: Below minimum threshold 2.DEF: Above maximum threshold 3.DEF: Negative loop deviation 4.DEF: Positive loop deviation

Conditions for applying the fault finding procedure to stored faults: The fault is declared present after: – the ignition is switched on. – the engine is started. NOTES

1.DEF 2.DEF 3.DEF 4.DEF

Special notes: If the fault is present: – the engine stops and the level 2 warning light comes on: 1.DEF, – the level 1 warning light comes on: 2.DEF, 3.DEF, 4.DEF, – engine torque is limited: 2.DEF, 3.DEF, 4.DEF, – the rail pressure is regulated by a regulator built into the rail (DRV): 2.DEF, 3.DEF, 4.DEF.

NOTES

Priorities when dealing with a number of faults: Deal with faults DF897 Pump pressure regulator circuit, DF898 Rail pressure regulator circuit first, if they are present or stored.

Check that there are no leaks on the high pressure diesel fuel circuit. Repair if necessary. Check the level of fuel in the tank. Check the low pressure circuit by running test 3 low pressure circuit test and check that there are no exterior leaks or air leaks in the low pressure fuel circuit. Run test SC035 High pressure fuel circuit fault finding . Check the condition of the pressure regulator connector on the pump (MPROP). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check the condition of the pressure regulator connector on the rail (DRV). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-153




13B

PUMP PRESSURE REGULATOR CIRCUIT CO: Open circuit CC.0: Short circuit to earth CC.1: Short circuit to + 12 V 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – ignition is switched on – the regulator is actuated using command AC226 Pump pressure regulator .

NOTES

Special notes: The fuel flow regulator is built into the high pressure pump. If the fault is present: – the quantity of fuel injected limited and the engine speed limited to 3000 rpm: CO, CC.1, 1.DEF – regulation with open loop for fuel flow, – the level 2 warning light comes on: CC.0: engine stop, – the level 1 warning light comes on: CO, CC.1, 1.DEF, – pressure is regulated by the pump pressure regulator (MPROP).

Use bornier Elé. 1681 for all operations on the engine management computer connectors. See Wiring Diagrams Technical Note, Trafic II phase 2 .

CO

NOTES

None.

Check the condition of the pressure regulator connector on the pump (MPROP). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3HI of component 1105. Contact the Techline if the resistance is less than 1.5 Ω or greater than 1 kΩ. Check the continuity of the following connection: – 3HI between the components 120 and 1105. Check the + 12 V after relay feed on the following connection: – 37X of component 1105. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-154



13B

DF897 CONTINUED 1

CC.0

NOTES

None.

Check the condition of the pressure regulator connector on the pump (MPROP). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3HI of component 1105. Contact the Techline if the resistance is less than 1.5 Ω or greater than 1 kΩ. Check the continuity and insulation from earth of the following connection: – 3HI between the components 120 and 1105. Check the + 12 V after relay supply on the following connection: – 37X of component 1105. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

CC.1

NOTES

None.

Check the condition of the pressure regulator connector on the pump (MPROP). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3HI of component 1105. Contact the Techline if the resistance is less than 1.5 Ω or greater than 1 kΩ. Check the continuity and insulation from + 12 V of the following connection: – 3HI between components 120 and 1105. Check the + 12 V after relay supply on the following connection: – 37X of component 1105. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-155



13B

DF897 CONTINUED 2

1.DEF


NOTES

Check the condition of the pressure regulator connector on the pump (MPROP). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3HI of component 1105. Contact the Techline if the resistance is less than 2

Ω or

greater than 6 Ω.

Check continuity and make sure there is no interference resistance on the following connection: – 3HI between the components 120 and 1105. Check the + 12 V after relay feed on the following connection: – 37X of component 1105. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-156




13B

PRESSURE REGULATOR CIRCUIT ON RAIL CO: Open circuit CC.0: Short circuit to earth CC.1: Short circuit to + 12 V 1.DEF: Internal electronic fault

Conditions for applying the fault finding procedure to stored faults: The fault reappears after: – the ignition is switched on, – the regulator is actuated using command AC225 Rail pressure regulator .

NOTES

Special notes: The rail pressure regulator (DRV) is built into the high-pressure rail. DF898 Rail pressure regulator circuit depends on the pressure regulator on the rail (DRV). If the fault is present: – the quantity of fuel injected limited and the engine speed limited to 3000 rpm: CO, CC.1, 1.DEF, – the level 2 warning light will be lit, – the engine stops immediately for CO, CC.1, 1.DEF, – the engine stops after a few minutes for CC.0, – the rail pressure is regulated by a regulator built into the pump (MPROP). Use bornier Elé. 1681 for all operations on the engine management computer connectors.


CO

NOTES

None.

Check the condition of the pressure regulator connector on the rail (DRV). Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Measure the resistance between connections 37X and 3RG of component 1198. Contact the Techline if the resistance is less than 2

Ω or

greater than 1 k Ω.

Check the continuity of the following connection: – 3RG between the components 120 and 1198. Check the + 12 V after relay feed on the following connection: – 37X of component 1198. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-157



13B

DF898 CONTINUED 1

CC.0

NOTES

None.


Ω or


Check the continuity and insulation against earth of the following connection: – 3RG between the components 120 and 1198. Check the + 12 V after relay feed on the following connection: – 37X of component 1198. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

CC.1

NOTES

None.


Ω or


Check the continuity and insulation from + 12 V of the following connection: – 3RG between the components 120 and 1198. Check the + 12 V after relay supply on the following connection: – 3FB of component 1198. If the connection or connections are faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-158



13B

DF898 CONTINUED 2

1.DEF


NOTES


Ω or

greater than 6 Ω.

Check for continuity and the absence of interference resistance on the following connection: – 3RG between the components 120 and 1198. Check the + 12 V after relay supply on the following connection: – 3FB of component 1198. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$480.mif V5


13B-159

EDC16CP33 Program No.: C4 Vdiag No.: 14


NOTES


13B

HEATER PLUGS NOT CONFIGURED 1.DEF: Configuration/Initialisation

Special notes: If the fault is present: – engine torque limited, – an engine speed below 1500 rpm. The level 1 warning light is illuminated. Conditions in which the fault appears: This fault only appears when the computer is reprogrammed after a change in Vdiag 14.

If the fault is present, show the status ET781 Heater plugs. If status ET781Heater plugs is STATUS 3, this means that the heater plugs are not configured in the injection computer. To determine the type of heater plugs fitted to the engine, a coloured ring can be identified on the plugs: – slow plugs have a black ring, – fast plugs have a white ring. To configure the type of plugs installed, use command SC036 Reinitialise programming and select HEATER PLUGS . If the fault is stored, clear the fault If the fault is still present and the status ET781 Heater Plugs is not STATUS 3, contact the Techline.

AFTER REPAIR


EDC16CP33_V14_DF1069 MR-410-X83-13B000$480.mif V5

13B-160

DIESEL INJECTION


NOTES

Fault finding – Conformity check

13B

Only carry out this conformity check after a full check with the diagnostic tool. The values shown in this conformity check are given as a guide. Test conditions: ENGINE OFF, IGNITION ON.

MAIN COMPUTER STATUSES AND PARAMETERS

Order

1

Function

Power supply

2

Parameter or state checked or action

PR074: Battery voltage

PR055:

Engine speed

PR190:

Engine idle speed setpoint.

Engine speed 3

4

Injection configuration

5

ET104:

PR035:

7

8

9

Speed signal

8.5 V < X < 15 V

In the event of a fault, test the battery and carry out a fault finding procedure on the charging circuit.

Indicates the engine's speed of rotation in rpm. Ignition on at 0 rpm

In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/engine speed consistency .

Injector code use

Atmospheric pressure

Indicates the atmospheric pressure in mbar. In the event of a fault, consult the The sensor is incorporated interpretation of fault DF200 in the computer. Atmospheric pressure sensor . Default value: 750 mbar.

Rail pressure

0 bar < X < 90 bar If the coolant temperature < 30 ˚C.

In the event of a fault, consult the interpretation of fault DF007 Rail pressure sensor circuit .

PR059:

Inlet air temperature

Indicates the inlet air temperature in ˚C PR059 ≈ PR064 cold engine

In the event of a fault, consult the interpretation of DF002 Air temperature sensor circuit.

PR064:

Coolant temperature

Indicates the engine coolant temperature in ˚C PR059 ≈ PR064 cold engine

In the event of a fault, consult the interpretation of DF001 Coolant temperature sensor circuit

PR038:

Temperature

Fault finding

YES = completed In the event of a fault, consult the NO = not completed This status is shown if interpretation of DF066 Injector programming of the injector code(s) . codes has been completed.

Pressure 6

Display and notes

PR089:

Vehicle speed

Gives the vehicle speed in If there is a fault, carry out a mph. This parameter is multiplex network test (see 88B, transmitted by the ABS Multiplex). computer. This signal is And then complete fault finding on transmitted to the injection the ABS computer (see 38C, by a wire connection. Anti-lock braking system) .

EDC16CP33_V0C_CCONF / EDC16CP33_V10_CCONF/ EDC16CP33_V14_CCONF / EDC16CP33_V16_CCONF MR-410-X83-13B000$528.mif V5

13B-161

DIESEL INJECTION


NOTES

13B



MAIN COMPUTER STATUSES AND PARAMETERS (CONTINUED)

Order

10

Function

Inlet

11

Safety

12

Alternator charge

MR-410-X83-13B000$528.mif V5

Parameter or state checked or action PR132:

ET077:

Air flow

Impact detected

PR002: Alternator charge

Display and notes

Fault finding

Indicates the inlet air flow in kg/h 0 kg/h

In the event of a fault, consult the interpretation for fault DF056 Air flow sensor circuit

If YES, run complete fault NO This signal is transmitted by finding on the airbag computer the airbag computer via the (see 88C, Airbag and multiplex network. pretensioners) Indicates the alternator charge in %

13B-162

In the event of a fault, refer to Technical Note 6014A, Checking the charge circuit

DIESEL INJECTION


NOTES


13B


AIR CIRC. SUB-FUNCTION (TURBO/INLET)

Order

Function

1


PR059:

Display and notes

Fault finding


Indicates the inlet air temperature in ˚C. PR059 ≈ PR064 cold engine

In the event of a fault, consult the interpretation of fault DF002 Air temperature sensor circuit.

Gives the engine coolant temperature in ˚C PR059 ≈ PR064 cold engine

In the event of a fault, consult the interpretation of DF001 Coolant temperature sensor circuit.

Temperature 2

PR064:

Coolant temperature

3

PR009:

Turbocharging pressure setpoint

6

PR041 = PR035 ± 0.20 bar

PR035:


Indicates the atmospheric pressure in mbar. The sensor is incorporated in the computer. Default value: 750 mbar.

In the event of a fault, consult the interpretation of DF200 Atmospheric pressure sensor .

PR132:

Air flow

Indicates the inlet air flow in kg/h 0 kg/h

Air circulation 7

8

MR-410-X83-13B000$528.mif V5

None

Turbocharging pressure

PR041:

5

bar

In the event of a fault, consult the interpretation of DF004 Turbocharging pressure sensor circuit.

Turbocharging 4

≈ 1

PR490:

PR747:

Engine air flow

Damper valve position

In the event of a fault, consult the interpretation of parameter DF056 Indicates the flow of air Air flow sensor circuit. entering the engine in mg/st 0.0 mg/st Indicates the damper valve position as a percentage Stationary PR747 = 0%

13B-163

In the event of a fault, consult the interpretation of faults DF645 Damper valve position regulation, DF646 Damper valve position sensor and DF323 Damper valve .

DIESEL INJECTION


NOTES


13B


AIR CIRC. SUB-FUNCTION (TURBO/INLET) (CONTINUED)

Order

Function

9


Display and notes

Fault finding

Air flow sensor voltage

0V
In the event of a fault, consult the interpretation of parameter DF056 Air flow sensor circuit.

Atmospheric PR079: pressure sensor voltage

0V
PR225:

10

Sensor feed 11

PR083:

Air temperature sensor voltage

0V
12

Turbocharging PR224: pressure sensor voltage

0V
13

14

15

16

Speed signal

Exhaust gas recirculation

Engine speed

Air circulation

MR-410-X83-13B000$528.mif V5

PR089:

PR051:

PR055:

PR023:

In the event of a fault, consult the interpretation of faults DF011 Sensor feed voltage no. 1, DF012 Sensor feed voltage no. 2 and DF013 Sensor feed voltage no. 3.

Vehicle speed

Gives the vehicle speed in mph. This parameter In the event of a fault, carry out a is transmitted by the multiplex network test (see 88 ABS computer. This B, Multiplex) then fault finding on signal is transmitted to the ABS computer (see 38C, the injection by a wire Anti-lock braking system ). connection.

EGR valve position feedback

In the event of a fault, consult the interpretation of faults DF209 Indicates the EGR valve EGR valve position sensor opening ratio circuit and DF647 EGR valve position regulation.

Engine speed

Gives the engine's rotational speed in rpm. With the ignition on at 0 rpm

In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/engine speed consistency .

Air flow difference

Indicates the difference between the inlet air flow and the air entering the engine. X > 400 mg/st

In the event of a fault, consult the interpretation of fault DF056 Air flow sensor circuit.

13B-164

DIESEL INJECTION



13B


NOTES

FUEL CIRCUIT SUB-FUNCTION

Order


Function

1

Engine speed PR055:

Engine speed

2

Speed signal PR089:

Vehicle speed

3

PR008:

Rail reference pressure

4

PR038:

Rail pressure

5

PR213:

Rail pressure loop difference

Pressure

6

PR017:

Fuel flow

Flow PR157: Fuel flow setpoint

7

8

Fuel regulation

PR484:

9

PR364:

10

PR405:

11

Flow correction

12

PR406:

PR365:

Fuel regulation solenoid valve OCR* Cylinder no. 1 fuel correction Cylinder no. 2 fuel flow correction Cylinder no. 3 fuel flow correction

Display and notes

In the event of a fault, refer to the interpretation of DF195 Camshaft sensor/engine speed consistency. If there is a fault, carry out a Gives the vehicle speed in mph. multiplex network test (see 88B, This parameter is transmitted Multiplex). by the ABS computer. This And then complete fault finding signal is transmitted to the on the ABS computer (see 38C, injection by a wire connection. Anti-lock braking system) . Indicates the theoretical pressure value for optimal None engine operation X = 250 ± 50 bar In the event of a fault, consult the interpretation of fault DF007 0 bar < X < 90 bar Rail pressure sensor circuit. Gives the engine's rotational speed in rpm. With the ignition on at 0 rpm

X = PR008 - PR038 With ignition on 0.0 mg/st With ignition on 0.0 mg/st Indicates the solenoid valve opening control as a percentage 0.0 %

X = 0.0 mg/st

Cylinder no. 4 fuel flow correction

Opening cyclic ratio signal

MR-410-X83-13B000$528.mif V5

Fault finding

13B-165

In the event of a fault, consult the interpretation of DF897 Pump pressure regulator circuit. None In the event of a fault, consult the interpretation of DF897 Pump pressure regulator circuit.

In the event of a fault, consult test 10 Incorrect injector operation

DIESEL INJECTION


NOTES


13B


FUEL CIRCUIT SUB-FUNCTION (CONTINUED)

Order

Function

13


Display and notes

Fault finding

0V
In the event of a fault, refer to the interpretation of DF013 Sensor feed voltage no. 3.

Fuel temperature PR082: sensor voltage

0V
In the event of a fault, consult the interpretation of DF098 Fuel temperature sensor circuit .

PR063: Fuel temperature

Gives the fuel temperature - 30 ˚C < X < 90 ˚C Safe value: 100 ˚C

In the event of a fault, consult the interpretation of DF098 Fuel temperature sensor circuit .



Indicates the current absorbed by the rail pressure regulator PR006 ≈ PR007

In the event of a fault, consult the interpretation of DF898 Rail pressure regulator circuit.

PR080:

Rail pressure sensor voltage

Sensor feed 14

15

Temperature Coolant temperature

16

PR064:

17

Rail pressure PR006: regulator current

18

Rail pressure Indicates the theoretical PR007: regulator current current absorbed by the setpoint rail pressure regulator

Current

19

MR-410-X83-13B000$528.mif V5

PR739:

Fuel flow solenoid valve current

Indicates the current absorbed by the fuel flow solenoid valve ~ 200 mA

13B-166

None

In the event of a fault, consult the interpretation of DF897 Pump pressure regulator circuit.


DIESEL INJECTION

13B



NOTES

DRIVER PARAMETERS SUB-FUNCTION

Function

Engine speed

Accelerator pedal position

Parameter or state Display and notes checked or action PR055: Engine speed Gives the engine's rotational speed in rpm. Engine idle With the ignition on at PR190: speed setpoint. 0 rpm

PR030:


Indicates the accelerator pedal position. If there is no pressure on the pedal X = 0%

Fault finding

In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/engine speed consistency . In the event of a fault, refer to the interpretation of DF196 Pedal sensor circuit gang 1 or DF198 Pedal sensor circuit gang 2.

Pedal Accelerator pedal released PR086: potentiometer 0.70 V < X < 0.80 V voltage gang 1

Sensor feed

NOTEThis relates to normal operation. Pedal Accelerator pedal released PR088: potentiometer 0.30 V < X < 0.40 V voltage gang 2 Each time ignition is switched Non-conformity of the clutch switch signal Clutch pedal on ET034 is NO and changes can cause "engine racing" during gear ET034: registered to YES when the clutch pedal changes. is depressed

Clutch pedal

Speed signal

PR089: Vehicle speed

Temperature

PR064:

Coolant temperature

Accelerator pedal

PR003:

Pedal load

Clutch pedal

ET405:

Clutch pedal switch

Oil oxidation

PR874:

Last service

Gives the vehicle speed in mph. This parameter is sent by the ABS computer via a wire connection. Shows the engine coolant temperature in ˚C Indicates the accelerator pedal load in % Clutch pedal depressed: ACTIVE Clutch pedal released: INACTIVE This parameter indicates the vehicle mileage the last time a service was carried out.

In the event of a fault, carry out a multiplex network test (see 88B, Multiplexing), and then complete fault finding on the ABS computer (see 38C, Anti-lock braking system) . In the event of a fault, consult the interpretation of DF001 Coolant temperature sensor circuit In the event of a fault, refer to the interpretation of DF196 Pedal sensor circuit gang 1 or DF198 Pedal sensor circuit gang 2. In the event of a fault, consult the interpretation of status ET405 Clutch pedal switch

-

(*) Pedal voltages - when cold, ignition on (average values ± 0.2 data provided as a guide). PR030


0%

100 %

138 %

PR086

Pedal potentiometer gang 1 voltage *

0.73 V

3.50 V

4.53 V

PR088

Pedal potentiometer gang 2 voltage *

0.36 V

1.74 V

2.26 V

MR-410-X83-13B000$528.mif V5

13B-167

DIESEL INJECTION


13B



NOTES

PREHEATING/IGNITION SUB-FUNCTION Parameter or state checked or action

Function

Preheating

Display and notes

ET007:

Prepostheating control

ACTIVE when the heater plugs are activated, depending on the computer programming

ET120:

Prepostheating signal.

Indicates whether ET120 is PRESENT or ABSENT

Fault finding

If there is a fault refer to the interpretation of faults DF017 "Pre-postheating unit control circuit" and DF1069 "Heater plugs not configured".

Heater plug type. ET781*

Heater plugs

STATUS 1: Slow plugs. STATUS 2: Fast plugs. STATUS 3: Not defined.

Speed signal

Engine speed

Vehicle speed

Gives the vehicle speed in In the event of a fault, carry out a multiplex mph. This parameter is network test (see 88B, Multiplex) , then sent by the ABS computer fault finding on the ABS computer via a wire connection. (see 38C, Anti-lock braking system).

Engine speed

Indicates the engine's speed of rotation in rpm. With the ignition on at 0 rpm

In the event of a fault, refer to the interpretation of DF195 Camshaft sensor/engine speed consistency .

PR064:

Coolant temperature



PR059:


Shows the inlet air temperature PR059 ≈ PR064 cold engine

In the event of a fault, consult the interpretation of DF002 Air temperature sensor circuit .

Engine

Indicates whether the engine is in + after ignition feed RUNNING or STOPPED

None

PR089:

PR055:

Temperature

Engine status

ET038:

* Only with Vdiag 14 and 16.

MR-410-X83-13B000$528.mif V5

13B-168

DIESEL INJECTION


NOTES


13B


EMISSION CONTROL/OBD SUB-FUNCTION

Order

1

Function

Engine speed


PR055:

Display and notes

In the event of a fault, refer to Indicates the engine's speed of rotation in rpm. the interpretation of fault DF195 With the ignition on at Camshaft sensor/engine 0 rpm speed consistency.

Engine speed

2

EGR valve opening PR005: setpoint

Indicates the required opening ratio for the EGR valve

3

EGR valve position feedback loop PR022: difference

Indicates the percentage difference between the setpoint and the EGR valve

PR051:


Indicates the EGR valve opening ratio

PR128:

First EGR valve offset

4


5 6

PR129:

Last EGR valve offset

7

ET587:

Cooling of recirculated exhaust gas

PR132:

Air flow

8

Flow

9

10

MR-410-X83-13B000$528.mif V5

PR490:

PR171:

Fault finding

In the event of a fault, consult the interpretation of faults DF209 EGR valve position sensor circuit and DF647 EGR valve position regulation.

Indicates the percentage ≈ 20 %

INACTIVE Depending on the computer programming

Indicates the inlet air flow In the event of a fault, consult in kg/h the interpretation of parameter PR132 = 0 kg/h DF056 Air flow sensor circuit.

Engine air flow

Air flow setpoint for EGR

Indicates the flow of air entering the engine in mg/st PR490 = 0 mg/st Indicates the required air flow for the EGR valve

13B-169

None

DIESEL INJECTION


NOTES

13B



EMISSION CONTROL/OBD SUB-FUNCTION (CONTINUED)

Order

11

12

13

14

Function

Sensor feed

Speed signal

Air flow

EGR valve


PR077:

PR089:

EGR valve position sensor voltage

Vehicle speed

PR023: Air flow difference

PR220:

Display and notes

Fault finding

EGR valve in closed position

In the event of a fault, consult the interpretation of faults DF209 EGR valve position sensor circuit and DF647 EGR valve position regulation.

Gives the vehicle speed in If there is a fault, carry out a mph. This parameter is multiplex network test (see 88B, transmitted by the ABS Multiplex). computer. This signal is And then complete fault finding transmitted to the injection on the ABS computer (see 38C, by a wire connection. Anti-lock braking system) . Indicates the difference In the event of a fault, consult between the inlet air flow the interpretation of fault DF056 and the air entering the Air flow sensor circuit . engine in mg/st.

Displays the opening cycle EGR valve OCR* ratio percentage for the EGR valve.

*OCR: Opening cycle ratio

MR-410-X83-13B000$528.mif V5

13B-170

None

DIESEL INJECTION


NOTES


13B


ENGINE COOLING SUB-FUNCTION

Order

Function

1

Coolant temperature

2


PR055:

Display and notes

Fault finding

Coolant temperature

Shows the engine coolant temperature in ˚C


Engine speed

Gives the engine's rotational speed in rpm. With the ignition on at 0 rpm

In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/engine speed consistency.

Indicates the engine's speed of rotation with air conditioning in rpm. With the ignition on at 0 rpm

NONE

0V

Engine speed

3

Engine speed PR053: requested by air conditioning

4

Coolant temperature sensor voltage

5

Sensor feed

Speed signal

6

PR084:

PR089:

Vehicle speed

Gives the vehicle speed If there is a fault, carry out a in mph. This parameter multiplex network test (see 88B, is transmitted by the Multiplex). ABS computer. This And then complete fault finding on signal is transmitted to the ABS computer (see 38C, the injection by a wire Anti-lock braking system) . connection.

ET143:

Low speed fan assembly relay control

In the event of a fault, consult the interpretation of DF018 Lowspeed fan assembly control circuit.

Relay control 7

MR-410-X83-13B000$528.mif V5

ET144:

High-speed fan assembly relay control

INACTIVE Cold engine with climate control switched off

13B-171

In the event of a fault, consult interpretation of DF019 Highspeed fan assembly control circuit.


DIESEL INJECTION

13B



NOTES

COLD LOOP SUB-FUNCTION Parameter or state checked or action

Function

Speed signal

PR089:

Vehicle speed

Coolant temperature

PR064:

Coolant temperature

PR055:

Engine speed

PR053:

Engine speed requested by air conditioning

Indicates the engine's speed of rotation with air conditioning in rpm. With the ignition on at 0 rpm

ET079:

Air conditioning present

YES or NO Depending on equipment

ET018:

Air conditioning request

Completed or Not completed

PR061:

Exterior air temperature

Gives the external air temperature in ˚C

PR290:

Air conditioning refrigerant pressure sensor voltage

Indicates the voltage of the refrigerant pressure sensor in volts

Air conditioning

Refrigerant pressure sensor PR037:

Air conditioning ET752: shut-off

MR-410-X83-13B000$528.mif V5

Refrigerant pressure

Air conditioning shut-off

Fault finding

Gives the vehicle speed in In the event of a fault, carry out a mph. This parameter is multiplex network test (see 88B, transmitted by the ABS Multiplex), then fault finding on the ABS computer. This signal is computer (see 38C, Anti-lock braking transmitted to the injection system) . by a wire connection. In the event of a fault, consult the Shows the engine coolant interpretation of DF001 Coolant temperature in ˚C temperature sensor circuit Indicates the engine's speed of rotation in rpm. With the ignition on at 0 rpm

Engine speed


Display and notes

In the event of a fault, refer to the interpretation of DF195 Camshaft sensor/engine speed consistency.

None

None

If there is a fault, refer to the interpretation of DF232 "Refrigerant pressure sensor circuit".

Indicates value of the If there is a fault, apply the fault finding refrigerant fluid pressure in procedure for DF232 "Refrigerant the system in bar, pressure sensor circuit" . If the fault is still present, replace the refrigerant 2bar < PR037 < 27 bar sensor Default value: 0 bar STATUS 1: battery voltage too low STATUS 2: refrigerant overpressure In the event of a fault, consult the interpretation of ALP9 The air STATUS 3: refrigerant underpressure conditioning does not work . STATUS 4: Engine running STATUS 5: Too much heat

13B-172


DIESEL INJECTION

13B



NOTES

HEATING SUB-FUNCTION

Function

Engine status

Engine speed

Temperature

Speed signal

Parameter or state checked or action ET038:

Engine

PR055:

Engine speed

PR064:

Coolant temperature

PR089:

Vehicle speed

Display and notes

Indicates whether the engine is in + after ignition feed RUNNING or STOPPED Indicates the engine's speed of rotation in rpm. With the ignition on at 0 rpm Indicates the engine coolant temperature in ˚C PR059 ≈ PR064 cold engine Gives the vehicle speed in mph. This parameter is transmitted by the ABS computer. This signal is transmitted to the injection by a wire connection.

Heating element No. 1 relay control ACTIVE or INACTIVE . Heating element Depending on the ET206: No. 2 relay control computer programming, air Heating element and coolant temperatures. ET207: No. 3 relay control

Fault finding

None

In the event of a fault, refer to the interpretation of DF195 Camshaft sensor/engine speed consistency . In the event of a fault, consult the interpretation of DF001 Coolant temperature sensor circuit In the event of a fault, carry out a multiplex network test (see 88B, Multiplex), then fault finding on the ABS computer (see 38C, Anti-lock braking system).

ET205:

Relay control

ET024:

Heating element request

ET025: ET026:

Heating element no. 1 request

ACTIVE or INACTIVE .

Heating element Depending on the no. 2 request computer programming, air Heating element and coolant temperatures. no. 3 request

Number of Number of heating ET780 *: heating elements elements*

0 or 4

* Except Vdiag 0C.

MR-410-X83-13B000$528.mif V5

None

13B-173

None

None

DIESEL INJECTION


NOTES

13B



CRUISE CONTROL/SPEED LIMITER SUB-FUNCTION

Order

Function


Display and notes

Fault finding

1

PR089:

Vehicle speed

If there is a fault, carry out a Gives the vehicle speed in multiplex network test (see mph. This parameter is 88B, Multiplex). transmitted by the ABS And then complete fault finding computer. This signal is on the ABS computer transmitted to the injection (see 38C, Anti-lock braking by a wire connection. system) .

2

PR130:

Cruise control setpoint

Indicates the cruise control cruising speed

Cruise control can only be activated for a speed. V > 18 mph (30 km/h)

INACTIVE: when no button is pressed.

In the event of a fault, refer to the interpretation of status ET042 Cruise control/ speed limiter .

CRUISE CONTROL: cruise control ON/OFF button pressed

Lights the green warning light on the instrument panel.

SPEED LIMITER: speed limiter ON/OFF button pressed

Lights the orange warning light on the instrument panel.

Cruise control/ speed limiter

3

ET042:

4

ET704:

Cruise control/ Speed limiter

Brake switch no. 1 Brake pedal depressed ACTIVE

Brake pedal position

5

MR-410-X83-13B000$528.mif V5

Brake pedal released INACTIVE ET705:

Brake switch no. 2

13B-174

Nonconformity of the brake signals and or the clutch switch signals can cause "engine racing" during gear changes. In the event of a fault, consult the interpretation of statuses ET704 Brake switch no. 1, ET705 Brake switch no. 2 and ET405 Clutch pedal switch

DIESEL INJECTION


13B



NOTES

CRUISE CONTROL/SPEED LIMITER SUB-FUNCTION (CONTINUED)

Order

6

Function

Clutch pedal position


ET405:

Clutch pedal switch

Display and notes

Fault finding

Clutch pedal depressed ACTIVE

In the event of a fault, consult the interpretation of status ET405 Clutch pedal switch.

Clutch pedal released INACTIVE STATUS 1:

Brake pedal depressed

STATUS 2:

Clutch pedal depressed

STATUS 3:

Suspend button pressed.

Driver deactivation ET556: of the cruise control/ STATUS 4: speed limiter

7

STATUS 5:

Deactivation of cruise control/ speed limiter

STATUS 1:

Automatic gearbox in defect mode.

STATUS 2:

Monitoring by injection computer

STATUS 4:

9

10

Cruise control/ speed limiter buttons

Speed restriction

11

MR-410-X83-13B000$528.mif V5

Gear lever in neutral position

Lack of correlation STATUS 6: between the request and the vehicle speed

Deactivation by ET557: cruise control/speed STATUS 3: limiter function

8

Traction control request

In the event of a fault, apply interpretation of status ET556 Driver deactivation of the cruise control/speed limiter .

Vehicle speed monitoring Cruise control or speed limiter monitoring

ET703:

Cruise control/ speed limiter buttons

Not detected Inactive Resume Suspend More Less

ET739:

Maximum authorised speed

Indicates the maximum speed authorised following speed restriction

Optional vehicle speed restriction

With Without

ET741:

13B-175

In the event of a fault, apply interpretation of status ET557 Deactivation by cruise control/speed limiter function.

In the event of a fault, consult the interpretation of DF051 Cruise control/ speed limiter function.

None

DIESEL INJECTION


NOTES


13B


START SUB-FUNCTION Order

Function

1


Computer + after ignition feed

Display and notes

Fault finding

Ignition on PRESENT

In the event of a fault, apply the interpretation of DF046 Battery voltage or DF151 Main relay circuit.

Power supply 2

3

4

Alternator charge

Engine status

5 6

Engine immobiliser

7

8

9

10

Starting

Safety

Preheating

MR-410-X83-13B000$528.mif V5

PR074:

Battery voltage

8.5 V < X < 15 V


PR002:

Alternator charge

Indicates the alternator charge in %

In the event of a fault, refer to Technical Note 6014A, Checking the charge circuit

ET038:

Engine


None

ET341:

Immobiliser code programmed

YES

ET076:

Starting

AUTHORISED

ET003:

Engine immobiliser

INACTIVE

ET238:

ET077:

ET120:

In the event of a fault, (see 87B, Passenger compartment connection unit, conformity check)

Synchronisation

NOT COMPLETED then becomes Completed when under the starter motor

Any phase difference between the camshaft sensor and the TDC sensor (chain slack or timing shift) will lead to the appearance of DF195 Camshaft sensor/engine speed consistency. When starting is not possible: the status while the engine is being cranked becomes COMPLETED.

Impact detected

NO This signal is transmitted by the airbag computer via the multiplex network.

If YES, run complete fault finding on the airbag computer (see 88C, Airbag and pretensioners)

Pre-postheating signal.

PRESENT upon activation of the heater plugs. According to computer programming.

In the event of a fault, consult the interpretation of fault DF017 Preheating unit control circuit .

13B-176

DIESEL INJECTION


NOTES


13B

Only carry out a conformity check after a complete check with the diagnostic tool. The values shown in this conformity check are given as a guide. Test conditions: ENGINE OFF, IGNITION ON.

PROTECTION SUB-FUNCTION:

Order

1

Function

Safety

2 3

Engine immobiliser

4

MR-410-X83-13B000$528.mif V5


Display and notes

Fault finding

If YES, run complete fault finding on the airbag computer (see 88C, Airbag and pretensioners).

ET077:

Impact detected


ET341:


YES

ET076:

Starting

AUTHORISED

ET003:

Engine immobiliser

INACTIVE

13B-177

In the event of a fault, (see 87B, Passenger compartment connection unit, conformity check).

DIESEL INJECTION


NOTES


13B

Only carry out this conformity check after a full check with the diagnostic tool. The values shown in this conformity check are given as a guide. Execution conditions: ENGINE WARM AT IDLE SPEED, FUNCTION TEMPERATURE > 80 ˚C, WITHOUT ELECTRICAL CONSUMER.

MAIN COMPUTER STATUSES AND PARAMETERS Order 1

Function

Power supply

2


4

Injection configuration

5

Pressure 6

PR074:

Battery voltage

8.5 V < X < 15 V

PR055:

Engine speed

PR190:


The difference between the engine speed and the idling speed setpoint should be less than 50 rpm

In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/engine speed consistency.

This status indicates whether or not the injector codes have been programmed. ET104: Injector code use YES = completed NO = not completed Indicates the atmospheric pressure in mbar. Atmospheric PR035: The sensor is built into the pressure computer. Default value: 750 mbar. Idle speed 270 bar ± 20 bar PR038: Rail pressure Full load 1700 bar ± 20 bar PR059:

7

Temperature PR064:

8

Speed signal

PR089:

9

Inlet

PR132:

10

Safety

ET077:

11

Alternator charge

PR002:

MR-410-X83-13B000$528.mif V5

Fault finding


Engine speed 3

Display and notes

In the event of a fault consult the interpretation of DF066 Injector code(s).

In the event of a fault, consult the interpretation of DF200 Atmospheric pressure sensor . In the event of a fault, consult the interpretation of fault DF007 Rail pressure sensor circuit.

In the event of a fault, consult the Shows the inlet air temperature interpretation of fault DF002 Air temperature sensor circuit. In the event of a fault, consult the Coolant Shows the engine coolant interpretation of DF001 Coolant temperature temperature in ˚C temperature sensor circuit. Gives the vehicle speed in mph. If there is a fault, carry out a multiplex This parameter is transmitted by network test (see 88B, Multiplex) . Vehicle speed the ABS computer. This signal is And then complete fault finding on transmitted to the injection by a the ABS computer (see 38C, Antilock braking system). wire connection. In the event of a fault, consult the Air flow Indicates the inlet air flow in kg/h interpretation of parameter DF056 Air flow sensor circuit . NO If YES, run complete fault finding on This signal is transmitted by the Impact detected the airbag computer (see 88C, airbag computer via the multiplex Airbag and pretensioners ). network. In the event of a fault, refer to Alternator charge Indicates the alternator charge in % Technical Note 6014A, Checking the charging circuit. Inlet air temperature

13B-178


NOTES

DIESEL INJECTION Fault finding – Conformity check

13B

Only carry out this conformity check after a full check with the diagnostic tool. The values shown in this conformity check are given as a guide. Execution conditions: ENGINE WARM AT IDLE SPEED, FUNCTION TEMPERATURE > 80 ˚C, WITHOUT ELECTRICAL CONSUMER. AIR CIRC. SUB-FUNCTION (TURBO/INLET)

Order

Function

1


PR059:


Display and notes

Fault finding

Shows the inlet air temperature

In the event of a fault, consult the interpretation of DF002 Air temperature sensor circuit.



Temperature 2

3

PR064:

Coolant temperature

PR009:


≈ 1

bar

Turbocharging 4

PR041:


PR041 = PR035 ± 0.20 bar

In the event of a fault, consult the interpretation of DF004 Turbocharging pressure sensor circuit. In the event of a fault, consult the interpretation of DF200 Atmospheric pressure sensor .

5

PR035:


Indicates the atmospheric pressure in mbar. The sensor is built into the computer. Default value: 750 mbar.

6

PR132:

Air flow

Do not interpret this value

Engine air flow

Indicates the inlet air flow entering the engine in mg/st.

Air circulation 7

8

MR-410-X83-13B000$528.mif V5

PR490:

PR747:

None


Indicates the damper valve position as a percentage PR747 = PR672

13B-179

In the event of a fault, consult the interpretation of parameter DF056 Air flow sensor circuit. In the event of a fault, consult the interpretation of faults DF645 Damper valve position regulation, DF646 Damper valve position sensor and DF323 Damper valve.


NOTES

DIESEL INJECTION

13B



AIR CIRC. SUB-FUNCTION (TURBO/INLET) (CONTINUED)

Order

Function

9

10

Sensor feed

11

12

13

Speed signal

14


15

16

Engine speed

Air circulation

MR-410-X83-13B000$528.mif V5


Display and notes

Fault finding

In the event of a fault, consult the interpretation of parameter DF056 Air flow sensor circuit.

PR225:


0V
PR079:

Atmospheric pressure sensor voltage

0V
PR083:

Air temperature sensor voltage

0V
PR224:

Turbocharging pressure sensor voltage

0V
In the event of a fault, consult the interpretation of faults DF011 Sensor feed voltage no. 1, DF012 Sensor feed voltage no. 2 and DF013 Sensor feed voltage no. 3.

PR089:

Vehicle speed

Gives the vehicle speed in mph. This parameter is transmitted by the ABS computer. This signal is transmitted to the injection by a wire connection.

If there is a fault, carry out a multiplex network test (see 88B, Multiplex). And then complete fault finding on the ABS computer (see 38C, Anti-lock braking system) .

PR051:


Do not interpret this value.

None

PR055:

Engine speed

The difference between the engine speed and the idling speed setpoint should be less than 50 rpm.

In the event of a fault, refer to the interpretation of DF195 Camshaft sensor/ engine speed consistency .

PR023:

Air flow difference

Indicates the difference between the inlet air flow and the air entering the engine in mg/st.

In the event of a fault, consult the interpretation of fault DF056 Air flow sensor circuit.

13B-180

DIESEL INJECTION



13B


NOTES

FUEL CIRCUIT SUB-FUNCTION Order

1


Function

Engine speed

Engine speed

PR089:

Vehicle speed

PR008:


4

PR038:

Rail pressure

5

PR213:


2

Speed signal

PR055:

3

Pressure

6

PR017:

Fuel flow

PR157:

Fuel flow setpoint

Flow 7

8

Display and notes

The difference between the In the event of a fault, consult engine speed and the idling the interpretation of fault DF195 speed setpoint should be Camshaft sensor/engine less than 50 rpm speed consistency. Gives the vehicle speed in If there is a fault, carry out a mph. This parameter is multiplex network test (see 88B, transmitted by the ABS Multiplex). computer. This signal is And then complete fault finding transmitted to the injection on the ABS computer (see 38C, by a wire connection. Anti-lock braking system) . Indicates the theoretical pressure value for optimal None engine operation X = 250 ± 50 bar ± 40 bar X = PR008 - PR038

In the event of a fault, consult the interpretation of fault DF007 Rail pressure sensor circuit.

Engine running PR017 = PR157

In the event of a fault, consult the interpretation of DF897 Pump pressure regulator circuit. None

Fuel regulation Indicates the solenoid valve Fuel regulation PR484: solenoid valve opening control as a OCR* percentage

9

PR364:

10

PR405:

Flow correction 11

12

Cylinder no. 1 fuel correction Cylinder no. 2 fuel flow correction

PR406:


PR365:


- 5 mg/stroke < X < 5 mg/ stroke

* Opening cyclic ratio signal

MR-410-X83-13B000$528.mif V5

Fault finding

13B-181

In the event of a fault, consult the interpretation of DF897 Pump pressure regulator circuit.

In the event of a fault, consult test 10 Incorrect injector operation.

DIESEL INJECTION


NOTES


13B


FUEL CIRCUIT SUB-FUNCTION (CONTINUED)

Order

Function

13


Display and notes

Fault finding

0V
In the event of a fault, refer to the interpretation of DF013 Sensor feed voltage no. 3.

PR080:


PR082:

Fuel temperature sensor voltage

0V
In the event of a fault, consult the interpretation of DF098 Fuel temperature circuit.

Fuel temperature

Gives the fuel temperature - 20 ˚C < X < 90 ˚C Safe value: 100 ˚C

In the event of a fault, consult the interpretation of DF098 Fuel temperature sensor circuit.

Gives the coolant temperature in ˚C.


Sensor feed 14

15

PR063:

Temperature 16

17

18

Current

19

MR-410-X83-13B000$528.mif V5

PR064:

Coolant temperature

PR006:

Rail pressure regulator current

PR007:

Rail pressure regulator current setpoint

PR739:


Indicates the current absorbed by the rail pressure regulator PR006 = PR007

Indicates the current absorbed by the fuel flow solenoid valve 700 mA ± 100 mA

13B-182

In the event of a fault, consult the interpretation of DF898 Rail pressure regulator circuit. None In the event of a fault, consult the interpretation of DF897 Pump pressure regulator circuit.



13B


NOTES

DRIVER PARAMETERS SUB-FUNCTION Parameter or state checked or action

Function

PR055:

Engine speed

PR190:


Engine speed

Accelerator PR030: pedal position

PR086:

Sensor feed PR088:


Indicates the accelerator pedal position. If there is no pressure on the pedal X = 0 %

Pedal Accelerator pedal released released potentiometer 0.39 V ± 0.03 voltage gang 2

ET034:

Clutch pedal registered

Speed signal

PR089:

Vehicle speed

Fault finding

The difference between In the event of a fault, refer to the idling speed and its setpoint interpretation of fault DF195 Camshaft should be less than 50 rpm. sensor/engine speed consistency .

Pedal Accelerator pedal released released potentiometer 0.74 V ± 0.03 voltage gang 1

Clutch pedal

MR-410-X83-13B000$528.mif V5

Display and notes

In the event of a fault, refer to the interpretation of DF196 Pedal sensor circuit gang 1 or DF198 Pedal sensor circuit gang 2.

IMPORTANT This corresponds to normal operation.

Each time ignition is switched on ET034 is NO Non-conformity of the clutch switch signal and changes to YES when can cause "engine racing" during gear the clutch pedal is changes. depressed Gives the vehicle speed in If there is a fault, carry out a multiplex mph. This parameter is network test (see 88B, Multiplex). transmitted by the ABS And then complete complete fault finding on on the computer. This signal is ABS computer (see 38C, Anti-lock transmitted to the injection braking system) . by a wire connection.

13B-183


DIESEL INJECTION

13B



NOTES

DRIVER PARAMETERS SUB-FUNCTION (CONTINUED) Parameter or state checked or action

Function

Temperature

PR064:

Coolant temperature

Accelerator pedal

PR003:

Pedal load

Clutch pedal

ET405:

Clutch pedal switch

Oil oxidation

PR874:

Last service

Display and notes

Shows the engine coolant temperature in ˚C Indicates the accelerator pedal load in % Clutch pedal depressed: ACTIVE Clutch pedal released: INACTIVE This parameter indicates the vehicle mileage the last time a service was carried out.

Fault finding

In the event of a fault, f ault, consult the interpretation of DF001 Coolant temperature sensor circuit In the event of a fault, f ault, consult the interpretation of DF196 Pedal sensor circuit gang 1 or DF198 Pedal sensor circuit gang 2. In the event of a fault, f ault, consult the interpretation of status ET405 Clutch pedal switch.

-

(*) Pedal voltages - when cold, ignition on (average values ± 0.2 data provided as a guide). PR030

Accelerator pedal position position

PR086

Pedal potentiometer gang 1 voltage * Pedal potentiometer gang 2 voltage *

PR088

MR-410-X83-13B000$528.mif V5

13B-184

0%

100 %

138 %

0.73 V

3.50 V

4.53 V

0.36 V

1.74 V

2.26 V

DIESEL INJECTION


13B



NOTES

PREHEATING/IGNITION SUB-FUNCTION

Function

Preheating


Engine speed

ET007:

Prepostheating control

ET120:

Prepostheating signal

Indicates whether status is PRESENT or ABSENT.

Heater Plugs

Heater plug type STATUS 1: Slow plugs STATUS 2: Cold plugs STATUS 3: Not defined

Vehicle speed

Indicates the vehicle speed in mph (km/h). This parameter is transmitted by the ABS computer. This signal is transmitted to the injection by a wire connection.

In the event of a fault, carry out a multiplex network test (see 88B, Multiplex), then fault finding on the ABS computer (see 38C, Anti-lock braking system) .

PR055:

Engine speed

The difference between idling speed and its setpoint should be less than 50 rpm.


PR064:

Coolant temperature


In the event of a fault, f ault, consult the interpretation of DF001 Coolant temperature sensor circuit

PR059:


Shows the inlet air temperature

In the event of a fault, f ault, consult the interpretation of DF002 Air temperature sensor circuit.

Engine

Indicates whether the engine is in + after ignition feed , RUNNING or STOPPED

None

PR089:

Temperature

Engine status

ET038:

* Only with Vdiag 14 and 16.

MR-410-X83-13B000$528.mif V5

Fault finding

ACTIVE when the heater plugs are activated According to computer computer programming

ET781*:

Speed signal

Display and notes

13B-185

In the event of a fault, f ault, consult the interpretation of DF017: Prepostheating postheating control circuit.

DIESEL INJECTION


NOTES


13B


EMISSION CONTROL/OBD SUB-FUNCTION

Order

Function


Display and notes

Fault finding

In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/ engine speed consistency .

PR055:

Engine speed

The difference between the idle speed and its setpoint should be less than 50 rpm

PR005:

EGR valve opening setpoint

Do not interpret this value

3

PR022:

EGR valve position feedback loop difference

4

PR051:


PR128:


PR129:


7

ET587:


ACTIVE or INACTIVE depending on computer program

8

PR132:

Air flow

± 50 mg/stroke

PR490:

Engine air flow

Indicates the inlet air flow in mg/st

PR171:


Do not interpret this value.

None

EGR valve in the closed position 1
In the event of a fault, f ault, consult the interpretation of faults DF209 EGR valve position sensor circuit and DF647 EGR valve position regulation.

1

Engine speed

2

5


6

9

Flow

10

11

12

Sensor feed

Speed signal

MR-410-X83-13B000$528.mif V5

PR077:

PR089:


Vehicle speed

In the event of a fault, f ault, consult the interpretation of faults DF209 EGR valve Do not interpret this value position sensor circuit and DF647 EGR valve position regulation. These 2 values should be close together and approximately 20 % ±5%

In the event of a fault, f ault, consult the interpretation of DF304 EGR by-pass circuit. In the event of a fault, f ault, consult the interpretation of parameter DF056 Air flow sensor circuit .

Gives the vehicle speed If there is a fault, carry out a in mph. This parameter is multiplex network test (see transmitted by the ABS 88B, Multiplex). computer. This signal is And then complete complete fault transmitted to the finding on the ABS injection by a wire computer (see 38C, Anticonnection. lock braking system).

13B-186

DIESEL INJECTION


NOTES

13B



EMISSION CONTROL/OBD SUB-FUNCTION (CONTINUED)

Order

13

14

Function

Air flow

EGR valve


PR023:

PR220:

Display and notes

Fault finding

Air flow difference

Indicates the difference between the inlet air flow and the air entering the engine in mg/st.

In the event of a fault, consult the interpretation of fault DF056 Air flow sensor circuit .

EGR valve OCR*

Displays the opening cycle ratio percentage for the EGR valve.

None

*OCR: Opening cycle ratio

MR-410-X83-13B000$528.mif V5

13B-187

DIESEL INJECTION


NOTES


13B


ENGINE COOLING SUB-FUNCTION

Order

1

Function

Coolant temperature

2


Display and notes

Fault finding

Coolant temperature



PR055:

Engine speed


In the event of a fault, refer to the interpretation of fault DF195 Camshaft sensor/ engine speed consistency .

PR053:


Indicates the engine's speed of rotation with air conditioning in rpm. 0 rpm if air conditioning off.

None


0V

PR089:

Vehicle speed


If there is a fault, carry out a multiplex network test (see 88B, Multiplex). And then complete fault finding on the ABS computer (see 38C, Anti-lock braking system).

ET143:


ET144:


PR064:

Engine speed 3

4

5

Sensor feed

Speed signal

6

PR084:

Relay control 7

MR-410-X83-13B000$528.mif V5

(air conditioning off) INACTIVE OR ACTIVE Depending on engine coolant temperature

13B-188

In the event of a fault, consult the interpretation of DF018 Low-speed fan assembly control circuit. In the event of a fault, consult interpretation of DF019 High-speed fan assembly control circuit.


DIESEL INJECTION

13B



NOTES

COLD LOOP SUB-FUNCTION

Function

Speed signal

Coolant temperature


In the event of a fault, carry out a multiplex network test (see 88B, Multiplex), then fault finding on the ABS computer (see 38C, Anti-lock braking system) .

PR089:

Vehicle speed

PR064:

Coolant temperature



Engine speed




Indicates the engine's speed of rotation with air conditioning in rpm. 0 rpm if air the conditioning is off.

ET079:


YES or NO Depending on equipment

ET018:


Completed or Not completed

PR061:


Gives the external air temperature in ˚C

Engine speed PR053:

Air conditioning

MR-410-X83-13B000$528.mif V5

Fault finding


PR055:


Display and notes

13B-189

None

None



13B


NOTES

COLD LOOP SUB-FUNCTION (CONTINUED)

Function

Refrigerant pressure sensor Refrigerant pressure sensor


MR-410-X83-13B000$528.mif V5


Air conditioning refrigerant pressure sensor voltage

PR037:


ET752:


Display and notes

Fault finding

Indicates the voltage of the refrigerant pressure sensor in volts

In the event of a fault, refer to the interpretation for fault DF232 Refrigerant pressure sensor circuit .

Indicates value of the refrigerant fluid pressure in the system in bar, 2 bar < PR037 < 27 bar Default value: 0 bar STATUS 1 : battery voltage too low STATUS 2: refrigerant overpressure STATUS 3: refrigerant underpressure STATUS 4: Engine running STATUS 5: Too much heat

If there is a fault, apply the fault finding procedure for DF232 "Refrigerant pressure sensor circuit" . If the incident persists, replace the refrigerant sensor.

13B-190

In the event of a fault, consult the interpretation of ALP9 The air conditioning does not work .

DIESEL INJECTION


NOTES

13B



HEATING SUB-FUNCTION

Function

Engine status

Engine speed

Temperature

Speed signal

Relay control


PR055:

Engine speed

PR064:

Coolant temperature

PR089:

Vehicle speed

ET205:

Heating element No. 1 relay control


In the event of a fault, refer to the interpretation of DF195 Camshaft sensor/engine speed consistency. In the event of a fault, consult the interpretation of DF001 Coolant temperature sensor circuit

Depending on the computer programming, air and coolant temperatures.

None

ACTIVE or INACTIVE.

0 or 4

* Except Vdiag 0C.

MR-410-X83-13B000$528.mif V5

None

ACTIVE or INACTIVE.

Heating element no. 2 request Heating element ET026: no. 3 request Number of ET780 *: heating elements* ET025:

Fault finding

Indicates the vehicle speed in mph (km/h). In the event of a fault, carry out a This parameter is multiplex network test (see 88B, transmitted by the ABS Multiplex), then fault finding on the computer. This signal is ABS computer (see 38C, Anti-lock transmitted to the injection braking system). by a wire connection.

Depending on the computer programming, air and coolant temperatures.

ET024:

Number of heating elements

Indicates whether the engine is in + after ignition feed, RUNNING or STOPPED The difference between the idle speed and its setpoint should be less than 50 rpm

Heating element No. 2 relay control Heating element No. 3 relay control Heating element no. 1 request

ET206: ET207:

Heating element request

Engine

Display and notes

13B-191

None

None

DIESEL INJECTION


NOTES

13B



CRUISE CONTROL/SPEED LIMITER SUB-FUNCTION

Order

Function

1

2


Display and notes

Fault finding

If there is a fault, carry out a multiplex network test (see 88B, Multiplex). And then complete fault finding on the ABS computer (see 38C, Anti-lock braking system) .

PR089:

Vehicle speed


PR130:


Indicates the cruise control cruising speed

Cruise control can only be activated for a speed. V > 18 mph (30 km/h)

INACTIVE : when no button is pressed.

In the event of a fault, refer to the interpretation of status ET042 Cruise control/ speed limiter .

CRUISE CONTROL : cruise control ON/OFF button pressed

Lights the green warning light on the instrument panel.

SPEED LIMITER: speed limiter ON/OFF button pressed

Lights the orange warning light on the instrument panel.

Cruise control/ speed limiter

3

MR-410-X83-13B000$528.mif V5

ET042:

Cruise control/ Speed limiter

13B-192

DIESEL INJECTION


NOTES

13B



CRUISE CONTROL/SPEED LIMITER SUB-FUNCTION (CONTINUED) Order 5 6

7

Function

Brake pedal position

Clutch pedal position

8


Display and notes

Fault finding

Non-conformity of the brake signals and or the clutch switch signals can cause the engine to race during gear changes.

ET704:

Brake switch no. 1

Brake pedal depressed ACTIVE

ET705:

Brake switch no. 2

Brake pedal released INACTIVE

ET405:

ET556:

Clutch pedal switch

Driver deactivation of the cruise control/speed limiter

Deactivation of cruise control/ speed limiter

Clutch pedal depressed ACTIVE Clutch pedal released INACTIVE STATUS 1: STATUS 2:

Brake pedal depressed Clutch pedal depressed

STATUS 3:

Suspend button pressed. Traction control request Gear lever in neutral position. Inconsistency between the request and the vehicle speed. Automatic transmission in defect mode. Monitoring by injection computer. Vehicle speed monitoring. Cruise control or speed limiter monitoring Not detected Inactive Resume Cancel Plus Minus

STATUS 4: STATE 5: STATE 6: STATUS 1:

Deactivation by cruise control/ ET557: speed limiter function

9

STATUS 2: STATUS 3: STATUS 4:

10

Cruise control/ speed limiter ET703: buttons

11

ET739:

Speed restriction 12

MR-410-X83-13B000$528.mif V5

ET741:

Cruise control/ speed limiter buttons Maximum authorised speed Optional vehicle speed restriction

In the event of a fault, consult the interpretation of statuses ET704 Brake switch no. 1, ET705 Brake switch no. 2 and ET405 Clutch pedal switch

In the event of a fault, apply interpretation of status ET556 Driver deactivation of the cruise control/speed limiter.

In the event of a fault, apply interpretation of status ET557 Deactivation by cruise control/speed limiter function.

In the event of a fault, consult the interpretation of fault DF051 Cruise control/speed limiter function.

Indicates the maximum speed authorised following speed restriction None With None

13B-193

DIESEL INJECTION


NOTES


13B


START SUB-FUNCTION Order

Function

1


Display and notes

Fault finding

Running PRESENT

In the event of a fault, apply the interpretation of DF046 Battery voltage or DF151 Main relay circuit.

Computer + after ignition feed

Power supply 2

3

4

Alternator charge

Engine status

5 6

Engine immobiliser

7

8

9

10

Starting

Safety

Preheating

MR-410-X83-13B000$528.mif V5

PR074:

Battery voltage

8.5 V < X < 15 V

PR002:

Alternator charge

Indicates the alternator charge in %

ET038:

Engine


ET341:


YES

ET076:

Starting

AUTHORISED

ET003:

Engine immobiliser

INACTIVE

ET238:

ET077:

ET120:

Synchronisation

Impact detected

Pre-postheating signal

NOT COMPLETED then becomes Completed when under the starter motor

In the event of a fault, test the battery and carry out a fault finding procedure on the charging circuit. In the event of a fault, refer to Technical Note 6014A, Checking the charging circuit. None

In the event of a fault, (see 87B, Passenger compartment connection unit, conformity check) Any phase difference between the camshaft sensor and the TDC sensor (chain slack or timing shift) will lead to the appearance of DF195 Camshaft sensor/engine speed consistency. When starting is not possible: the status while the engine is being cranked becomes COMPLETED.

If YES, run complete fault NO This signal is transmitted finding on the airbag computer by the airbag computer (see 88C, Airbag and via the multiplex network. pretensioners) . PRESENT when the heater plugs are switched on, depending on the computer program.

13B-194

In the event of a fault, consult the interpretation of fault DF017: Pre-postheating control circuit .


NOTES


13B


PROTECTION SUB-FUNCTION:

Order

1

Function

Safety

2 3

Engine immobiliser

4

MR-410-X83-13B000$528.mif V5


Display and notes

Fault finding

If YES, run complete fault finding on the airbag computer (see 88C, Airbag and pretensioners)

ET077:

Impact detected


ET341:


NO

ET076:

Starting

AUTHORISED

ET003:

Engine immobiliser

INACTIVE

13B-195

In the event of a fault, (see 87B, Passenger compartment connection unit, conformity check)

DIESEL INJECTION


Fault finding – Status summary table

Tool status

Diagnostic tool title

ET001

+ After ignition computer feed

ET003

Engine immobiliser

ET007

Pre-postheating control

ET018


ET024


ET025


ET026


ET034

Clutch signal registered

ET038

Engine

ET042

Cruise control/speed limiter

ET076

Starting

ET077

Impact detected

ET079


ET104

Injector code use

ET120

Pre-postheating signal

ET143


ET144


ET205

Heating element no. 1 relay control

ET206


ET207


ET238

Synchronisation

ET341


ET405

Clutch pedal switch

ET556

Driver deactivation of the cruise control/speed limiter

ET557

Deactivation by cruise control/speed limiter function

ET587


ET703

Cruise control/speed limiter buttons

ET704

Brake switch no. 1

ET705

Brake switch no. 2

ET739

Maximum authorised speed

ET741

Optional vehicle speed restriction

ET752


ET780 *

Number of heating elements*

ET781 **

Heater plugs

* Except Vdiag 0C. **Only withVdiag 14 and 16. MR-410-X83-13B000$576.mif V5

13B-196

13B


DIESEL INJECTION Fault finding – Interpretation of statuses

13B

COMPUTER + AFTER IGNITION FEED ET001

NOTES

ABSENT

See Wiring Diagram Technical Note for Trafic II phase 2 .

NOTES

Ignition on

If the ignition is not switched on, status ET001 should be "ABSENT" . As soon as the ignition is switched on, the computer should be supplied with power. Status ET001 becomes "PRESENT". If this status remains locked on ABSENT, follow the procedure below: – Check the condition of the fuse in the engine fuse and relay box. – Check for continuity and the absence of interference resistance on the following connection: – connection code 3FAC, between components 120 and 983. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Check the condition of the connector of component 120. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. If the fault is still present, contact Techline.

PRESENT

NOTES

Ignition on

Normal operating condition. The computer is correctly supplied after the ignition has been switched on.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Switch off the ignition and carry out a road test followed by a test with the diagnostic tool .

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13B-197



13B

PRE-POSTHEATING UNIT CONTROL ET007

NOTES

ACTIVE

See Trafic II phase 2 Wiring Diagrams Technical Note .

When the ignition is switched on, status ET007 should be ACTIVE for a time that varies according to the engine coolant temperature. Both the relay and the heater plugs are supplied. After starting, the status should remain ACTIVE for a variable period according to the engine coolant temperature. This is postheating. If ET007 is INACTIVE when the ignition is switched on, check: – Supply fuse F1B of component 777. – The supply to components 680, 681, 682, 683 following relay actuation, and their connections. Important: The plugs feed voltage varies on this engine. – The continuity and absence of interference resistance on the following connections: – 37AB between components 257 and 682, – 37AA between components 257 and 681, – 37Z between components 257 and 680, – 37AC between components 257 and 683. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the wiring, otherwise replace it. – Check that component 257 is correctly connected and in good condition. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repairs) , repair the connector; otherwise replace the wiring. If the vehicle starts, postheating is ended and status ET007 remains ACTIVE during the engine operating phase, consult the interpretation of faults DF017 Pre-postheating unit control circuit and DF025 Pre-postheating unit diagnostic line .

INACTIVE

If the vehicle does not start, the status remains INACTIVE and preheating was not executed when the ignition was switched on or during the starting phase. Check the continuity and for the absence of interference resistance on the following connections: – 3FY, between components 120 and 257. – 3FF, between components 120 and 257. Check the + 12 V battery feed to the pre-postheating unit. – Connection BP17 of component 257. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the wiring, otherwise replace it.

AFTER REPAIR

Deal with any other faults. Clear the fault memory. Switch off the ignition and carry out a road test followed by a test with the diagnostic tool.


13B-198



13B

CLUTCH SIGNAL DETECTED ET034

NOTES

NO

YES

See Trafic II phase 2 Wiring Diagrams Technical Note .

When the vehicle ignition is switched on without the clutch pedal being depressed, status ET034 Clutch signal registered is NO. When the driver depresses the clutch pedal, status ET034 Clutch signal registered becomes YES until the ignition is next switched off. If NO appears despite the clutch pedal being depressed, carry out the following operations: – Remove the clutch switch, check the insulation between connections MJ and 145X of component 675, with the switch in the rest position. – Repeat this operation with the switch engaged and check the continuity between the two connections. If both these checks are not correct, replace the clutch switch. Check the condition of the clutch switch connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repairs), repair the connector; otherwise replace the wiring. Then check the continuity and absence of interference resistance of the following connection: – connection code 145X between components 120 and 675 – Check for complete earthing on connection MJ of component 675. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-199



13B

CRUISE CONTROL/SPEED LIMITER ET042

NOTES


LIMITER

When the driver presses the speed limiter switch, status ET042 cruise control/speed limiter becomes SPEED LIMITER.

CRUISE CONTROL

When the driver presses the cruise control switch, status ET042 cruise control/speed limiter becomes CRUISE CONTROL. If SPEED LIMITER appears when the driver presses the cruise control button, carry out the following operations: Check the + 12 V after relay feed on the following connection: – AP3 of component 1081 . With the button in the rest position, check the insulation: between AP3 and 3FX of component 1081. between AP3 and 3PD of component 1081. – Check the continuity between AP3 and 3FX of component 1081 in cruise control position. – Check the continuity between AP3 and 3PD of component 1081 in the speed limiter position. Replace the cruise control/speed limiter On/Off control if necessary. Check the continuity and absence of interference resistance of the following connections: – 3FX between components 120 and 1081. – 3PD between components 120 and 1081. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-200



13B

STARTING ET076

PROHIBITED

Refer to the passenger compartment connection unit fault finding procedure (see 87B Passenger Compartment Connection Unit) .

AUTHORISED

In this case, the engine management authorises start-up and the fault is therefore related to another engine component which is involved in the start-up phase, or it is related to other upstream components; refer to Passenger compartment Connection Unit (see 87B, Passenger Compartment Connection Unit ).

AFTER REPAIR



13B-201



13B

INJECTOR CODE USE ET104

NO

YES

FAULTY

AFTER REPAIR

– If status ET104 Injector code use is NO, program the injector codes using: either command SC002 Enter injector codes, or command SC001 Write saved data when replacing with a blank computer or after reprogramming (Consult the procedures defined in the Interpretation of commands section). When injector code programming is complete, status ET104 Injector code use changes to YES. – If status ET104 Injector code use is FAULTY, program the injector codes using: either command SC002 Enter injector codes, or command SC001 Write saved data when replacing with a new computer or after reprogramming. (Consult the procedures defined in the Interpretation of commands section).



13B-202



13B

PRE-POSTHEATING SIGNAL ET120

NOTES

PRESENT

ABSENT

AFTER REPAIR

Check the battery voltage.

Status ET120 is PRESENT when preheating is complete. If status ET120 permanently remains ABSENT, consult the interpretation of fault DF025 Pre-postheating unit diagnostic line. Status ET120 is ABSENT until pre-postheating ends.



13B-203



13B

LOW-SPEED FAN ASSEMBLY RELAY CONTROL ET143

NOTES

If the vehicle is fitted with air conditioning, the fan assembly electrical circuit includes 2 relays . The 1st speed cooling fan assembly relay will be actuated when the engine coolant temperature exceeds 99 ˚C and its function will be to cool the engine so that the engine temperature does not exceed 102 ˚C. If the engine coolant temperature exceeds 102 ˚C, the 2nd speed cooling fan will be actuated and the engine cooling fan will operate more quickly. See Trafic II phase 2 Wiring Diagrams Technical Note.

Important If the vehicle is equipped with air conditioning, the engine cooling fan will run at 1st speed as soon as the air conditioning compressor is activated. It is possible to actuate the low-speed fan assembly using command AC154 LOW-SPEED FAN ASSEMBLY . ACTIVE

When the coolant reaches 99 ˚C, the injection computer commands the low-speed fan assembly relay, and status ET143 becomes ACTIVE. The relay then supplies the fan assembly and the cooling fan switches on. If status ET143 is ACTIVE, but the cooling fan is not running, perform the following operations: – Check the condition of fuse F2F of the engine relay/fuse box. Disconnect the low-speed and high-speed relays, check that they are operating correctly and check the condition of the relay mounting connectors. See Wiring Diagrams Trafic II phase 2 . If one of the connectors is faulty and there is a repair method ( see Technical Note 6015A, Repairing electrical wiring, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the + 12 V after relay feed on the following connection: – 37X of component 335. Check continuity and make sure there is no interference resistance on the following connection: – 49L between components 335 and 321. Check continuity and make sure there is no interference resistance on the following connection: – 49R between components 905 and 321. Check continuity and make sure there is no interference resistance on the following connection: – 49J between components 335 and 120. – Check for complete earthing on connection MW of component 262.

If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the wiring, otherwise replace it. INACTIVE

AFTER REPAIR

If the engine temperature is lower than 99 ˚C , the engine cooling fan cannot switch on and the lowspeed fan relay of the cannot be run. Status ET143 must therefore be INACTIVE when the control relay and the engine cooling fan are not supplied.


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13B-204



13B

HIGH-SPEED FAN ASSEMBLY RELAY CONTROL ET144

NOTES

If the vehicle is not fitted with air conditioning, the low-speed fan assembly relay is not present. The circuit therefore only contains a single control relay to supply the engine cooling fan. The engine cooling fan will thus have only one operating speed. It is possible to actuate the high-speed fan assembly using command AC153 HIGHSPEED FAN ASSEMBLY.


ACTIVE

When the coolant reaches 102 ˚C, the injection computer commands the fan assembly relay, and status ET144 becomes ACTIVE. The relay then supplies the cooling fan. If status ET144 is ACTIVE, but the cooling fan is not running, perform the following operations: – Check the condition of fuse F2F of the engine relay/fuse box. – Disconnect component 336, check its operation and the condition of the relay mounting connectors (see Wiring Diagrams Trafic II phase 2 ). If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repairs) , repair the connector; otherwise replace the wiring. Check the + 12 V after relay feed on the following connection: – 37X of component 336. Check for continuity and the absence of interference resistance on the following connection: – 49K between components 336 and 120. Check for continuity and the absence of interference resistance on the following connection: – 49R between components 336 and 905. – Check for complete earthing on connection MW of component 905. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it.

INACTIVE

AFTER REPAIR

When the cooling request is no longer executed by the injection computer, status ET144 becomes INACTIVE . The fan assembly should then switch off.



13B-205



13B

SYNCHRONISATION ET238

Synchronisation is carried out during the engine starting phase. The camshaft position sensor and the TDC sensor are synchronised. This synchronisation, once performed, allows the computer to identify cylinder no. 1, and to recognise the exact top dead centre position of this cylinder. Synchronisation also allows the computer to determine the injection programming. COMPLETED

Status ET238 is COMPLETED when the engine is started. The computer has identified cylinder no. 1 and has identified the exact top dead centre position. Injection phasing and engine management are now possible, and the engine should be working properly.

NOT COMPLETED

Status ET238 is NOT COMPLETED when the engine has been stopped and + after ignition feed is on. If status ET238 remains NOT COMPLETED after an attempted start, consult the interpretation of fault DF195 camshaft sensor/engine speed consistency .

AFTER REPAIR



13B-206



13B

IMMOBILISER CODE PROGRAMMED ET341

YES

NO

Status ET341 is "YES" if dialogue is possible between the UCH computer and the injection computer and the key code is recognised. The engine is only authorised to start if the code is recognised by the UCH computer and if status ET003 Immobiliser is INACTIVE . Status ET341 is NO if dialogue is not possible between the UCH computer and the injection computer (status ET003 Immobiliser remains ACTIVE ). This fault may be caused by incorrect key programming or a lack of key programming. In this case, refer to the UCH fault finding procedure (see 87B, Passenger compartment connection unit, Configurations and programming ) and follow the key programming procedure. If the key programming is not the cause, test the multiplex network and check that the dialogue between the UCH and the injection computer is possible. If dialogue is not established, contact the Techline.

AFTER REPAIR



13B-207



13B

CLUTCH PEDAL SWITCH ET405

NOTES

Special notes: Perform the tests if the statuses are not consistent with the system operating programming.

See Trafic II phase 2 Wiring Diagrams Technical Note.

INACTIVE

Check the condition and fitting of the clutch switch Remove the clutch switch, check the insulation between connections MJ and 145X of component 675, with the switch in the rest position. – Repeat this operation with the switch engaged, and check the continuity between the two connections. If both these checks are not correct, replace the clutch switch. Then check the continuity and absence of interference resistance of the following connection: – 145X between components 120 and 675. – Check for complete earthing on connection MJ of component 675. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair) , repair the wiring, otherwise replace it.

ACTIVE

Check the condition and fitting of the clutch pedal switch. Remove the clutch switch, check the insulation between connections MJ and 145X of component 675, with the switch in the rest position. – Repeat this operation with the switch engaged, and check the continuity between the two connections. If both these checks are not correct, replace the clutch switch.

AFTER REPAIR



13B-208



13B

DRIVER'S DEACTIVATION OF THE CRUISE CONTROL/SPEED LIMITER ET556

NOTES

STATUS 1

Cruise control remains deactivated as long as the vehicle speed does not exceed a speed V >18 mph (30 km/h). IMPORTANT: Certain deactivations are stored by the computer. To reinitialise this status, run RZ001 Fault memory

BRAKE PEDAL DEPRESSED The cruise control function is deactivated each time the brake pedal is depressed. Status ET556 becomes STATUS 1, when the vehicle is being driven, with cruise control active and the brake pedal depressed. Status ET556 becomes STATUS 1 without depressing the brake pedal; refer to the interpretation of statuses ET704 Brake switch no. 1 and ET705 Brake switch no. 2.

STATUS 2

CLUTCH PEDAL DEPRESSED The cruise control function is deactivated if the gearbox is no longer coupled to the engine (clutch pedal depressed). Status ET556 becomes STATUS 2 when the vehicle is being driven, with cruise control active and the clutch pedal depressed. Status ET556 becomes STATUS 2 without depressing the clutch pedal; refer to the interpretation of status ET405 Clutch pedal switch.

STATUS 3

SUSPEND BUTTON PRESSED

Status ET556 changes to STATUS 3 when the vehicle is being driven, with cruise control active, if the driver presses the cruise control/speed limiter 0 button. If status ET556 becomes STATUS 3 without pressing cruise control/speed limiter 0 button, run fault finding on the cruise control/speed limiter control R/0 button.

AFTER REPAIR



13B-209



13B

ET556 CONTINUED

STATUS 4

TRACTION CONTROL REQUEST If the vehicle being diagnosed is fitted with traction control, the cruise control function is deactivated each time traction control is selected. Status ET556 changes to STATUS 4 when the vehicle is being driven, with cruise control active and traction control requested. Status ET556 changes to STATUS 4 without a traction control request (see 38C, Antilock braking system).

STATUS 5

GEAR LEVER IN NEUTRAL POSITION

Status ET556 changes to STATUS 5, when the vehicle is being driven, with cruise control active. – If the driver puts the gear lever in neutral without declutching. This deactivates cruise control. If status ET556 becomes STATUS 5 without putting the gear lever in neutral without declutching, contact the Techline. STATUS 6

INCONSISTENCY BETWEEN REQUEST AND VEHICLE SPEED

Status ET556 changes to STATUS 6 if the computer detects too great a difference between the speed requested by the driver and the vehicle speed. This may occur when driving with cruise control active on a very uneven surface. If status ET556 changes to STATUS 6 without a great difference in the speeds, contact the Techline.

AFTER REPAIR

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13B-210



13B

CRUISE CONTROL/SPEED LIMITER DEACTIVATION BY FUNCTION ET557

NOTES

STATUS 1

Cruise control remains deactivated as long as the vehicle speed does not exceed a speed V >18 mph (30 km/h). IMPORTANT: Certain deactivations are stored by the computer. To reinitialise this status, run RZ001 Fault memory

AUTOMATIC TRANSMISSION IN DEFECT MODE

Status ET557 becomes STATUS 1 if the automatic transmission is operating in defect mode. In the event of any faults, run fault finding on the Automatic transmission computer. If the fault is still present, contact Techline. STATUS 2

MONITORING BY INJECTION COMPUTER

If status ET557 changes to STATUS 2 if the injection computer detects a fault on the injection system: – Faults on the accelerator pedal – Engine speed sensor or camshaft faults – Engine speed greater than 4700 rpm – Engine speed less than 1000 rpm. Carry out a multiplex network test, then an injection system test, and carry out fault finding on any faults. If the fault is still present, contact Techline. STATUS 3

VEHICLE SPEED MONITORING

Status ET557 changes to STATUS 3 if the vehicle speed received by the computer is invalid. In the event of any faults, run fault finding on the ABS computer (see 38C, Anti-lock braking system). If the fault is still present, contact Techline. STATUS 4

CRUISE CONTROL OR SPEED LIMITER MONITORING

If status ET557 is STATUS 4, consult the fault finding procedure for status ET042 Cruise control/speed limiter function to test the cruise control system components and find the faulty component. If status ET557 changes to STATUS 4, deal with the faults present or stored in the computer. If the fault is still present, contact Techline.

AFTER REPAIR



13B-211



13B

BRAKE SWITCH NO. 1 ET704

NOTES

ACTIVE


When the driver depresses the brake pedal, status ET704 becomes ACTIVE and status ET705 Brake switch no.2 becomes ACTIVE . If the driver presses hard on the brake pedal and status ET704 remains INACTIVE , check whether the brake lights at the rear of the vehicle have come on. Remove the brake switch and check the condition of its connector. Check the condition of the ABS/ESP computer connectors. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repairs), repair the connector; otherwise replace the wiring. Check the + 12 V after relay feed of the following connection: – AP26 of component 160. Disconnect the engine management computer and check the continuity and insulation of the following connection against + 12 volts and against earth : – 65A between components 1094 (or 118) and 160 If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Remove and check the operation of the brake switch: – in rest position: continuity between connections AP26 and 5A of component 160, – pressed: infinite resistance between connections AP26 and 5A of component 160. Replace the brake switch if necessary. If the fault is still present, perform fault finding on the anti-lock braking system electronic stability program then, if no faults are picked up, perform fault finding on the multiplexed network.

INACTIVE

AFTER REPAIR

When the driver releases the brake pedal, status ET704 should become INACTIVE and status ET705 Brake switch no. 2 should become INACTIVE. If that does not happen, check the condition and operation of the brake light switch by carrying out the checks in the ACTIVE section.


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13B-212



13B

BRAKE SWITCH NO. 2 ET705

NOTES

ACTIVE


When the driver depresses the brake pedal, status ET704 Brake switch no. 1 becomes ACTIVE and status ET705 becomes ACTIVE . If the driver depresses the brake pedal and status ET705 remains INACTIVE , check whether the brake lights at the rear of the vehicle have come on. Remove the brake switch and check the condition of its connector. Check the condition of the t he engine management computer connectors. If one of the connectors is faulty and there is a repair method ( see Technical Note ), repair the 6015A, Repairing electrical wiring, Wiring: Precautions for repair ), connector, otherwise replace the wiring. Check the + 12 V after relay feed of the following connection: – AP26 of component 160. Disconnect the ABS/ESP computer and check the continuity and insulation of the following connection against + 12 V and against earth: – 65A between components 120 and 160. – 5A between components 120 and 160. If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the wiring, otherwise replace it. Remove and check the operation of the brake switch: – in rest position: continuity continuity between connections connections AP26 and 5A of component 160; – pressed: infinite resistance resistance between connections connections AP26 and 5A of component 160. Replace the brake switch if necessary. If the fault is still present, run fault finding on the injection computer .

INACTIVE

AFTER REPAIR

When the driver releases the brake pedal, status ET704 Brake switch no. 1 should become INACTIVE and status ET705 should become INACTIVE. If that does not happen, check the condition and operation of the brake light switch by carrying out the checks in the ACTIVE section.



13B-213



13B

HEATER PLUGS ET781

STATUS DEFINITION

STATUS 1

This status indicates what type of heater plugs are f itted to the engine.

Slow spark plugs

Status ET781 is "STATUS 1" if the heater plugs fitted to the engine have black rings. If not, use command SC036 ''Reinitialise programming'' and select ''HEATER PLUGS". STATUS 2

Quick spark plugs

Status ET781 is "STATUS "STATUS 2" 2 " if the heater plugs fitted to the engine have white rings. If not, use command SC036 ''Reinitialise programming'' and select ''HEATER PLUGS". VEHICLE SPEED MONITORING

Status ET557 changes to STATUS 3 if the vehicle speed received by the t he computer is invalid. In the event of any faults, run fault finding on the ABS computer (see 38C, Anti-lock braking system) . If the fault is still present, contact Techline. STATUS 3

Not defined

Status ET781 is STATUS 3 when the heater plugs are not configured on the injection computer. Refer to the interpretation of DF1069 ''Unconfigured heater plugs'' to determine the heater plugs fitted to the engine, visually check the colour of the plug rings, then run command SC036 Reinitialise programming and select ''HEATER PLUGS''.

AFTER REPAIR



13B-214


DIESEL INJECTION Fault finding – Parameter summary table

Tool parameter


PR002

Alternator charge

PR003

Pedal load

PR005

EGR valve opening setpoint

PR006

Rail pressure regulator current

PR007

Rail pressure regulator current setpoint

PR008


PR009


PR017

Fuel flow

PR022

EGR valve position feedback loop difference

PR023

Air flow difference

PR030

Accelerator pedal position position

PR035


PR037


PR038

Rail pressure

PR041


PR042

Filtered turbocharging pressure

PR051


PR053


PR055

Engine speed

PR059


PR061


PR063

Fuel temperature

PR064

Coolant temperature

PR074

Battery voltage

PR077


PR079

Atmospheric pressure sensor sensor voltage

PR080


PR082

Fuel temperature sensor voltage

PR083

Air temperature sensor sensor voltage

PR084


PR086

Pedal potentiometer potentiometer voltage gang 1

PR088

Pedal potentiometer gang 2 voltage

MR-410-X83-13B000$672.mif V5

13B-215

13B

DIESEL INJECTION


Fault finding – Parameter summary table

Tool parameter


PR089

Vehicle speed

PR128


PR129


PR130


PR132

Air flow

PR157

Fuel flow setpoint

PR171


PR175

Vehicle speed/engine speed ratio

PR190


PR213


PR220

EGR valve OCR*

PR224

Turbocharging pressure sensor voltage

PR225


PR290

Air conditioning refrigerant refrigerant pressure sensor voltage voltage

PR364

Cylinder no. 1 fuel correction

PR365


PR405


PR406


PR484

Fuel regulation solenoid valve OCR*

PR490

Engine air flow

PR672

Damper valve position setpoint

PR739


PR747


PR874

Last service

*OCR: Opening cyclic ratio

MR-410-X83-13B000$672.mif V5

13B-216

13B


DIESEL INJECTION Fault finding – Interpretation of parameters

13B

ACCELERATOR PEDAL POSITION PR030

NOTES

There must be no present or stored faults. Perform this fault finding procedure: – after finding an inconsistency inconsistency in the parameter, parameter, – after a customer complaint complaint (e.g. loss of power).

See Wiring diagrams, Trafic II phase 2.

ELECTRICAL CONFORMITY OF THE SENSOR:

Check the continuity and absence of interference resistance of the following connections: – connection code 3LR, – connection code 3LS, – connection code 3LT, – connection code 3LU, – connection code 3LW, – connection code 3LV, between components 120 and 921. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical ), repair the wiring, otherwise replace it. wiring repair, Wiring: Precautions for repair ), Pedal sensor connected , vehicle with ignition on and engine stopped: – check that the value of of PR030 Accelerator pedal position : 0% no load, 100% full load, 138% full load after pedal kickdown point. If the value is not correct, replace the accelerator pedal sensor.

AFTER REPAIR

Repeat the conformity check from the start.

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13B-217



13B

RAIL PRESSURE PR038

NOTES

There must be no present or stored faults. Perform this fault finding procedure: – after finding an inconsistency in the parameter, – after a customer complaint (starting faults, poor performance, stalling etc.), – after an interpretation of command AC225 Rail pressure regulator .



Check the condition of the rail pressure sensor connector. Check the condition of the engine management computer connectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring. Check for continuity and absence of interference resistance of the following connections: – 3LX between components 120 and 1032 . – 3LY between components 120 and 1032 . – 3LZ between components 120 and 1032. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check that there are no external diesel leaks from the high pressure fuel circuit. With the ignition on and the engine stopped for over 1 minute: View parameter PR038 Rail pressure. – If the pressure is below 90 bar , the sensor is in order. – If the pressure is above 90 bar , contact the Techline.

AFTER REPAIR



13B-218



13B

TURBOCHARGING PRESSURE PR041

NOTES

There must be no present or stored faults. Perform this fault finding procedure: – after finding an inconsistency in the parameter, – after a customer complaint (e.g. loss of power), – after interpretation of command AC004 Turbocharging solenoid valve.



Check for continuity and absence of interference resistance of the following connections: – 3LQ between components 120 and 1071. – 3LP between components 120 and 1071. – 3LN between components 120 and 1071. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Vehicle with ignition on, and the engine stopped for over 1 minute: Compare the values of PR041 Turbocharging pressure and PR035 Atmospheric pressure.

If the difference between PR041 and PR035 is greater than 0.1 bar , check the value of PR035 Atmospheric pressure by comparing it with the reading on a vehicle in the workshop which is correct. If the value of PR035 Atmospheric pressure is not correct (difference greater than 0.1 bar between the 2 vehicles), contact the Techline. Otherwise (when the value PR035 Atmospheric pressure is correct), change the turbocharging pressure sensor. If the difference between PR041 and PR035 is less than 0.1 bar , Start the engine, with the engine idling: Compare the values of PR041 Turbocharging pressure and PR035 Atmospheric pressure.

If the difference between PR041 and PR035 is greater than 0.2 bar . Check the air inlet circuit: absence of leaks or blockages in the low and high pressure air circuit ducts: presence and tightness of the mounting clips, mounting of the turbocharger pressure sensor, intercooler, etc. Check that the damper valve is not jammed closed.

Repair if necessary.

AFTER REPAIR



13B-219



FILTERED TURBOCHARGING PRESSURE PR042

PARAMETER DEFINITION

This parameter indicates the filtered turbocharging pressure in bar .

PR042 corresponds to the average value of PR041 Turbocharging pressure.

AFTER REPAIR



13B-220

13B



13B

EGR VALVE POSITION FEEDBACK PR051

NOTES

There must be no present or stored faults. Perform this fault finding procedure: – after finding an inconsistency in the parameter, – after a customer complaint (loss of power, smoke etc.). – after interpretation of command AC103 EGR by-pass.



Check for continuity and absence of interference resistance of the following connections: – 3JM between components 120 and 169. – 3EL between components 120 and 169. – 3GC between components 120 and 169. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, contact the Techline.

AFTER REPAIR



13B-221



13B

INLET AIR TEMPERATURE PR059

NOTES

There must be no present or stored faults. Perform this fault finding procedure: – after finding an inconsistency in the parameter, – after a customer complaint (e.g. lack of power).



With the flow sensor disconnected, check the insulation from earth of the following connection: – connection code 3ABQ, between components 120 and 799. Check the + 12 V after relay supply to the air flowmeter. – connection 3FB of component 799. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3ABQ and 3DU of component 799. If the resistance is not: 9202 Ω ± 486 Ω at - 10˚C 5774 Ω ± 277 Ω at + 0˚C 3714 Ω ± 161 Ω at + 10˚C 2448 Ω ± 96 Ω at + 20˚C 1671 Ω ± 59 Ω at + 30˚C 1150 Ω ± 36 Ω at + 40˚C 817 Ω ± 23 Ω at + 50˚C 583 Ω ± 15 Ω at + 60˚C 427 Ω ± 09 Ω at + 70˚C 316 Ω ± 06 Ω at + 80˚C 238 Ω ± 04 Ω at + 90˚C Replace the air flowmeter (see MR 408, Mechanical, 12A, Fuel mixture, Air flowmeter, Removal - Refitting ).

AFTER REPAIR



13B-222



13B

FUEL TEMPERATURE PR063

NOTES




Check for continuity and absence of interference resistance of the following connections: – 3FAB between components 120 and 1066. – 3LD between components 120 and 1066. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3FAB and 3LD of component 1066, If the resistance is not: 3820 Ω ± 282 at + 10˚C 2050 Ω ± 100 at + 25˚C 810 Ω ± 47 at + 50˚C Replace the fuel temperature sensor (see MR 408, Mechanical, 13B, Diesel injection, Diesel temperature sensor, Removal - Refitting ).

AFTER REPAIR



13B-223



13B

COOLANT TEMPERATURE PR064

NOTES




Check for continuity and absence of interference resistance on the following connections: – 3C between components 120 and 244. – 3JK between components 120 and 244. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Measure the resistance between connections 3C and 3JK of component 244. If the resistance is not: 12460 Ω ± 1128 Ω at + 10˚C 2252 Ω ± 112 Ω at + 25˚C 811 Ω ± 39 Ω at + 50˚C 283 Ω ± 8 Ω at + 80˚C 115 Ω ± 3 Ω at + 110˚C replace the coolant temperature sensor (see MR 408, Mechanical, 19A, Cooling, Coolant temperature sensor, Removal - Refitting).

AFTER REPAIR



13B-224



13B

AIR FLOW PR132

NOTES

There must be no faults present. Perform this fault finding procedure: – after finding an inconsistency in the parameter, – or after a customer complaint (lack of power, smoke etc.).


Test the air inlet circuit (from the air filter inlet to the inlet manifold tracts, apply test 4 Turbocharged air inlet circuit check ): – air filter unit inlet not blocked and filter not clogged, – visual inspection only, run test 4 from ALP 2, – oil vapour recirculation circuit connected correctly, – absence of leaks or blockages in the low and high pressure air circuits: pipes, presence and tightness of the mounting clips, mounting of the turbocharger pressure sensor, intercooler, etc. – check that the damper valve is not jammed closed.

Carry out the necessary repairs. Check the electrical conformity of the air flowmeter : Check the + 5 V supply to the air flowmeter. – connection 3KJ of component 799. Check the + 12 V after relay supply to the air flowmeter. – connection 37X of component 799. Check the continuity and absence of interference resistance of the following connections: – connection code 3DV, between components 120 and 799. – connection code 3DU, between components 120 and 799. with the flow sensor connected, the vehicle ignition on and engine stopped: Check the voltage between connections 3DU and 3DV of component 799. – If the voltage is not between 0.3 V ± 0.7 V, replace the air flowmeter (see MR 408, Mechanical, 12A, Fuel mixture, Air flowmeter, Removal - Refitting ).

AFTER REPAIR



13B-225


DIESEL INJECTION Fault finding – Command summary table

13B

SUMMARY OF AVAILABLE COMMANDS

NOTES

The commands are run to check the correct operation of certain components or to replace parts.

Tool command


SC001

Write saved data

SC002

Enter injector codes

SC003

Save computer data

SC031

Operational fault finding of cylinders

SC035

High pressure fuel circuit fault finding

SC036

Reinitialise programming

SC037

Compression test

SC040

Speed limiter

SC041

Modification of commercial vehicle idle speed

RZ001

Fault memory

RZ005

Programming

RZ034

Computer memory

AC004

Turbocharging solenoid valve

AC012

Damper valve

AC031

Thermoplunger no. 3 relay

AC037

Preheating relay

AC063


AC064


AC070 *

Air conditioning compressor

AC103

EGR by-pass

AC153

High-speed fan assembly

AC154

Low-speed fan assembly

AC225

Rail pressure regulator

AC226

Pump pressure regulator

VP010

Write VIN

VP036

Fuel supply inhibited

* (Except Vdiag 0C).

MR-410-X83-13B000$768.mif V5

13B-226


DIESEL INJECTION Fault finding – Interpretation of commands

13B

WRITE SAVED DATA SC001

NOTES

To use this command, first save the data with the SC003 Save computer data command. Writing is carried out after the computer has been reprogrammed or replaced. Engine stationary

Select scenario SC001 Write saved data in the diagnostic tool. Note: if no files have been saved beforehand, a write error will appear when command SC001 Write saved data is run. Validating this command writes the data saved using command SC003 Save computer data . The data is as follows: – vehicle-specific idling, – injector codes, – options available on the vehicle and generated by the computer. The data is used to configure the computer and prevent: – engine malfunction after reprogramming or replacing the computer, – incorrect interpretation of the information provided by the diagnostic tool.

AFTER REPAIR


EDC16CP33_V0C_SC001/EDC16CP33_V10_SC001/ EDC16CP33_V14_SC001/EDC16CP33_V16_SC001 MR-410-X83-13B000$816.mif V5

13B-227



13B

ENTER INJECTOR CODES SC002

NOTES

This command is carried out after the replacement of one or more injectors. Engine stopped.

To enter this data, select command SC002 Enter injector codes on the diagnostic tool. Procedure to be followed: – Read the 7-character alphanumeric codes engraved on the upper section of the injector bodies. – Enter each injector code for the associated cylinder. – Important: cylinder no. 1 is located at the timing end. – Confirm the change of injector code configuration. – When the command is completed, the modified codes appear in the current column. – Check that the codes correspond to those read earlier. If the codes entered appear in neither the current column nor the desired column, check the codes read and make sure the data has been entered correctly. – Exit fault finding mode. – Switch off the ignition and wait for 1 min. – Switch the ignition back on and check for faults. – DF066 Injector code(s) should be "stored". If DF066 is still present, the command has not been executed correctly. Start the procedure again and follow the instructions. If the procedure is still not effective, follow the procedure below: A fault could cause the DF066 Injector code(s) to be reported and also incorrect validation of command SC002 . If the power latch* is not performed after the ignition is switched off, the injection computer will not store the new injector codes. Switch off the ignition and check that the immobiliser warning light flashes 2 seconds after switching the ignition off. If the warning light flashes as soon as the ignition is switched off, the power latch* has not been executed and the command will not have been recognised. If all these checks do not enable the command to be confirmed, contact the Techline. * The immobiliser warning light will flash a few seconds after switching the ignition off.

AFTER REPAIR



13B-228



13B

SAVE COMPUTER DATA SC003

NOTES

This save is performed before reprogramming or replacing the computer. Engine stopped.

Select scenario SC003 Save computer data in the diagnostic tool. Confirming this command saves the following vehicle-specific data: – Vehicle-specific idling. – Injector code(s). – Options available on the vehicle and managed by the computer. – Various offsets for components, EGR, damper valve. This information will be saved in the diagnostic tool. After saving has finished, use the command SC001 Enter saved data to be able to set the new computer parameters, after programming and reprogramming.

AFTER REPAIR



13B-229



13B

OPERATIONAL FAULT FINDING OF CYLINDERS SC031

NOTES

This command is used for fault finding of the output of each cylinder and injector.

Reminder: cylinder no. 1 is located at the timing end.

Procedure to be followed: – select scenario SC031, – once the conditions have been met, press the Confirm button; the test will take approximately 5 minutes, – the tool displays cylinder no. 1 cut-off , and engine speed variation is noticeable when the cylinder cuts off; then the procedure is the same for the other three cylinders, – the diagnostic tool displays the results, – end of test. Interpretation of results:

– If the displayed results are VALID, it means that the entire cylinder and injector assembly is in order. There is no need for any operation. Results

Interpretation of results

Cylinder 1

VALID

No operation

Cylinder 2

VALID

No operation

Cylinder 3

VALID

No operation

Cylinder 4

VALID

No operation

– If a displayed result is INVALID, the cylinder or injector is not correct.

Cylinder X

AFTER REPAIR

Difference compared to average

Results


Negative number or Positive number

INVALID

Apply Part B of Test 10 Poor injector operation



13B-230


DIESEL INJECTION

13B

Fault finding – Interpretation of commands

HIGH PRESSURE FUEL CIRCUIT FAULT FINDING SC035

NOTES

This command is used for interpreting the condition of the high pressure fuel circuit (high-pressure pump, rail and injectors)

Procedure to be followed: – select scenario SC035, – once conditions are met, select confirm, – with the command in progress: do not operate on the vehicle, – at the end of the test, the engine stops (only on certain Vdiags), – the diagnostic tool displays the results, Interpretation of results: STEP X (X is the variable from 1 to 4)

Rising time Rail pressure

Drop off time Rail pressure


STEP X

TOO SLOW

TOO SLOW

Check 1

STEP X

TOO SLOW

TOO FAST

Check 2

STEP X

TOO SLOW

OK

Check 3

STEP X

OK

TOO SLOW

Check 4

STEP X

OK

TOO FAST

Check 5

STEP X

OK

OK

No operation

OK

No operation

STEP 5

If another result is displayed on the screen of the CLIP diagnostic tool, contact the Techline.

AFTER REPAIR



13B-231



SC035 CONTINUED

Explanation of results interpretation: Check 1: – Run Test 10 Incorrect injector operation . – Apply ALP6 Fuel circuit leaks. – Apply Test 3 Low pressure circuit check. – If the fault is still present, replace the high pressure pump. Check 2: – Run Test 10 Incorrect injector operation . – Apply ALP6 Fuel circuit leaks. – Run the part of Test 3 Low pressure circuit check which concerns the fuel filter. – Check the rail pressure regulator (see AC225 Rail pressure regulator ). – If the fault is still present, replace the high pressure pump. Check 3: – Run Test 10 Incorrect injector operation . – Apply Test 3 Low pressure circuit check. – If the fault is still present, replace the high pressure pump. Check 4: – Replace the high pressure pump. Check 5: – Run Test 10 Poor injector operation . – Check the rail pressure regulator (see AC225 Rail pressure regulator ).

AFTER REPAIR

MR-410-X83-13B000$816.mif V5


13B-232

13B



13B

REINITIALISE PROGRAMMING SC036

NOTES

This command allows you to reinitialise the following components: – the injectors, – the EGR valve, – the damper valve. – the heater plugs (only with the Vdiag 14). Use the command SC036 with the ignition on and engine stopped.

To run this command, select scenario SC036 Reinitialise programming in the diagnostic tool. Procedure to be followed: – on the main screen, select the component to reinitialise after an operation (removal - refitting or replacement of the component or reprogramming of the computer), – Important: when reinitialising injectors, do not forget that cylinder no. 1 is located at the timing end, – select Finish on the Configuration performed screen to return to the main screen, – end of test.

AFTER REPAIR



13B-233



13B

COMPRESSION TEST SC037

NOTES

This command allows you to: – find out the general condition of the combustion chamber ( in automatic mode), – take cylinder compression measurements, without disconnecting the injector connectors or the TDC sensor ( in manual mode).

To run this command, select scenario SC037 Compression test in the diagnostic tool. Reminder: cylinder no. 1 is located at the timing end 2 possible modes:

– Automatic mode tells you about the overall condition of the combustion chamber; no mechanical or electrical operations are needed on the engine compartment (heater plug removal, injector connector disconnection, etc.). Only the diagnostic tool and the battery/starter charger are used. Manual mode allows you to take compression measurements without disconnecting the injector connectors or the TDC sensor . Remove all the heater plugs. The tools used are: the diagnostic tool, the battery/starter charger, the compression gauge and the M9R flexible end piece, part no. Mot. 1772. 1. Procedure to follow for automatic mode: (cylinder no. 1 is located at the timing end)

– – – – –

before running this command, start then stop the engine (ignition on, forced + after ignition feed), select automatic mode, once conditions are met, select confirm to start the test, command in progress, the overall results screen shows the difference in time between the rise and fall of the piston in the compression phase for each cylinder; the unit of time is µs (microseconds), – if one of the values displayed in the results column are outside the minimum and maximum values, refer to manual mode, – if one of the values displayed in the results column is completely different to the other values displayed on the screen, refer to manual mode, – end of test.

AFTER REPAIR


EDC16CP33_V0C_SC037/EDC16CP33_V10_SC037/EDC16CP33_V14_SC037/EDC16CP33_V16_SC037 MR-410-X83-13B000$816.mif V5

13B-234



13B

SC037 CONTINUED

2. Procedure to follow for manual mode: (cylinder no. 1 is located at the timing end) Carry out this procedure for each cylinder before running this command, – start then stop the engine (ignition on, forced + after ignition feed), – remove all the heater plugs, – connect the compression gauge to the M9R flexible end piece, part no. Mot. 1772, – select manual mode, – once conditions are met, select confirm to start the test, – with the command running, Restart procedure for another cylinder at the end of the starting cycle? appears on screen, – select YES to restart or carry out other cylinder compression measurements, – select NO to exit manual mode. If the values on the compression gauge are not between 21 and 23 bar , the compression is incorrect, – check the following components: (valves, segments, cylinder head gaskets, pistons, engine block), – end of test.

AFTER REPAIR

MR-410-X83-13B000$816.mif V5


13B-235



13B

CHANGING COMMERCIAL VEHICLE IDLE SPEED SC041

NOTES

This command allows changing the idle speed to increase the available power for the electric network of the vehicle. Use the command SC041 with the ignition on and engine stopped.

To run this command, select scenario SC041 on the diagnostic tool. Procedure to be followed: ● select the accelerated idle speed with decrease or increase in the interval 800 to 2000 rpm by increments or decrements of 50 rpm, ● when the idle speed is in the interval 800 to 1300 rpm , the accelerated idle deactivation speed is configurable. Enter a speed between 0 and 18 mph (0 and 30 km/h) or leave the speed of 18 mph (30 km/h) by default, ● when the accelerated idle speed is in the interval 1300 to 2000 rpm, the accelerated idle deactivation speed is not configurable, ● select validate to register the configuration, ● the screen configuration completed indicates that the configuration was successfully completed, select finish to return to the main screen, ● end of test.

AFTER REPAIR


EDC16CP33_V0C_SC041/EDC16CP33_V10_SC041/EDC16CP33_V14_SC041/EDC16CP33_V16_SC041 MR-410-X83-13B000$816.mif V5

13B-236



13B

PROGRAMMING RZ005

NOTES

This command enables you to reinitialise the entire computer configuration according to the vehicle.

Command RZ005 reconfigures the computer. If the computer has no configuration data, use command RZ005 to enter the options fitted on the vehicle: – air conditioning, – passenger compartment heating resistor, – cruise control/speed limiter. These options are detected by the computer even if command RZ005 is not used. The computer is configured as soon as the one of the vehicle's optional system components is operated.

AFTER REPAIR


EDC16CP33_V0C_RZ005/EDC16CP33_V10_RZ005/EDC16CP33_V14_RZ005/EDC16CP33_V16_RZ005 MR-410-X83-13B000$816.mif V5

13B-237



COMPUTER MEMORY RZ034

NOTES

IMPORTANT Only use this command if DF107 Computer Memory is present.

Use scenario SC003 Save computer data. Use command RZ034. Switch off the ignition and wait for the message Communication lost with computer. Switch on the ignition again. Use scenario SC001 Write saved data. In case of error when executing the scenario SC001 Write saved data. Reconfigure the computer correctly: – use the scenario SC002 Enter injector codes, – use the scenario SC036 Reinitialise programming. Perform a road test to reinitialise the parameters of the vehicle.

AFTER REPAIR


EDC16CP33_V0C_RZ034/EDC16CP33_V10_RZ034/EDC16CP33_V14_RZ034/EDC16CP33_V16_RZ034 MR-410-X83-13B000$816.mif V5

13B-238

13B



13B

TURBOCHARGING SOLENOID VALVE AC004

NOTES

Perform this fault finding procedure: – following interpretation of an unresolved fault, or – following application of the interpretation of PR041 Turbocharging pressure or, – after a customer complaint (loss of power, smoke etc.). See Wiring diagrams, Trafic II phase 2.

1 - The following procedure is for checking that the turbocharger and its control circuit are working correctly. Preliminary operation: Check the high pressure air circuit sealing : run test 3: Low pressure circuit check . Pipe not joined or pierced, pressure sensor disconnected or poorly fitted (seal present), exchanger pierced. To test the intercooler: stabilise the engine speed between 3500 and 4000 rpm with the vehicle stopped and check that there are no leaks.

Measure the resistance between connections 37X and 3MG of component 1475. Replace the solenoid valve if its resistance is not 16.5 Ω ± 0.8 Ω at +23˚C. Check the continuity of the following connection: – 3MG between the components 120 and 1475 . Check the + 12 V after relay feed on the following connection: – 37X of component 1475. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Run command AC004 Turbocharging solenoid valve ; if a faint whistling noise is heard along with a clicking from the solenoid valve, go to stage 2, otherwise check the operation of the computer output stage: Vehicle with + after ignition, clear the faults displayed by the diagnostic tool. With the voltmeter in the direct current position: With the turbocharging solenoid valve connected, connect the voltmeter earth lead to connection 3MG of component 1475 and the positive lead to connection 37X of component 1475. Run command AC004 Turbocharging solenoid valve; the voltmeter should display four successive voltages of 2.4 V ± 0.2 V. If the measurement is not correct, contact the Techline.

AFTER REPAIR


EDC16CP33_V0C_AC004/EDC16CP33_V10_AC004/EDC16CP33_V14_AC004/EDC16CP33_V16_AC004 MR-410-X83-13B000$816.mif V5

13B-239



13B

AC004 CONTINUED

2 - Turbocharger control circuit check – With the engine stopped, make sure that the control rod is in the resting position. – Start the engine and make sure that the control rod actuates to the upper stop. (when the engine is switched off, the control rod should return to the rest position) If the control rod does not move correctly, carry out the following checks: 1) Control vacuum check: – Disconnect the solenoid valve inlet hose and connect it to a pressure gauge. – Start the engine and run it at a stable idle speed. – If the vacuum pressure does not reach 400 mbar ± 150: check the vacuum pressure circuit from the vacuum pump. – Stop the engine, reconnect the inlet hose and go to step no. 2. 2) Check the solenoid valve actuation: – Disconnect the solenoid valve outlet hose . – Start the engine and run it at a stable idle speed. – Place your hand on the solenoid valve and block the outlet union with your thumb. – If there is no perceptible vibration of the solenoid valve, contact the Techline. 3) Check the solenoid valve operation: – Connect the pressure gauge to the solenoid valve outlet union. – Start the engine and run it at a stable idle speed. If the vacuum pressure does not reach 400 mbar ± 150 , replace the solenoid valve.

AFTER REPAIR

MR-410-X83-13B000$816.mif V5


13B-240



13B

DAMPER VALVE AC012

NOTES

Carry out this interpretation: – after DF645 Damper valve position regulation, DF646 Damper valve position sensor , – or after a customer complaint (starting faults, poor performance).

See Wiring diagrams, Trafic II phase 2 .

Measure the resistance between connections 38KQ and 38KP of component 1461. Replace the valve if its resistance is not 1250 Ω ± 375 Ω. Check the continuity and absence of interference resistance of the following connections: – 38KQ between components 120 and 1461, – 38KP between components 120 and 1461. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. B) With the vehicle ignition on, engine stopped: Make sure the damper valve is open , If not, clean or replace the damper valve. Actuate the valve using command AC012 Damper valve and check the valve's movement and its rest position.

Check the operation of the computer output stage with a voltmeter in t he alternating current position: Actuate the valve with command AC012: Connect the voltmeter earth lead to connection 38KS of component 1461 and the positive lead to connection 38KQ of component 1461. The voltmeter should display three cycles of ON-OFF (12.5 V then return to 0 V). If the measurement is correct, replace the damper valve. If the measurement does not show any operation, contact the Techline.

AFTER REPAIR



13B-241



13B

THERMOPLUNGER NO. 3 RELAY AC031

NOTES

Check that the computer is correctly configured using command LC056 Thermoplungers. There must be no present or stored faults: Perform this fault finding procedure if there is a fault with the passenger compartment heating - demisting. See Wiring diagrams, Trafic II phase 2.

If the "Thermoplunger no. 3 relay" does not operate when command AC031 Thermoplunger no. 3 relay is run. Check the condition of the mounting connector of component 1775 on the engine fuse box. Check the condition of the connectors of component 120. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

If the fault is still present, check as follows that this relay is controlled by component 120: Disconnect the component 1775, fit a 50 to 100 Ω resistor on its mounting instead of the coil, and connect a voltmeter as follows: – positive terminal to + 12 V battery, – negative terminal to connection 3JD of component 1775 . Run command AC031. If the voltmeter indicates the battery voltage (4 ON-OFF cycles of 10 seconds ), replace the thermoplunger no. 3 relay. If the voltmeter does not show the battery voltage (4 ON-OFF cycles of 10 seconds), contact the Techline. If the "thermoplunger no. 3 relay" operates with command AC031 , but there is still a passenger compartment heating/demisting fault, check the following using the wiring diagram: The conformity of the thermoplunger maxi-fuse. Check for + 12 V battery feed on connection BP91 of component 1775. Check the conformity of thermoplunger no. 3 relay. Check the continuity of connection 3JD between components 1775 and 1547. Measure the resistance of the thermoplunger*. The presence of earth on the water chamber (thermoplunger mounting). Also check the level of the cooling circuit and that there are no leaks. Carry out the necessary repairs.

* supplier: Champion: charge resistance: 608 mΩ ± 61 mΩ

AFTER REPAIR



13B-242



13B

PREHEATING RELAY AC037

This command is only run if fault DF025 Preheating unit diagnostic line or DF017 Preheating unit control circuit is present or stored and if no other fault is present. NOTES


Before applying the following fault finding procedure, check that the battery voltage is not below 12 V. Otherwise, recharge the battery. Step 1: Using a multimeter fitted with a current clamp, bring the 4 heater plug supply wires together. Run command AC037 Preheating relay and measure the current consumed by the 4 heater plugs. If the current consumed is not between 60 and 80 A, go to step 2, otherwise end of fault finding procedure. Step 2 Check the connections on the pre-postheating unit, heater plugs and injection computer. Repair if necessary.

Measure the resistance of the heater plugs. If this resistance is > 2 Ω, replace the defective plug(s). Check the continuity and absence of interference resistance of the following connections: – 37AC , between components 257 and 683, – 37Z between components 257 and 680, – 37AA , between components 257 and 681, – 37AB , between components 257 and 682. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check the condition of the preheating unit supply fuse. Replace it if necessary. Check the + 12 V battery feed to the preheating unit on the following connection: – BP17 of component 257. Check the continuity and absence of interference resistance on the following connections: – 3FY between components 120 and 257, – 3FF between components 120 and 257. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If the fault is still present, replace the preheating unit (see MR 408, Mechanical, 13C, Preheating, Preheating unit, Removal - Refitting).

AFTER REPAIR



13B-243



13B


NOTES

Check that the computer is correctly configured using command LC056 Thermoplungers. There must be no present or stored faults: Perform this fault finding procedure if there is a fault with the passenger compartment heating - demisting. See Wiring diagrams, Trafic II phase 2.

If the "thermoplunger no. 1 relay" does not operate when command AC063 Thermoplunger no. 1 relay is run: Check the condition of the mounting connector of component 1773 on the engine fuse box. Check the condition of the connectors of component 120. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

If the fault is still present, check as follows that this relay is controlled by component 120: Disconnect the component 1773, fit a 50 to 100 Ω resistor on the mounting instead of the coil, and connect a voltmeter as follows: – positive terminal to + 12 V battery – negative terminal to connection 3JS of component 1773. Run command AC063. If the voltmeter indicates the battery voltage (4 ON-OFF cycles of 10 seconds ), replace the thermoplunger no. 1 relay. If the voltmeter does not show the battery voltage (4 ON-OFF cycles of 10 seconds), contact the Techline. If the thermoplunger no. 1 relay operates with command AC063, but there is still a fault with the passenger compartment heating/demisting, check the following using a wiring diagram: The conformity of the thermoplunger maxi-fuse. Check for + 12 V battery feed on connection BP91 of component 1773. Check the conformity of component 1773. Check the continuity of connection 3JS between components 1773 and 1547 . Measure the resistance of the thermoplunger*. The presence of earth on the water chamber (thermoplunger mounting). Also check the level of the cooling circuit and that there are no leaks. Carry out the necessary repairs. * supplier: Champion: charge resistance: 608 mΩ ± 61 mΩ

AFTER REPAIR



13B-244



13B


NOTES

Check that the computer is correctly configured using command LC056 Thermoplungers. There must be no present or stored faults. Perform this fault finding procedure if there is a fault with the passenger compartment heating - demisting. See Wiring diagrams, Trafic II phase 2.

Special notes: The "Thermoplunger no. 2 relay" supplies thermoplungers 2 and 3 in parallel.

If the "thermoplunger no. 2 relay" does not operate correctly , when command AC064 Thermoplunger no. 2 relay is run: Check the condition of the mounting connector of component 1774 on the engine fuse box. Check the condition of the connectors of component 120. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

If the fault is still present, check as follows that this relay is controlled by the engine management computer: Disconnect the component 1774, fit a 50 to 100 Ω resistor on its mounting instead of the coil, and connect a voltmeter as follows: – positive terminal on + 12 V battery, – negative terminal on connection 3JC of component 1774. Run command AC064. If the voltmeter shows the battery voltage (4 ON-OFF cycles of 10 seconds ), replace thermoplunger relay no. 2. If the voltmeter does not show the battery voltage (4 ON-OFF cycles of 10 seconds), contact the Techline. If the thermoplunger no. 2 relay operates with command AC064, but there is still a passenger compartment heating/demisting fault. Check using the wiring diagram: The conformity of the thermoplunger maxi-fuse.

Check for + 12 V battery feed on connection BP92 of component 1774. Check the conformity of component 1774. Check the continuity of connection 3JC between components 1774 and 1547. Measure the resistance of the thermoplungers.* The presence of earth on the water chamber (thermoplunger mounting). Also check the level of the cooling circuit and that there are no leaks. Carry out the necessary repairs. * supplier: Champion: charge resistance: 608 mΩ ± 61

AFTER REPAIR



13B-245



13B

AIR CONDITIONING COMPRESSOR AC070

There must be no present or stored faults. Perform this fault finding procedure if there is a fault with the passenger compartment air conditioning. NOTES

Special notes: See Wiring diagrams, Trafic II phase 2.

If, when command AC070 is run, the air conditioning compressor relay is not actuated: Check the condition of the air conditioning compressor clutch relay connectors. If the connector is faulty and there is a repair procedure ( see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. Check the conformity of the air conditioning fuse. Disconnect component 584 and check the + 12 V feed at the following connections: – 37X of component 584, – BP1G of component 584. Check for an earth on the following connection: – MW of component 171. Check the insulation, continuity and the absence of interference resistance of the following connections: – 38K between the components 120 and 584. – 38R between components 584 and 171. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR


EDC16CP33_V10_AC070/EDC16CP33_V14_AC070/EDC16CP33_V16_AC070 MR-410-X83-13B000$816.mif V5

13B-246



13B

EGR BY-PASS AC103

Carry out this fault finding procedure when the interpretation of fault DF304 EGR by-pass circuit has not been resolved. NOTES


Measure the resistance between connections 37X and 3TP of component 1301: 43 Ω to 49 Ω at + 25˚C 32 Ω to 37 Ω at - 40˚C If the resistance is not correct, replace the EGR by-pass solenoid valve. Check for continuity and the absence of interference resistance on the following connection: – 3TP between components 120 and 1301. Check the + 12 V after relay supply on the following connection: – 37X of component 1301. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. If you notice no valve movement when running command AC103, ensure that the computer output stage is functioning: Vehicle with + after ignition, clear the faults displayed by the diagnostic tool. With the voltmeter in the direct current position: With the EGR BY-PASS solenoid valve connected, connect the voltmeter earth lead to connection 3TP of component 1301 and the positive lead to connection 37X of component 1301. Run command AC103, the voltmeter should display four successive readings which are approximately equal to the 12 V battery voltage.

If the voltmeter indicates no control or a continuous voltage, contact the Techline. If activation has run correctly, check the vacuum control: – Disconnect the solenoid valve inlet hose and connect it to a pressure gauge. – Start the engine and run it at a stable idle speed. – If the vacuum pressure does not reach 400 mbar ± 150, check the vacuum pressure circuit from the vacuum pump. Repair if necessary.

AFTER REPAIR



13B-247



13B

HIGH SPEED FAN ASSEMBLY AC153

NOTES

There must be no present or stored faults: Perform this fault finding after an engine cooling fault. Engine stopped. This command is only applicable for vehicles equipped with air conditioning. See Wiring diagrams, Trafic II phase 2.

If command AC153 does not actuate the high speed fan assembly relay: Check the condition of the mounting connectors of component 336. If the fault is still present, check as follows that component 336 is controlled by component 120: Disconnect the component 336, fit a 50 to 100 Ω resistor on its mounting instead of the coil, and connect a voltmeter as follows: – positive terminal to + 12 V battery, – negative terminal to connection 49K of component 336. Run command AC153. If the voltmeter shows the battery voltage (4 ON-OFF cycles of 10 seconds), replace the relay. If the voltmeter does not show the battery voltage (4 ON-OFF cycles of 10 seconds), contact the Techline. If the high speed fan assembly relay is supplied using command AC153, but there is still a fan assembly actuation fault, check using the wiring diagram: The conformity of the fan assembly maxi-fuse. Check the + 12 V battery feed to connection BP7 of component 336. Check the conformity of the high-speed fan assembly relay. Check the continuity of connection 49R between components 336 and 905. Check the conformity of the fan assembly. Check for complete earthing on connection MW of component 905. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-248



13B

LOW-SPEED FAN ASSEMBLY AC154

NOTES

There must be no present or stored faults. Perform this fault finding after an engine cooling fault or air conditioning fault. Engine stopped. See Wiring diagrams, Trafic II phase 2.

If, when running command AC154, the low speed fan assembly relay does not operate: Check the condition of the low-speed fan assembly relay mounting connectors. If the fault is still present, check as follows that component 335 is controlled by component 120: Disconnect the low-speed fan assembly relay, fit a 50 to 100 Ω resistor on the relay mounting in place of the coil, and connect a voltmeter as follows: – positive terminal to + 12 V battery – negative terminal to connection 49J of component 335. Run command AC154. If the voltmeter shows the battery voltage (4 ON-OFF cycles of 10 seconds), replace the relay. If the voltmeter does not show the battery voltage (4 ON-OFF cycles of 10 seconds), contact the Techline. If the low speed fan assembly relay is supplied using command AC154, but there is still a fan assembly actuation fault, check using the wiring diagram. The conformity of the fan assembly maxi-fuse. Check the continuity of connection 49L between components 335 and 321. Check the low speed resistor (resistance and connections). Check the continuity of connection 49R between components 905 and 321. Check for complete earthing on connection MW of component 905. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR



13B-249



13B

RAIL PRESSURE REGULATOR AC225

NOTES

Perform this fault finding procedure: – following interpretation of an unresolved fault, – following an inconsistency recorded in the parameters, – following a customer complaint (starting problems, engine speed instability, injection noise).


Step 1

Check for continuity and the absence of interference resistance on the following connection: – 3RG between the components 120 and 1198. Check the + 12 V after relay supply on the following connection: – 37X of component 1198. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Run command AC225, if you can hear a slight whistling noise and cracking from the pressure regulator, go to step 2 , otherwise, ensure that the computer output stage is functioning correctly: Vehicle with + after ignition, clear the faults displayed by the diagnostic tool. With the voltmeter in the direct current position: With the rail pressure regulator connected, connect the voltmeter earth lead to connection 3RG of component 1198 and the positive lead to connection 37X of component 1198. Run command AC225; the voltmeter should display four successive voltages of 2.2 V ± 0.2 V.

If the measurement is not correct, contact the Techline.

STEP 2

AFTER REPAIR



13B-250



13B

AC225 CONTINUED

Step 2 In the event of rail overpressure: Check that there are no air bubbles in the diesel fuel low pressure circuit. Check that the rail pressure sensor is operating correctly. Interpretation of parameter PR038 Rail pressure. If these checks do not reveal any faults, replace the rail regulator. In the event of rail underpressure: Check that the rail pressure sensor is operating correctly. Interpretation of parameter PR038 Rail pressure. Check the low pressure diesel circuit priming. Check the conformity of the diesel filter connections. Check the condition of the filter (clogging and water saturation). Check that there are no air bubbles between the filter and the high pressure pump. Check the low and high pressure diesel circuit sealing: use ALP 6 Fuel circuit leaks (visual inspection, touch tests, odours, etc.) on: the pump casing, overpressure valve, pipes, injector and rail unions, injector wells, etc. Check the conformity of the seal fitting on the pressure regulator. Check the operation of the injectors: run Test 10: Incorrect injector operation.

Carry out the necessary repairs. If the engine starts:

Clear any faults. Check the rail pressure regulator using ALP 7 Rough idling. With the engine warm, leave it running at idle speed a few minutes (3 to 5 minutes) : – If it stalls and the fault reappears, replace the rail pressure regulator. – If it does not stall, stabilise the engine speed at 2000 rpm (1 minute) then accelerate under full load until it cuts out. If the engine stalls, contact the Techline If the engine does not startor there is no timing: replace, in the first instance, the rail pressure regulator, and if the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$816.mif V5


13B-251



13B

PUMP PRESSURE REGULATOR AC226

NOTES

Perform this fault finding procedure: – following interpretation of an unresolved fault, – following an inconsistency recorded in the parameters, – following a customer complaint (starting problems, engine speed instability, injection noise).


Step 1

Check for continuity and the absence of interference resistance on the following connection: – 3HI between the components 120 and 1105. Check the + 12 V after relay feed on the following connection: – 37X of component 1105. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Run command AC226. If there is a slight whistling noise and cracking from the pressure regulator, go to step 2, otherwise, check that the computer output stage is operating correctly: Vehicle with + after ignition, clear the faults displayed by the diagnostic tool. With the voltmeter in the direct current position: With the pump pressure regulator connected, connect the voltmeter earth lead to connection 3HI of component 1105 and the positive lead to connection 37X of component 1105. Run command AC226; the voltmeter should display four successive voltages of 2.2 V ± 0.2 V.

If the measurement is not correct, contact the Techline.

STEP 2

AFTER REPAIR



13B-252



13B

AC226 CONTINUED

Step 2 In the event of rail overpressure: Check that there are no air bubbles in the diesel fuel low pressure circuit. Check that the rail pressure sensor is operating correctly. Interpretation of parameter PR038 Rail pressure. If these checks do not reveal any faults, replace the pump regulator. In the event of rail underpressure: Check that the rail pressure sensor is operating correctly. Interpretation of parameter PR038 Rail pressure. Check the low pressure diesel circuit priming. Check the conformity of the diesel filter connections. Check the condition of the filter (clogging and water saturation). Check that there are no air bubbles between the filter and the high pressure pump. Check the low and high pressure diesel circuit sealing: use ALP 6 Fuel circuit leaks (visual inspection, touch tests, odours, etc.) on: the pump casing, overpressure valve, pipes, injector and rail unions, injector wells, etc. Check the conformity of the seal fitting on the pressure regulator. Check the operation of the injectors: run Test 10: Incorrect injector operation.

Carry out the necessary repairs. If the engine starts:

Clear any faults. Check the pump pressure regulator by applying ( see ALP 7 Rough idle). With the engine warm, leave it to idle for a few minutes (3 to 5 minutes): – If it stalls and the fault reappears, replace the pump regulator. – If it does not stall, stabilise the engine speed at 2000 rpm (1 minute) then accelerate under full load until it cuts out. If the engine stalls, contact the Techline. If the engine does not startor there is no timing: replace, in the first instance, the pump regulator and if the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$816.mif V5


13B-253



13B

INHIBIT FUEL SUPPLY VP036

NOTES

This command enables you to disable the supply to the injectors. This command is carried out with the engine switched off, and ignition on.

This command allows the injectors to be locked, so that starting is not possible. Command VP036 allows the engine compressions to be checked in complete safety without disconnecting the injector connectors or the TDC sensor . Procedure to follow: (cylinder no. 1 is located on the flywheel end) – Remove all of the heater plugs, connect the compression gauge with the M9R flexible end piece, part no. MOT 1772, to a cylinder. – Position the gear lever in neutral (manual gearbox) or to position P (sequential gearbox). – Depress the brake pedal and keep in depressed position. – Activate command VP036. – Attempt to start the vehicle (within 10 seconds of activating command VP036). – Check the engine compressions. Repeat the procedure for another cylinder. WARNING Keep the brake pedal depressed for the duration of the test.

This command is inhibited automatically after 10 seconds .

EDC16CP33_V0C_VP036/EDC16CP33_V10_VP036/EDC16CP33_V14_VP036/EDC16CP33_V16_VP036 MR-410-X83-13B000$816.mif V5

13B-254

DIESEL INJECTION


NOTES

Fault finding – Customer complaints

13B

Only check the customer complaint after performing a complete check with the diagnostic tool.

NO DIALOGUE WITH ENGINE MANAGEMENT COMPUTER

ALP1

STARTING FAULT OR STARTING IMPOSSIBLE

ALP2

POOR PERFORMANCE

ALP4

IRREGULAR ENGINE OPERATION

ALP5

FUEL SYSTEM LEAKS

ALP6

ROUGH IDLE

ALP7

ENGINE STALLING

ALP8

AIR CONDITIONING DOES NOT WORK

ALP9

OIL LEAKS FROM THE TURBOCHARGER

ALP10

TURBOCHARGER NOISE

ALP11

SMOKE FROM THE EXHAUST

ALP12

MR-410-X83-13B000$864.mif V5

13B-255


ALP1

NOTES

DIESEL INJECTION Fault finding – Fault Finding Chart

13B

No dialogue with engine management computer

Before following this ALP, repair the multiplex network (see 88B, Multiplexing). See Wiring diagrams, Trafic II phase 2 .

STEP 1 Check the conformity of the vehicle type, and the domain selected on the tool. Check that the tool is not faulty by trying to establish dialogue with a computer on another vehicle. Check the supply to the diagnostic socket: – + Before ignition. – + After ignition. – Earth.

Check the conformity of the + after ignition feed fuse. – The conformity of the injection relay mounting supplies. Check the conformity of the main relay (relay removed): – Insulation between connections 3FB1 and BP10 of component 983. – Measure the resistance between connections 3FAC and BP10 of component 983. Replace the relay if its resistance is not: 65 Ω ± 5. Disconnect the engine management computer and check that there are no conducting parts on the computer studs. If this reveals any kind of impurity, rectify it and try to establish dialogue. If the fault is still present, place the bornier Elé. 1681 on the engine harness: Check for continuity and absence of interference resistance on the following multiplex connections: – Multiplex line L, between components 120 and 225. – Multiplex line H, between components 120 and 225. Check the + 12 V after relay supply of the following connections: – 37X of component 120, – 3FB1 of component 120, – 3FB2 of component 120. Check for complete earthing on connections NF of component 120. When shunting the "normally open" contact of the supply relay on connections BP38 and 3FB1 of component 983, check the + 12 V supply on the following connections: – 37X of component 120 (via shunt test). – 3FB1 of component 120 (via shunt test). – 3FB2 of component 120 (via shunt test).

Check the continuity and absence of interference resistance of the following connection: – 3FAC between components 120 and 983. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it.

AFTER REPAIR

Carry out a road test followed by a complete check with the diagnostic tool.

EDC16CP33_V0C_ALP01/EDC16CP33_V10_ALP01/EDC16CP33_V14_ALP01/EDC16CP33_V16_ALP01 MR-410-X83-13B000$912.mif V5

13B-256



13B

ALP1 CONTINUED

Try to start communication with another computer on the same vehicle.

If dialogue is established with another computer on the same vehicle go to step 2. If dialogue is not established with any other computer on the same vehicle, (see 88B, Multiplexing, ALP 1) . STEP 2 Contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-257



ALP2

13B

Starting difficult (or impossible)

Before dealing with this customer complaint, check that there are no faults, and the conformity (or otherwise) of the parameters and statuses using the diagnostic tool. NOTES

If the customer complaint is not ironed out, perform the following checks:


Impossible

Is it difficult or impossible to start the engine?

PART B

Difficult PART A:

Check the engine earths. If the engine speed is less than 200 rpm, consult Technical Note 6014A, Checking the charging circuit , then Technical Note 3632A, Starter fault finding . If an engine speed of 200 rpm is achieved with the starter, consult the parameter PR055 Engine speed. If the engine speed is zero with the diagnostic tool: measure the resistance between connections 3BG and 3BL of component 149. Replace the engine speed sensor if its resistance is not between 722 Ω and 978 Ω. Check for continuity and absence of interference resistance of the following connections: – 3BG between components 120 and 149. – 3BL between components 120 and 149. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check the conformity of the engine earths (oxidation, tightness, etc.). Check the mounting and condition of the engine speed sensor (overheating). Replace if necessary. Check the synchronisation of the camshaft sensors and the engine speed sensors with the display of ET238 Synchronisation. If synchronisation is not active, refer to the checks described in DF195 Engine speed/ camshaft sensor consistency .

AFTER REPAIR


EDC16CP33_V0C_ALP02/EDC16CP33_V10_ALP02/ EDC16CP33_V14_ALP02/EDC16CP33_V16_ALP02 MR-410-X83-13B000$912.mif V5

13B-258



13B

ALP2 CONTINUED 1

Test the high pressure fuel circuit: Run scenario SC035 High pressure fuel circuit fault finding . To interpret the result, apply the interpretation of command SC035 (see Interpretation of commands ).

Check the fuel circuit for leaks using test 3 Low pressure circuit check . Check that the heater plugs are actuated using the AC037 Preheating relay command. Check the tightness and the condition of the inlet circuit, run test 4: Turbocharged air inlet circuit check and follow the related fault finding procedure. Check that the exhaust is not blocked, run test 1: Exhaust pipe check and follow the related fault finding procedure. Check the consistency of the signal from the engine coolant temperature sensor. Check the operation of the rail pressure regulator ( DRV) using command AC225 Rail pressure regulator and then the operation of the pump pressure regulator ( MPROP) using command AC226 Pump pressure regulator . Check that the heating elements operate, and check the relevant electrical consumption with a current clamp. Check the timing setting. Check the efficiency of the cylinder compressions using command VP036 Inhibit fuel circuit supply. End of part A

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-259

DIESEL INJECTION


Fault finding – Fault Finding Chart

13B

ALP2 CONTINUED 2

PART B

Is there diesel in the tank?

NO

Fill the tank with diesel fuel. Bleed the low and high pressure diesel circuit.

YES

Does the starter motor work properly? (Check that the engine speed reaches > ~ 200 rpm with the starter motor, PR055 Engine speed).

NO

Consult Technical Note 6014A, Checking the charging circuit, then Technical Note 3632A Starter fault finding.

YES

Using the diagnostic tool, check the conformity of the immobiliser: ET003 Immobiliser must be INACTIVE . ET003 not in order, or immobiliser warning light permanently on

ET003 correct (immobiliser code warning light off)

Consult the fault finding procedure for the UCH (see 87B, Passenger Compartment Connection Unit).

Continue the fault finding procedure with Part A of this fault finding chart.

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-260



ALP4

NOTES

13B

Poor performance

Before dealing with this customer complaint, check that there are no faults, and the conformity (or otherwise) of the parameters and statuses using the diagnostic tool. If the customer complaint is not ironed out, perform the following checks:

IMPORTANT In the event of the engine overheating above 118˚C, the computer deliberately limits the fuel flow (overheating warning light comes on from 115˚C). – Please observe the cleanliness guidelines and safety advice.

If the vehicle speed is constantly limited, if necessary, reconfigure the float limit speed using command SC040 Speed limiter . Perform the following road test (looking for a loss of power when accelerating under full load): – in the highest gear ratio, accelerate fully, – lift your foot off the accelerator pedal completely for at least 2 seconds, – accelerate fully again, – release the accelerator pedal completely, – accelerate slightly. If loss of power was not noted during slight acceleration and if there was a loss of engine power during each acceleration at full load, replace the diesel injector fuel return rail and its overpressure valve (see MR 408 Mechanical, 13B, Diesel injection, Diesel injector fuel return rail: Removal - Refitting ).

Is the poor performance accompanied by smoke?

NO

YES

B

AFTER REPAIR



13B-261



13B

ALP4 CONTINUED 1

B

If the fault is still present, test the high pressure fuel circuit : – Run scenario SC035 High pressure fuel circuit fault finding. – To interpret the result, apply the interpretation of command SC035 (see Interpretation of commands). Check that the fuel tank is correctly filled and that the appropriate fuel is used. Run test 8 Diesel fuel conformity check . – Check that the injectors are correctly fitted (presence and conformity of the sealing washer ). Checking procedure: – Take a straightedge approximately 40 cm long and place it on the 4 injectors. The straightedge should rest on the 4 injectors. – If one or more injector(s) are not in order, remove and check the conformity of the washer. – If one injector does not touch the straight edge (clearance above 1 mm), remove the injector and check for the washer. – Clean the injector well and the injector, refit the injector and its correct sealing washer. – Check the sealing and the condition of the inlet circuit, run test 4 Turbocharged air inlet circuit check . – Check the condition of the air flowmeter, run test 5 Air flowmeter . Check the turbocharger: – run test 2 Air line at the turbocharger. – run test 6 Turbocharger control solenoid valve check. – run test 7 Turbocharger.

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-262


DIESEL INJECTION

13B


ALP4 CONTINUED 2

is the engine running on all cylinders? NO Test the high pressure fuel circuit: Run scenario SC035 High pressure fuel circuit fault finding . To interpret the result, apply the interpretation of command SC035 (see Interpretation of commands) .

YES

If the fault is still present

C

AFTER REPAIR

MR-410-X83-13B000$912.mif V5

C


13B-263



13B

ALP4 CONTINUED 3

C

Check the conformity of the accelerator pedal position sensor, the brake pedal sensor, the atmospheric pressure sensor, the exhaust gas recirculation valve and the damper valve. – Check the consistency of the signal: from air flow sensor, engine coolant temperature sensor, fuel temperature sensor and engine speed sensor. Check the connections, the continuity and the absence of interference resistance of the air flowmeter (run DF056 Air flow sensor circuit), the engine coolant temperature sensor (run DF001 Coolant temperature sensor circuit), the fuel temperature sensor (run DF098 Fuel temperature sensor circuit ), and the engine speed sensor (run DF195 Camshaft sensor/engine speed consistency ). Check: – That the diesel filter is not clogged. – That there are no leaks on the high and low pressure diesel circuits: run test 3 Low pressure circuit check. – That the oil vapour rebreathing system is connected. – The pump pressure regulator (MPROP ), (jamming - sticking); apply the interpretation of command AC226 Pump pressure regulator . – The rail pressure regulator (DRV), (jamming - seizing); apply the interpretation of command AC225 Rail pressure regulator . – Check the engine timing (and the position of the high pressure pump sprocket). – Check the engine compressions, run command VP036 Inhibit fuel circuit supply. – Measure the engine compressions with the special tool. If the fault is still present, contact the Techline.

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-264



ALP5

13B

Irregular engine operation

Before dealing with this customer complaint, check that there are no faults, and the conformity (or otherwise) of the parameters and statuses using the diagnostic tool. NOTES

If the customer complaint is not ironed out, perform the following checks.


If the engine races during gear changes, check, if there is a floor carpet, that this is not blocking the accelerator pedal, the brake pedal and the clutch pedal, then check the conformity of the clutch switch and the conformity of the accelerator pedal sensor when the pedal is released. Measure the resistance between connections 3BG and 3BL of component 149. Replace the sensor if its resistance is not: 850 Ω ± 128 Ω at +20˚C. Check for continuity and absence of interference resistance of the following connections: – 3BG between components 120 and 149, – 3BL between components 120 and 149. If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the wiring, otherwise replace it. Check the conformity of the engine earths (oxidation, tightness, etc.). Check the attachment and the condition of the TDC sensor (heating). Replace if necessary. Check the low-pressure circuit: run test 3 Low pressure circuit check . – Apply the procedure used for checking the air flow, (see conformity check). Check the turbocharger: – run test 2 Air line at the turbocharger . – run test 6: Turbocharger control solenoid valve check . run test 7 Turbocharger . If the fault is still present, test the high pressure fuel circuit : Apply scenario SC035 High pressure fuel circuit fault finding. To interpret the result, apply the interpretation of command SC035 (see Interpretation of commands ).

AFTER REPAIR



13B-265

DIESEL INJECTION



ALP6

NOTES

13B

Fuel system leaks

Before dealing with this customer complaint, check that there are no faults, and the conformity (or otherwise) of the parameters and statuses using the diagnostic tool. If the customer complaint is not ironed out, perform the following checks. IMPORTANT Please observe the cleanliness guidelines and safety advice.

Procedure for checking for an external leak on the fuel circuit: Clean away traces of grease with clean thinner and wipe the part or parts concerned with cleaning cloths. Start the engine and increase the engine temperature until the diesel fuel reaches 40/50˚C. Stop the engine and check for traces of grease on the part or parts concerned. If this is the case, replace the part or parts concerned. Bleed the fuel circuit and continue the checks.

Does the priming bulb show traces of grease? (Visual and tactile inspections)

YES

NO

Does the diesel filter show traces of grease? (Visual and tactile inspections)

YES

NO

Are there greasy marks on the return pipes? (Visual and tactile inspections)

YES

NO

AFTER REPAIR



Check the assembly of the components and the condition of the seal at the union of the two components, if the leak is at the seal. Replace the part or the parts concerned. Bleed the fuel circuit and continue the checks. Check the counter pressure valve located on the fuel return line, after the injectors.

13B-266

DIESEL INJECTION



13B

ALP6 CONTINUED 1

NO

Does the high pressure pump show traces of grease? (Visual and tactile inspections)

YES

On the component

NO

Do the high pressure pipes and the injector rail show traces of grease? (Visual and tactile inspections)

YES

NO

Do the injectors show traces of grease? (Visual and tactile inspections)

Location of the leak: Where does the leak appear?

YES

NO

B

On the union/join

– If the leak is on the component, replace this and the high pressure pipe(s) at the same time as the component.

– If the leak is on the join of a high pressure pipe and the component, remove the high pressure pipe and perform a visual inspection of the unions: if you find damaged unions, change the faulty component and the high pressure pipe(s) removed at the same time as the component. – For safety reasons, high pressure pipes must not be refitted.

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-267



13B

ALP6 CONTINUED 2

B

Run command SC035 High pressure fuel circuit fault finding . While running the test, check that there are no leaks from the high pressure circuit. Is there a leak from the high pressure circuit? NO End of fault finding. Reminder: Only replace the rail, pump or injector if there is damage to the union and this damage is visible during checks. Bleed the fuel circuit and continue the checks.

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-268



ALP7

NOTES

13B

Rough idle

Before dealing with this customer complaint, check that there are no faults, and the conformity (or otherwise) of the parameters and statuses using the diagnostic tool. If the customer complaint is not ironed out, perform the following checks:

Check the sealing and the condition of the inlet circuit using test 4: Turbocharged air inlet circuit check. Check the low pressure circuit using test 3: Low pressure circuit check. – Check the connections and wiring of the injectors. – Check the connections and wiring of the engine management computer to the injectors. If one of the connectors is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, wiring: precautions for repair), repair the connector, otherwise replace the wiring.

Check the high pressure circuit (external leaks). (See the end of the Fuel circuit external leaks fault finding chart).

Check the engine parameters: – check the update of the engine management computer calibration (last calibration). – Check the charging circuit, apply Technical Note 6014A, Checking the charging circuit. – Check that the engine speed signal is correct using an oscilloscope: no interference, broken tooth, etc. If not correct, check: – The wiring. – The flywheel position and the condition of the flywheel teeth. – Check the position and tightness of the engine speed sensor. – Check the conformity of the IMA codes.

– Check the engine timing (and the position of the high pressure pump sprocket).

Check the lower engine: – Check the compressions using the command VP036 Inhibit fuel circuit supply. – Check the engine mountings. If the checks are correct, contact the Techline.

AFTER REPAIR



13B-269



ALP8

13B

Engine stalling

IMPORTANT

Fault mode: – Injector is switched off while charging, then injection is restarted when the charge drops. – No CLIP fault is reported, except sometimes DF569 Turbocharging circuit (turbocharging loop difference as no longer enough energy for the turbine). Do not deal with this fault DF569 which is an indirect result of the fault mode described in this section. – The Diesel return rail is faulty (injector outlet to 10 bar valve), and is no longer able to correctly provide the counter pressure required for injector operation. – The injector's hydraulic amplifier drains and the injectors no longer open, even though they conform electrically and the rail pressure is correct. – However, when the charges are smaller, the hydraulic amplifier starts again and the injectors operate again. Cause: – The Diesel return rail is faulty (injector outlet to 10 bar valve). Action: Replace the return rail.

AFTER REPAIR



13B-270

DIESEL INJECTION



ALP9

13B

Air conditioning does not work

With the ignition on, does the air conditioning control warning light come on when it is activated?

NO

YES

Check that the other control panel functions operate and check the electrical supply and earth of the table. If the connection is faulty and if there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ).

Switch on the + after ignition feed with the air conditioning button pressed and use the diagnostic too l to check the air conditioning request ET018 Air conditioning request. Is the air conditioning request recognised by the engine management computer?

NO

YES

Check the connection between the control panel and the engine management computer. If the connection is faulty and if there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair) .

Display the following parameter values: ET752 Air conditioning cut-off PR064 Coolant temperature PR037 Refrigerant pressure PR074 Battery voltage Are the parameters within the recommended ranges? YES

Contact the Techline

AFTER REPAIR

If the refrigerant pressure is too low, carry out a sealing test to locate any possible leaks. Perform a complete test on the air conditioning system (with a road test) until a satisfactory level of cold is reached. Check the cabin filter.



NO

13B-271

DIESEL INJECTION


ALP 10

NOTES

13B


Oil leaks from the turbocharger

Before dealing with this customer complaint, check that there are no faults, and the conformity (or otherwise) of the parameters and statuses using the diagnostic tool. If the customer complaint is not eliminated, perform the following checks.

Check the area around the turbocharger Note: An oil leak does not correspond always to a turbocharger fault, the oil leak can arise from the area around the turbocharger. According to the vehicle type, maximum visual access will either be from above or from below. 1 - Do not start the engine. Check the area around the turbocharger and identify the origin of the leaks. Clean the oil traces on the turbocharger. 2 - Start the engine and let it warm up several minutes. IMPORTANT If the air filter was removed previously, refit it before starting the engine (risks foreign matter entering the air inlet circuit). Accelerate with no load several times, progressively increasing the duration before releasing the accelerator pedal. Visually inspect the exterior condition of the fuel supply pipes and the turbocharger oil return and the area around it. Identify the origin of the leaks. Is an oil leak present at the air compressor inlet or outlet? YES

NO

Check the air compressor inlet or outlet Check for a loose interface (inlet or outlet) that is the cause of the air leak. Note: it is normal to find traces of oil inside the pipes at the turbocharger inlet or outlet as the air passing into the compressor is laden with oil from the engine rebreathing circuit. Is the suspected interface properly tightened?

NO

YES

AFTER REPAIR

Replace the pipe concerned (see MR 408, Mechanical, 12B, Turbocharging).



Tighten the interface or the concerned pipe. end of the procedure

13B-272

DIESEL INJECTION


13B


ALP 10 CONTINUED 1

Is an oil leak present only at the casing of the compressor section? YES

NO

The turbocharger is not faulty. The oil leak is from another engine component and the oil is flowing onto the turbocharger.

B

AFTER REPAIR

MR-410-X83-13B000$912.mif V5


13B-273

DIESEL INJECTION


13B


ALP 10 CONTINUED 2

B

Is an oil leak present at the turbocharger oil supply inlet or outlet? YES Check the turbocharger oil supply inlet and outlet Check for a loose interface (inlet or outlet) that is the cause of the oil leak.

NO

NO

Tighten the pipe concerned. End of procedure.

Is the suspected interface properly tightened?

YES

Replace only the seal or the pipe of the section concerned (see MR 408, Mechanical, 12B, Turbocharging ).

Is an oil leak present at the interfaces of the turbine casing and the exhaust pipes?

YES

NO

The turbocharger is not faulty. There is probably another fault in the engine. Mark the component that is the source of the leak and refer to the repair manual (see MR408, Mechanical, 10A, Engine and peripherals).

AFTER REPAIR

MR-410-X83-13B000$912.mif V5

End of procedure.


13B-274



ALP 11

13B

Noise from the turbocharger

Apply Technical Note 5164A, Noise fault finding.

Note: Pay close attention to faulty components that might result in unjustified replacement of the turbocharger. For example, whistling does not necessarily indicate damage to the turbocharger (this could be coming from the exhaust, the timing, the gearbox, etc.).

AFTER REPAIR


EDC16CP33_V0C_ALP11 / EDC16CP33_V10_ALP11 / EDC16CP33_V14_ALP11 / EDC16CP33_V16_ALP11 MR-410-X83-13B000$912.mif V5

13B-275

DIESEL INJECTION


13B


ALP 12

Exhaust fumes

Run test 2 Air line at the turbocharger . Run test 6: Turbocharger control solenoid valve check .

Is the vehicle equipped with a particle filter?

NO

YES

Start the engine and warm it up at idle speed for 10 minutes. IMPORTANT

Perform fault finding on the "particle filter" function, consult the TESTS or corresponding ALP.

If the air filter was previously removed, refit it before starting the engine (risk of aspirating foreign bodies into the air inlet circuit). Perform several rapid and brief accelerations under no load. Note: The presence of smoke is often normal. It is the quantity, density, colour and persistence that are deciding factors. Is the exhaust outlet producing abnormal smoke?

YES

NO

Consult test 7 Turbocharger .

AFTER REPAIR

The turbocharger is not faulty. There is probably another fault in the engine. Refer to the corresponding TEST or ALP.


EDC16CP33_V0C_ALP12 / EDC16CP33_V10_ALP12 / EDC16CP33_V14_ALP12 / EDC16CP33_V16_ALP12 MR-410-X83-13B000$912.mif V5

13B-276


DIESEL INJECTION Fault finding – Test

13B

EXHAUST SYSTEM CHECK

TEST1

AIR LINE AT THE TURBOCHARGER

TEST2

LOW PRESSURE CIRCUIT TEST

TEST3

TURBOCHARGED AIR INLET CIRCUIT CHECK

TEST4

AIR FLOWMETER

TEST5

TURBOCHARGER CONTROL SOLENOID VALVE CHECK

TEST6

TURBOCHARGER

TEST7

DIESEL FUEL CONFORMITY CHECK

TEST8

POOR INJECTOR OPERATION

MR-410-X83-13B000$960.mif V5

TEST10

13B-277

DIESEL INJECTION


Fault finding – Test

TEST1

13B

Exhaust system check

Special note: This test is only carried out on vehicles which are not fitted with a particle filter.

NOTES

Engine stopped: Check that the silencer outlet is not blocked. Repair or replace the silencer, if necessary.

Check the seal of the exhaust manifold on the contact surface between the turbocharger and the exhaust manifold. Is the seal in order?

NO

Repair or replace the defective part.

YES

Loosen the catalytic converter on the turbocharger side. Place a wooden block between the two parts. Start the vehicle and check if the engine runs better. Is the engine running normally?

NO

If the exhaust system is not the cause of the fault, see ALP5 Irregular engine operation

YES

Retighten the catalytic converter. Loosen or disconnect the intermediate chamber on the catalytic converter side. Put a wooden block between the two parts if necessary. Start the vehicle and check if the engine runs better. Is the engine running normally?

NO

Replace the catalytic converter.

NO

Replace the intermediate chamber.

YES

Retighten the intermediate chamber. Loosen or disconnect the silencer on the intermediate chamber side. Place a wooden block between the two parts, if necessary. Start the vehicle and check if the engine runs better. Is the engine running normally? YES

Replace the silencer.

EDC16CP33_V0C_TEST01/EDC16CP33_V10_TEST01/EDC16CP33_V14_TEST01/EDC16CP33_V16_TEST01 MR-410-X83-13B000$960.mif V5

13B-278

DIESEL INJECTION


13B


TEST2

Air line at the turbocharger

Check that the air filter is present. Check the replacement interval of the air filter on the maintenance booklet. Compare the part nos. of the fitted air filter on the vehicle and of the air filter recommended by the manufacturer. Check the direction of fitting of the air filter. Is the air filter correctly fitted on the vehicle? YES Check the condition of the air filter Visually inspect the condition of the filtering section of the air filter. Is the air filter or its seal damaged? Is the air filter fouled (does it contain a lot of impurities)?

NO

YES

Replace the air filter (see MR 408, Mechanical, 12A, Fuel mixture, Air filter, Removal - Refitting).

YES

Replace the defective parts (see MR 408, Mechanical, 12B, Turbocharging).

NO Low pressure circuit check Note: Depending on the vehicle type, the best visual access will be either from above or from below.

Visually inspect the condition of the following components: - fresh air inlet scoop on the front panel of the vehicle, - air inlet pipe to the air filter, - air pipe of the filter up to the compressor inlet, - air flowmeter mountings. Is one of these components incorrect (pipes dislodged, torn, bent, pierced or kinked)? NO

EDC16CP33_V0C_TEST02 /EDC16CP33_V10_TEST02/EDC16CP33_V14_TEST02/EDC16CP33_V16_TEST02 MR-410-X83-13B000$960.mif V5

13B-279

DIESEL INJECTION



13B

TEST2 CONTINUED

High pressure circuit check Note: Depending on the vehicle type, the best visual access will be either from above or from below. Visually inspect the condition of the following components: – outlet pipe of the compressor to the turbocharging air cooler, – outlet pipe of the turbocharging air cooler to the inlet manifold, – inlet manifold, – pressure and temperature sensors. Is one of these components incorrect (pipes dislodged, torn, bent, pierced or kinked)? YES NO

Exhaust circuit check Visually inspect the condition of the following engine sections: – from the exhaust manifold circuit to the turbocharger turbine, – from the turbine outlet pipe to the end of the exhaust pipe, – from the inlet manifold to the EGR valve, – pressure and temperature sensors connected. Do certain of these components have blackish or whitish traces? NO

Run test 6: Turbocharger control solenoid valve check .

MR-410-X83-13B000$960.mif V5

13B-280

Replace the defective parts (see MR 408, Mechanical, 12B, Turbocharging).

DIESEL INJECTION



TEST3

13B

Low pressure circuit check

Check the fuel filter: – Conformity of the fuel filter (correct part number and RENAULT filter). – Positioning and amount of clogging in the filter element. – Positioning and condition of the seals. – If there is metal swarf in the filter: Replace the fuel filter, bleed the circuit and continue the fault finding procedure.

Supplying the injection system with fuel from an additional tank.

This operation aims to detect possible faults in the low pressure supply system of a vehicle by replacing it entirely with an additional tank. Mode:

– Disconnect the diesel fuel supply pipe at the fuel filter inlet and seal it with a plug. – Connect a tube to the fuel filter inlet and insert the other end into a clean container which is approximately 5 litres in volume. – Disconnect the diesel fuel return pipe from the diesel fuel temperature sensor (pump return and injector return junction), and seal it off with a plug. – Connect a transparent tube to the diesel fuel temperature sensor union and insert the other end in the container. – Fill the container with clean diesel fuel. – Start the engine and let the system drain itself of its air (there must not be any air bubbles in the return pipe).

Is the customer complaint still present?

YES

NO

Are the low pressure circuit connections in order and in good condition?

NO

If the low pressure circuit is in order, reconnect the various pipes of the low pressure circuit and repeat the fault finding chart fault finding or of the fault that referred you to this test. Carry out the necessary repairs.

YES


13B-281



13B

TEST3 CONTINUED

Check the condition of the priming bulb, and that it is working properly. Perform repairs if necessary and continue the test.

Check the condition of all of the low pressure circuit pipes from the tank to the injection pump (in particular, the pipes should not be pinched).

If the fault is still present with a low fuel level, check the consistency of the actual fuel level and that indicated on the instrument panel. – The bailing unit is supplied via a venturi valve located beneath it. Check that the opening of the venturi (6 to 8 mm in diameter) is not blocked by dirt contained in the fuel tank. Check the priming of the low pressure diesel circuit.

Check that the fuel tank is correctly filled and that the appropriate fuel is used. Run test 8 Diesel fuel conformity check .

Low pressure circuit correct.

MR-410-X83-13B000$960.mif V5

13B-282


TEST4

Engine stopped: Check the tightness (air leak or intake) of the low and high pressure air circuit (before/after the turbocharger).


13B

Checking the turbocharged air inlet circuit

Check the parts that are abnormally greasy of the circuit and reveal a lack of tightness. Check: – the condition and fitting of the ducts (foreign, clogged, not joined, kinked, broken, pierced, cut bodies, tightness of the mounting bolts, etc.). – the presence, condition and fitting of the seals. – the present and tightening of the clamps. – The fitting of the turbocharging pressure sensor. – The pipe and the take-off point between the air duct and the turbocharging sensor. Carry out the necessary repairs.

Checking the air filter.

Check: – the condition of the damper valve, – the tightening of the mounting bolts, – cracks in the damper valve. Carry out the necessary repairs. Replace if necessary.

Carry out a visual inspection of the EGR circuit sealing. Note : the operating play in the EGR heat exchanger valve shaft produces small black marks due to a slight leak of no importance. Do not replace this part. Replace if necessary.

Check: – That the air filter unit inlet and outlet are not blocked. – the condition and the assembly of the air filter unit (disconnected, broken, pierced …). – The cleanliness, conformity and the absence of deformation of the filter element. – The air flowmeter: run test 5 Air flowmeter . Carry out the necessary repairs. Check that there is no leakage on the exhaust manifold, in particular at the exhaust manifold / turbocharger interface. Check the exhaust: run test 1 Exhaust pipe check . Carry out the necessary repairs. Check the condition of the intercooler: – clogging, – leaks (vehicle stationary, stabilise the engine speed between 3500 rpm and 4000 rpm and check that there are no leaks). Replace if necessary.

Check that the turbocharging pressure sensor take-off point is not blocked. Replace if necessary. END OF TEST.


13B-283


TEST5

DIESEL INJECTION

13B


Air flowmeter

Damage to electrical components

Visual inspection: remove the flow sensor - the components should not be broken. Replace the air flowmeter if necessary.

Oxidation of the electrical components

Visual inspection: remove the air flowmeter, there should not be any green deposits on the electrical components. Replace the air flowmeter if necessary.

Clogging of the air flowmeter

Test: – Check the values for conformity: – During the first 5 seconds after starting, – PR064 Coolant temperature: 80˚C, – PR055 Engine speed: idling, – PR059 Inlet air temperature between 30 and 70˚C, – PR132 Air flow: 24 ± 4 kg/h, – PR051 EGR valve position feedback 26 ± 4%, – PR023 Air flow difference between - 50 and + 50 mg/stroke. Replace the air flowmeter if necessary. END OF TEST.


13B-284

DIESEL INJECTION


13B


TEST6

Turbocharger control solenoid valve test

Start the engine and let it run at idle speed for 1 minute. Check the battery voltage. If the value of the PR071 Computer power supply voltage is greater than 13 V, continue the test. Otherwise, check the charge circuit, then perform a road test to confirm the disappearance of the fault.

Checking the vacuum at the pressure regulator inlet Run the engine at idle speed.

Check the engine temperature using the CLIP parameter PR064 Coolant temperature . Let the engine warm up until the temperature reaches 80˚C . Disconnect the vacuum pipe from the end piece of the pressure regulator. Connect a vacuum pressure gauge to the end of the disconnected pipe and put it in the vacuum measurement position. Perform a quick acceleration by depressing the accelerator pedal completely and then releasing it immediately. The total duration of pressing and holding in the full load position must not exceed 1 second. During this acceleration, the engine speed must reach a value between 3000 and 4000 rpm . Repeat the operation 3 times. Read the maximum vacuum posted by the pressure gauge during the increase and decrease in the speed and after the return to idle speed. Tolerance intervals for the vacuum are: -1 bar < CORRECT vacuum value < -0.6 bar -0.6 bar < INCORRECT vacuum value < 0 bar Is the vacuum at the turbocharging pressure regulator inlet, posted by the pressure gauge within the tolerance interval? NO

YES

The solenoid valve is in order. If the customer complaint is Smoke from the exhaust, run ALP12 Smoke from the exhaust. Otherwise, run test 7 Turbocharger .

EDC16CP33_V0C_TEST06/EDC16CP33_V10_TEST06/EDC16CP33_V14_TEST06/EDC16CP33_V16_TEST06

MR-410-X83-13B000$960.mif V5

13B-285

DIESEL INJECTION


13B


TEST6 CONTINUED 1

Reconnect the vacuum pipe on the turbocharging pressure regulator.

Checking the vacuum at the solenoid valve outlet Leave the engine running at idle speed.

Disconnect the vacuum pipe from the end piece of the solenoid valve outlet. This pipe connects the solenoid valve to the turbocharging pressure regulator. Connect a vacuum pressure gauge to the solenoid valve outlet and put it in the vacuum measurement position. Perform a quick acceleration by depressing the accelerator pedal completely and then releasing it immediately. The total duration of pressing and holding in the full load position must not exceed 1 second. During this acceleration, the engine speed must reach a value between 3000 and 4000 rpm . Repeat the operation 3 times. Read the maximum vacuum posted by the pressure gauge during the increase and decrease in the speed and after the return to idle speed. Tolerance intervals for the vacuum are: -1 bar < CORRECT vacuum value < -0.6 bar -0.6 bar < INCORRECT vacuum value < 0 bar Is the vacuum displayed by the pressure gauge at the solenoid valve outlet within the tolerance interval? NO

YES

Reconnect the vacuum pipe on the turbocharging pressure regulator.

MR-410-X83-13B000$960.mif V5

13B-286

Replace the vacuum pipe between the solenoid valve and the turbocharging pressure regulator (see MR 408, Mechanical, 12B Turbocharging).

DIESEL INJECTION


13B


TEST6 CONTINUED 2

Visual inspection of the electrical connector of the solenoid valve Switch off the engine. Note: The requested checks are only visual. 1 Check that the connector is correctly connected and locked. 2 Check the absence of damage to the electric wires where they leave the insulation. Disconnect the connector to continue the checks. 3 Check the absence of thermal damage to the unit and mechanical damage to the lock. 4 Check the absence of deformations of the contacts (clips and tabs). 5 Check the sealing of the connector. Do the visual inspections show any damage? NO

YES

If there is a repair procedure (see Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair ), repair the connector, otherwise replace the wiring. After the repair, repeat the test from the start. Checking the vacuum at the solenoid valve inlet Run the engine at idle speed. Disconnect the vacuum pipe from the end piece of the solenoid valve inlet. This pipe connects the vacuum pump to the turbocharger solenoid valve. Connect a vacuum pressure gauge to the end of the disconnected pipe and put it in the vacuum measurement position. Read the vacuum posted by the pressure gauge. Tolerance intervals for the vacuum are: -1 bar < CORRECT vacuum value < -0.85 bar -0.85 bar < INCORRECT vacuum value < 0 bar Is the vacuum displayed by the pressure gauge at the solenoid valve inlet within the tolerance interval? NO

YES

Carry out the following operations. - reconnect the vacuum pipe to the turbocharger solenoid valve. - Check the conformity of the vacuum pipe connections. - visually check the condition of the vacuum pipes leaving the vacuum pump to the different supplied components. Refer to the repair manual

MR-410-X83-13B000$960.mif V5

13B-287

Replace the solenoid valve.


DIESEL INJECTION

13B


TEST7

Turbocharger

IMPORTANT Perform these checks without removing the turbocharger and with the vehicle ignition switched off.

Checking the turbocharger shaft WARNING Observe the following safety precautions: - wear high temperature protective gloves when the engine is hot, - do not wear oversize or baggy clothing or hanging jewellery, - watch out for possible triggering of the motor-driven cooling fan unit and the operation of the accessories belt or belts.

Note: The turbocharger shaft is the shaft that connects the compressor wheel and the turbine wheel. Depending on the vehicle type, the best visual access will be either from above or from below. Disconnect the air pipe located between the turbocharger and the air filter. Wearing gloves, check the operation of the turbocharger shaft by turning the vanes manually without forcing. Does the shaft have a kickdown point in rotation? Does the compressor wheel touch the casing of the turbocharger?

If for these 2 questions the response is NO

If YES for one of these 2 questions

Replace the turbocharger (see MR 408, Mechanical,12B Turbocharging, Turbocharger: Removal - Refitting and Technical Note 3938A, Broken turbocharger: Replacement instructions).


13B-288

DIESEL INJECTION


13B


TEST7 CONTINUED 1

Checking the condition of the turbocharger vanes.

Note: This check is facilitated by using a mirror and a bulb. Depending on the vehicle type, the best visual access will be either from above or from below. Visually check that the compressor vanes are in good condition. Are the vanes damaged or twisted? NO

YES

Replace the turbocharger (see MR 408, Mechanical,12B Turbocharging, Turbocharger: Removal - Refitting and Technical Note 3938A, Broken turbocharger: Replacement instructions ).

Which type of turbocharger is it? Fixed geometry turbocharger

Variable geometry turbocharger

MR-410-X83-13B000$960.mif V5

13B-289

DIESEL INJECTION


13B


TEST7 CONTINUED 2

Checking the turbocharging pressure regulator to determine if it is a variable geometry turbocharger

Note: The pressure regulator rod of a variable geometry turbocharger is orthogonal to the turbocharger shaft. Variable geometry turbochargers are controlled by a solenoid valve. Depending on the vehicle type, the best visual access will be either from above or from below. Note: If necessary, according to the vehicle type and the accessibility of the pressure regulator, connect the vacuum pump to the end of the pressure regulator pipe at the solenoid valve outlet. Using a manual vacuum pump, apply a vacuum on the turbocharging pressure regulator of approximately 650 mbar . 1 2 3 4

Check that the fitting is completely leaktight. Check that the control rod is resting against its stop . Lock the vacuum device and check that the pressure variation is not greater than 100 mbar in 10 seconds. Release the pressure and check that the control rod comes back to its initial position without jerking.

Repeat the complete sequence 3 times. Is the pressure regulator leaktight and is the rod movement correct? YES

NO

The turbocharger is correct. End of procedure.

MR-410-X83-13B000$960.mif V5


13B-290

DIESEL INJECTION


13B


TEST7 CONTINUED 3

Checking the turbocharging pressure regulator to determine if it is a fixed geometry turbocharger

Note: The pressure regulator rod of a fixed geometry turbocharger is aligned with the turbocharger shaft. Fixed geometry turbochargers are controlled by a solenoid valve. Depending on the vehicle type, the best visual access will be either from above or from below. Note: If necessary, according to the vehicle type and the accessibility of the pressure regulator, connect the vacuum pump to the end of the pressure regulator pipe at the solenoid valve outlet. Using a manual vacuum pump, apply a vacuum on the turbocharging pressure regulator of approximately 650 mbar . 1 2 3 4

Check that the fitting is completely leaktight. Check that the control rod moved several millimetres. Lock the vacuum device and check that the pressure variation is not greater than 100 mbar in 10 seconds. Release the pressure and check that the control rod comes back to its initial position without jerking.

Repeat the complete sequence 3 times. Is the pressure regulator leaktight and is the rod movement correct? YES

NO

The turbocharger is correct. End of procedure.

MR-410-X83-13B000$960.mif V5


13B-291



TEST7 CONTINUED 4

Deformed, twisted blade ("soft" foreign body)

Broken blades ("hard" foreign body)

MR-410-X83-13B000$960.mif V5

13B-292

13B


DIESEL INJECTION

TEST8


13B

Diesel fuel conformity check

WARNING During this operation, it is essential to: – refrain from smoking or bringing incandescent objects close to the work area, – protect yourself against fuel splashes due to residual pressure in the pipes, – wear safety goggles with side guards, – wear leaktight gloves (Nitrile type). IMPORTANT – To avoid any corrosion or damage, protect the areas on which fuel is likely to run. – To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components exposed to the open air. Preparations: Weigh an empty 1300 ml plastic cup (part no. 77 11 171 413 ) with its cover (part no. 77 11 171 416) using electronic scales similar to those used in body paint workshops (for example: PANDA part no. 77 11 224 995 ). Record the weight of the empty plastic cup. This type of plastic cup is used to prepare paint.

Remove 1 l of fuel at the diesel filter outlet, using a pneumatic transfer pump ( part no. 634-200) and place it in the 1300 ml plastic cup. Cover the plastic cup with its cover and let the fuel settle for approximately 2 minutes.

Is the fuel cloudy or does it separate into two parts?

YES

The diesel fuel contains water and is not compliant. Drain the fuel circuit, including the tank.

NO

A

EDC16CP33_V0C_TEST08 / EDC16CP33_V10_TEST08 /EDC16CP33_V14_TEST08 / EDC16CP33_V16_TEST08 MR-410-X83-13B000$960.mif V5

13B-293

DIESEL INJECTION


13B


TEST8 CONTINUED 1

Weigh the diesel fuel and note the fuel weight after subtracting the weight of the empty plastic cup and its cover. Does the fuel weight fall between the minimum and maximum weights given in the table below? Calculated weight (g.) Min. weight

Max. weight

Fuel temperature (˚C)

821

846

13

821

846

14

820

845

15

819

844

16

819

844

17

818

843

18

817

842

19

816

841

20

816

841

21

815

840

22

814

839

23

814

839

24

813

838

25

Check the fuel temperature by immersing a thermometer in the plastic cup. YES

MR-410-X83-13B000$960.mif V5

NO

13B-294



13B

TEST8 CONTINUED 2

End of test.

The fuel is not correct. If the fuel weight is less than the minimum value then there is petrol in the diesel fuel. If the fuel weight is greater than the maximum value then there is oil in the diesel fuel. Drain the fuel circuit, including the tank.

Note: If the weight measured reaches the upper and lower limits, the measurement can be performed with a 2230 ml plastic cup ( part no. 77 11 171 414 ) and its cover (part no. 77 11 171 417 ): – Carry out a quick test drive in order to mix the fuel, then remove 2 l of fuel. – Perform the test again and check the results by multiplying the limit values by 2. Contact the Techline if you have doubts or problems with the customer.

MR-410-X83-13B000$960.mif V5

13B-295

DIESEL INJECTION


13B


TEST10

Incorrect injector operation

Part A:

Run SC031 Cylinder operational fault finding. Is SC031 correct?

YES

The injectors are correct

NO Check the engine compressions: use a compression gauge, the M9R hose end piece, part number Mot.1772 and run command VP036 Fuel supply inhibition (see Interpretation of commands). Run the compressions on all cylinders. Are the compressions correct? NO Check the cylinder block.

YES Check the fitting of the injector concerned and repair if necessary. Otherwise change the concerned injector. After replacing the injector, follow the injector code programming procedure (see Replacement of components ), run SC036 Reinitialise programming, and select the number of the injector replaced. Repeat Part B of Test 10 to confirm the repairs.

IMPORTANT: When removing or refitting the injectors, observe the cleanliness guidelines and safety advice (see MR 408 Mechanical, 13B, Diesel injection, Diesel injectors: Removal - Refitting).


13B-296

EDC 16 ,2

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