MR391X2413B000 master

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Engine and peripherals

"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 result of changes introduced by themanufacturer in the production of the various component units and accessories fromwhich his vehicles are constructed."

V2

All rights reserved by Renault s.a.s.

Edition Anglaise

Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority ofRenault s.a.s.

© Renault s.a.s.

V2MR-391-X24-13B000$000_engTOC.mif

DIESEL INJECTION

EDC16 InjectionProgram No.: C1

Vdiag No.: 04Fault finding - Introduction 13B - 2Fault finding - Cleanliness guidelines 13B - 8Fault finding - System operation 13B - 10Fault finding - Allocation of computer tracks 13B - 16Fault finding - Replacement of components 13B - 19Fault finding - Fault summary table 13B - 23

Fault finding - Interpretation of faults 13B - 26Fault finding - Parameter summary table 13B - 106Fault finding - Conformity check 13B - 108Fault finding - Status summary table 13B - 140Fault finding - Interpretation of statuses 13B - 141Fault finding - Command summary table 13B - 163Fault finding - Interpretation of commands 13B - 164Fault finding - Customer complaints 13B - 182Fault finding - Fault Finding Chart 13B - 183Fault finding - Component operational test 13B - 190

13B

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13B - 2

DIESEL INJECTION

Fault finding - Introduction 13B

V2MR-391-X24-13B000$050_eng.mif

113BEDC16 InjectionProgram No.: C1

Vdiag No.: 04

DIESEL INJECTION

Fault finding - Introduction

1. SCOPE OF THIS DOCUMENT

This document presents the fault finding procedure applicable to all computers with the following specifications:

2. PREREQUISITES FOR FAULT FINDING

Documentation type:

Fault finding procedures (this manual): – Assisted fault finding (integrated into the diagnostic tool), Dialogys.

Wiring Diagrams: – Visu-Schéma (CD-ROM), paper.

Type of diagnostic tools:

– CLIP + multiplex line sensor

Special tooli ng required:

Vehicle(s): Master rear wheel drive phase II

Engine type and suffix: ZD3 600-604

Function concerned: Diesel injection

Computer name: BOSCH EDC16 C3

Program no.: C1

VDIAG No: 04

Special tool ing required

Multimeter

Elé. 1590 Bornier Clip + CAN probe

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Vdiag No.: 04

3. RECAP

Faults

Faults are declared to be either present or stored (depending on whether they appeared in a certain context andhave 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 onafter the + after ignition feed (without any system components being active).

For a present fault, apply the procedure described in the Interpretation of faults section.

For a stored fault , note the faults displayed and apply the instructions in the Notes section.

If the fault is confirmed when the instructions in the Notes section are applied, the fault is present. Deal with the faultIf the fault is not confirmed, check:

– the electrical lines which correspond to the fault, – the connectors on these lines (corrosion, bent pins, etc.), – the resistance of the component detected as faulty, – the condition of the wires (melted or split insulation, wear).

Conformity check

The aim of the conformity check is to check statuses and parameters that do not produce a fault display on thediagnostic tool when they are inconsistent. Therefore, this stage is used to:

– carry out fault finding on faults that do not have a fault display, and which may correspond to a customercomplaint.

– check that the system is operating correctly and 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 thecorresponding 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 bycustomer complaint.

A summary of the overall procedure to fol low is provided on the fo llowing

page in the form of a flow chart.

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Vdiag No.: 04

4. FAULT FINDING PROCEDURE

Check the battery charge and thecondition of the fuses

Print the system fault finding log(available on CLIP or in

the MR or NT)

Connect CLIP

noDialogue withthe computer?

yes

Read the faults

no

Faults

present

yes

Deal with present faults

Deal with stored faults

no

The cause isstill present

Fault

solved

yes

Refer to ALP No. 1

Conformity check

no


Fault

solved

Use fault finding charts (ALPs)

no


Fault

solved

Contact your Techline with thecompleted fault finding log

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Vdiag No.: 04

4. FAULT FINDING PROCEDURE (continued)

Wiring check:

Fault finding problems:

Disconnecting the connectors and/or manipulating 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 notpresent when the analysis is made (stored fault).

Visual inspection:

Look for damage under the bonnet and in the passenger compartment.Carefully check the fuses, insulation and wiring routing.Look for signs of oxidation.

Tactile inspection:

While manipulating the wiring harness, use the diagnostic tool to note any change in fault status from stored topresent.Make sure that the connectors are firmly 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 their crimping (no crimping onthe 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 to another wire.

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

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Vdiag No.: 04

5. FAULT FINDING LOG

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 warrantyreimbursement, and enables better analysis of the parts removed.

6. SAFETY ADVICE

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.

Before working on the injection system, ensure that the system pressure is nearing 0 bar.

IMPORTANT

IMPORTANT Any fault on a complex system requires thorough fault finding with the appropriate tools. TheFAULT 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 themanufacturer.

IT IS THEREFORE MANDATORY TO FILL OUT A FAULT FINDING LOG FOR EACH FAULT FINDINGPROCEDURE.

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Vdiag No.: 04

7. GENERAL OBSERVATIONS:

SWITCHING ON THE VEHICLE IGNITION FOR FAULT FINDING:

To run fault finding on the vehicle computers, proceed as follows: – switch on the ignition (key in + After ignition position), – check the battery voltage. It must be greater than 11 V. If not, recharge the battery, – connect the diagnostic tool and perform the required operations.

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DIESEL INJECTION SYSTEM

Fault finding - Cleanliness guidelines 13B

13B - 8V2MR-391-X24-13B000$100_eng.mif

113BEDC16 InjectionProgram No.: C1

Vdiag no.: 04


Fault finding - Cleanliness guidelines

I - RISKS ASSOCIATED WITH CONTAMINATION

The high pressure direct injection system is highly sensitive to contamination. The risks linked to 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 (evenparticles a few microns in size) should have entered the system during dismantling.

The cleanliness principle must be applied from the filter up to the injectors.

What are the sources of contamination? – metal or plastic chips, – paint, – fibres:

– cardboard, – from brushes, – from paper, – from clothing, – from cloths,

– foreign bodies such as hair, – ambient air – etc.

II - NOTES TO BE FOLLOWED BEFORE ANY OPERATION

Ensure that you have caps for any unions which are going to be opened (set of caps available from the PartsDepartment). The caps are single-use only. After use, they must be discarded (once used they are soiled andcleaning does not make them reusable). Unused caps must be discarded.

IMPORTANTIt is forbidden to clean the engine using a high pressure cleaner because of the risk of damaging connectors. Inaddition, moisture may collect in the connectors and create electrical connection faults.

IMPORTANTBefore any work is carried out on the high pressure injection system, protect: – the accessories and timing belts, – the electrical accessories, (starter motor, alternator, electric power assisted steering pump), – the flywheel surface, to prevent any diesel from running onto the clutch friction plate.

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Fault finding - Cleanliness guidelines 13B

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Vdiag no.: 04

Ensure that you have hermetically resealable plastic bags for storing removed parts. There is less risk that the partswill be exposed to impurities if they are stored in this way. The bags are to be used once only, and discarded afteruse.

Use lint-free cleaning cloths (part number 77 11 211 707). Using normal clothes or paper is prohibited. They are notlint-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 uncontaminatedreceptacle.

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 which are going to be opened.

Blow compressed air over the cleaned parts (tools, workbench, the parts, unions and injection system zones). Checkthat 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 capped to prevent impurities from entering the system. The capsto be used are available from the Parts Department. The caps 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 theyhave been capped.

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 which is replacing an old one must not be removed from its packaging until it can be fitted to thevehicle.

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Fault finding - System operation 13B

13B - 10V2MR-391-X24-13B000$150_eng.mif


Vdiag No.: 04

DIESEL INJECTION

Fault finding - System operation

The high pressure injection system is designed to deliver a precise quantity of diesel fuel to the engine at a setmoment.

It is fitted with a 112-track BOSCH "EDC16" computer.

The system comprises: – an electric low pressure pump, – a diesel filter, – a high pressure pump with a built-in low pressure pump (transfer pump), – a high pressure regulator mounted on the pump, – an injector rail, – a diesel fuel pressure sensor built into the rail, – four solenoid injectors, – a diesel fuel temperature sensor, – a coolant temperature sensor, – an air temperature sensor, – a cylinder reference sensor, – an engine speed sensor, – an EGR solenoid valve, – an accelerator pedal potentiometer, – a brake and clutch pedal position sensor, – an atmospheric pressure sensor integrated into the injection computer, – a flow sensor, – a turbocharging pressure sensor, – a turbocharging pressure regulation solenoid valve.

The "common rail" direct high pressure injection system works sequentially (based on the petrol engine multipointinjection).

This new injection system reduces operating noise, reduces the volume of pollutant gases and particles andproduces 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 thepump controls the quantity of diesel fuel supplied, according to the requirement determined by the computer. The railsupplies each injector through a steel pipe.

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Vdiag No.: 04

a) The computer:

This determines the injection pressure value necessary for the engine to operate correctly and controls the pressureregulator accordingly. It checks that the pressure value is correct by analysing the value transmitted by the pressure

sensor located on the rail.

It determines the necessary injection timing to deliver the right quantity of diesel fuel and the moment when injectionshould start.

It electrically controls each injector individually after determining these two values.

The flow injected into the engine is determined by: – the duration of injector control, – the rail pressure (regulated by the computer), – the injector opening and closing speed, – the needle stroke (determined by a constant for the type of injector), – the nominal hydraulic flow of the injector (specific to each injector).

The computer manages: – idling regulation, – exhaust gas flow reinjection to the inlet, – fuel supply check (advance, flow and rail pressure), – fan assembly control, – the air conditioning, – the cruise control function, – pre-post heating control, – fault warning lights via the multiplex network.

The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump).

It supplies the rail, for which the pressure is controlled by the fuel flow actuator for charging and by the injector valvesfor discharging. This compensates for pressure drops. The flow actuator allows the high pressure pump to supply theexact quantity of diesel fuel required to maintain the pressure in the rail. This component minimises the heatgenerated and improves engine output.In order to discharge the rail using the injector valves, the valves are controlled by brief electrical pulses which are: – short enough not to open the injector (passing through the feedback circuit from the injectors), – long enough to open the valves and discharge the rail.

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Vdiag No.: 04

The connections between the vehicle's various computers are multiplexed.

The multiplex network enables: – the computers' communication, – the instrument panel warning lights to function,

– vehicle fault feedback, – the need for the vehicle speed sensor in the gearbox.

The vehicle speed signal on the instrument panel is transmitted by the ABS computer via a wire connection, thensent out on the multiplex network by the instrument panel. The main users of the vehicle speed signal are theinjection computer and the airbag computer.

Some vehicles have a sensor for detecting water in the diesel fuel, located in the filter. If there is water in the fuel, theorange injection and pre/postheating warning light will come on.

The system can inject diesel fuel into the engine at a pressure of up to 1600 bar . Before each operation, check thatthe injector rail is depressurised and that the fuel temperature is not too high.

When working on the high pressure injection system, you must respect the cleanliness guidelines and safety advicespecified in this document.

Dismantling the interior of the pump and injectors is forbidden. Only the flow actuator, the diesel temperature sensorand the Venturi tube 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 contaminationfaults. If the pressure sensor is faulty it must be replaced, along with the rail and the high pressure pipes.

Supplying + 12 V directly to any component of the system is prohibited.

Ultrasonic decoking and cleaning are prohibited.

Never start the engine unless the battery is connected correctly.

In the event that electrical welding is carried out on the vehicle, the following must be disconnected:

– the battery – the injection computer.

WARNINGThe engine must not operate with:

– diesel fuel containing more than 10 % diester, – petrol, even in tiny quantities.

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Vdiag No.: 04

Cold loop air conditioning management:

The air conditioning system is the cold loop type. The injection computer is responsible for: – authorising cold requests in accordance with the refrigerant pressure, the engine coolant temperature

and the engine speed.

Cooling by viscous coupling:

The Master propulsion phase II is equipped with a hydraulic cooling fan (viscous coupling).

Fault finding cannot be run on this and it is not managed by the injection computer.

The ventilation fan operates: – as soon as the engine coolant temperature exceeds 90 ± 5 ˚C, – as soon as the air conditioning is authorised.

The ventilation fan speed of rotation depends on: – engine speed, – vehicle speed.

The ventilation fan no longer works if the engine coolant temperature is less than 75 ± 5 ˚C.

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Vdiag No.: 04

Management of the cruise control and the power take-off funct ion:

The cruise control function , when activated, maintains the vehicle at a preselected speed, regardless of thedriving conditions encountered. Using the control buttons the driver can increase the vehicle speed.

The cruise control function can be deselected either by: – deactivating the cruise control switch, – detecting system events, such as the brake pedal or clutch being depressed, – detecting system errors, such as inconsistent vehicle speed or excessive vehicle deceleration.

The cruise function can also be temporarily disabled when the driver wants to increase speed by depressing theaccelerator pedal. The cruising speed is resumed when the driver releases the accelerator pedal.It is possible to reactivate the cruise control function and resume the last cruising speed after deactivation (computersupply voltage not cut). The vehicle attempts to resume the cruising speed at a controlled acceleration rate.

The driver has the following controls to operate the cruise control function: – accelerator pedal, – brake pedal, – clutch pedal, – on/off switch functions for cruise control and power take-off, – instrument panel R button allowing cruising speed to be remembered following cruise control

deactivation, – instrument panel 0 button allowing the cruise control function to be stopped momentarily, – instrument panel ± button allowing the cruising speed to be increased or decreased.

The power take-off function (fast idle speed) enables specific equipment to be used: – power take-off (crane,.etc.) – urban roadwork equipment (tipper, concrete mixer,.etc.).

The driver has the following controls to operate the power take-off function: – on/off switch functions for cruise control and power take-off, – instrument panel R button permitting the last stored fast idle speed to be re-established, – instrument panel 0 button allowing the power take-off function to be deactivated momentarily, – instrument panel ± button allowing the fast idle speed to be increased or decreased.

Speed limiter

The objective is to be able to limit the maximum speed of vehicles which are subject to speed restriction regulationsto a speed which is less than or equal to the speed limit, and no longer only to the speed limit.

To meet this objective, it is possible to modify the maximum speed programmed in the engine computer using

After-Sales tools. Run command SC013 "Vehicle speed l imiter function" . The speed is to be set between42 mph (70 km/h) and 78 mph (130 km/h) depending on the regulations or not.

A speed limit value which is less than the regulatory limit (below restriction) must be programmed.

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Vdiag No.: 04

Exhaust gas recirculation management:

The exhaust gas recirculation system comprises a direct current EGR valve controlled by an H bridge in thecomputer. This system has a built-in valve position feedback potentiometer.

The EGR valve is controlled by a closed loop throughout the changing air flow. The potentiometer is used in the faultfinding procedure for the EGR valve position. An EGR cooler cools the exhaust fumes before they are redirected to the inlet.

b) WARNING LIGHT MANAGEMENT

Instrument panel display:

The computer manages the data display on the instrument panel relating to engine operation. This concerns4 functions:

– pre/postheating, – the coolant temperature, – Level 1 engine faults (non critical fault), – Level 2 engine faults (emergency stop).

These 4 functions are represented by 2 indicator lights on the instrument panel.

1. Pre/postheating warning light, non crit ical fault:

This warning light is used as an in operation indicator lamp and as a system fault indicator light: – Continuously lit for a few seconds + APC: indicates preheating. – Continuously lit when the engine is running: indicates a Level 1 fault, non critical fault (implies reduced

operation and limited level of safety. The user must carry out repairs as soon as possible).

2. Temperature/emergency stop warning light:

This light is used as an operation indicator light and as a system fault warning light. It comes on for 3 seconds whenswitched on (automatic test procedure managed by instrument panel).

– Flashing: indicates engine overheating (the driver remains free to stop the vehicle or not). – Continuously lit: indicates a level 2 fault (In this case, the injection is automatically cut after a few seconds).

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Fault finding - Allocation of computer tracks

13B - 16

13B

V2MR-391-X24-13B000$200_eng.mif


Vdiag no.: 04



32-track b lack connector A

Track Description

A1 Not used

A2 Cruise control On/Off switch

A3 Not used

A4 Not used

B1 Air conditioning compressor relaycontrol

B2 Not used

B3 Not used

B4 K line diagnostic socket outputC1 Not used

C2 Not used

C3 Not used

C4 Clutch pedal position sensor signal

D1 + After ignition feed

D2 Cruise control programming control

D3 Cruise control programming feedbacksignal

D4 Not used

Track Description

E1 Not used

E2 Air conditioning signal

E3 Power take-off On/Off switch

E4 Brake switch supply signal output

F1 Not used

F2 Accelerator potentiometer load 2supply

F3 Accelerator potentiometer load 2 signal

F4 Accelerator potentiometer load 2 earthG1 Protective relay supply

G2 Accelerator potentiometer load 1supply

G3 Not used

G4 Battery earth

H1 Battery earth

H2 Accelerator potentiometer load 1 signal

H3 Accelerator potentiometer load 1 signal

H4 Battery earth

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Vdiag no.: 04

Brown 48-track connector B

Track Description

A1 Cylinder 1 reference sensor earth(camshaft)

A2 Not used

A3 Not used

A4 Fuel rail pressure sensor supply

B1 TDC sensor supply signal

B2 Not used

B3 Not used

B4 Air flow sensor supplyC1 TDC sensor earth signal

C2 EGR valve engine supply signal

C3 Not used

C4 Fuel rail pressure sensor earth

D1 Cylinder 1 reference sensor signal(camshaft)

D2 EGR valve engine earth signal

D3 Not used

D4 Turbocharging pressure sensor earth

E1 Injection locking relay coil earth control

E2 Air flowmeter earth signal

E3 Not used

E4 Not used

F1 Refrigerant sensor signal

F2 Coolant temperature sensor supplysignal

F3 Refrigerant sensor supply

F4 Gas recirculation sensor supply

Track Description

G1 Air flowmeter supply signal

G2 Air temperature signal

G3 Fuel rail pressure sensor signal

G4 Turbocharger turbocharging pressuresensor supply

H1 Coolant temperature sensor earth

H2 Fuel temperature signal

H3 Not used

H4 Not usedJ1 Not used

J2 EGR valve potentiometer signal

J3 Not used

J4 Not used

K1 Not used

K2 Turbocharging pressure sensor signal

K3 Not used

K4 Not used

L1 Not used

L2 Not used

L3 Not used

L4 Not used

M1 Not used

M2 Protective relay + supply

M3 Not used

M4 Fuel pressure regulation solenoid valvecontrol

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Vdiag no.: 04

Grey 32-track connector C

Track Description

A1 Not used

A2 Not used

A3 Not used

A4 Preheating relay fault finding signal

B1 Not used

B2 Not used

B3 Brake lights contact signal

B4 Not used

C1 Fuel pump relay control

C2 EGR solenoid valve earth

C3 Refrigerant sensor earth

C4 Not used

D1 Not used

D2 Not used

D3 Not used

D4 Not used

Track Description

E1 Turbocharger operating solenoid valvecontrol

E2 Preheating relay control

E3 Not used

E4 Not used

F1 Fuel temperature earth

F2 Not used

F3 Not used

F4 Not usedG1 Injector command 4

G2 Injector command 2

G3 Injector 1 earth

G4 Injector 2 earth

H1 Injector command 1

H2 Injector command 3

H3 Injector 4 earth

H4 Injector 3 earth

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Fault finding - Replacement of components 13B

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Vdiag No.: 04

DIESEL INJECTION

Fault finding - Replacement of components

COMPUTER REPLACEMENT OR REPROGRAMMING OPERATIONS

The system can be programmed or reprogrammed via the diagnostic socket using the RENAULT CLIP diagnostictool (see Technical Note 3585A, Computer p rogramming and reprogramming procedure).

While the computer is being (re)programmed the engine fan assemblies are automatically t riggered.

Before reprogramming or replacing the computer in After-Sales operations, save the following data to thediagnostic tool: – The IMA codes (individual correction of the injector ). – The engine adaptives (engine speed, and options available on the vehicle) using command SC005 Computer

replacement data backup.

Af ter programming, reprogramming or replacing the computer: – Switch the ignit ion off and then on again, – Start and then stop the engine (to ini tialise the computer) and wait 30 seconds. – Use the diagnostic tool to carry out the following steps: – Use command VP001 Write VIN. – Use command SC007 Write data after replacing computer , to re-establish the injector codes and the engine

adaptives. – Run command CF001 "Passenger compartment heating resistor" and select " WITH" . – Deal with any faults detected by the diagnostic tool. Clear the computer memory. – Carry out a road test followed by a complete test with the diagnostic tool.

Operations to be carried out before the injection computer is reprogrammed:

Before reprogramming the injection computer, move the main Cruise control/Speed limiter switch to the restposition. The information about the cruise control or the speed limiter displayed on the instrument paneldisappears.Otherwise, if the main switch remains in the cruise control or speed limiter position during and after reprogramming,the Cruise control/Speed limiter function will not be operational.The procedure for resetting the function is as follows:

Vehicle ignition on. – Position the main switch in rest position (the computer then detects the rest position).

– Position the switch in Cruise control position to activate the Cruise control function. – Position the switch in Speed limiter position to activate the Speed limiter function.

IMPORTANT – Switch on the diagnost ic tool (mains or cigarette lighter feed). – Connect a battery charger. – Switch off all electr ical consumers (l ights, interior lights , air condit ioning, radio CD, etc.).

– Wait for the eng ine to cool (coolant temperature < 60˚, and air temperature < 50˚).

WARNING A computer wi thout the IMA option can be replaced by a computer with this opt ion. The codes havetherefore not been saved during command SC005.

In this case, status ET235 "Injector code use" changes to "YES", fault DF173 " Injector code programming"is present, and the engine functions in defect mode.Use command SC004 Injector calibration data inpu t (see interpretation of commands).

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Vdiag No.: 04

Note:In case of forgetting or non operation of the commands SC005 and SC007, after replacing or reprogramming thecomputer: – the IMA codes must be typed in for each injector (using command SC004 " Injector calibration data input"), – the EGR valve must be reinitialised (using command RZ010 "EGR valve fault adaptives").

IMPORTANT

– The injection computer retains the same immobiliser code for life. – The system has no security code. – It is not permitted to perform tests with computers borrowed from the Parts Department or from another vehicle

which must then be returned. These computers are hard-coded. – If the injection computer appears to be faulty, contact the Techline and refer to the fault finding log.

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Vdiag No.: 04

REPLACING THE EGR VALVE

After replacing the exhaust gas recirculation valve, the computer has to store the new valve offset (at 0 miles) andthe measured offset from the last time the ignition was switched off (in power latch phase*).

The computer detects clogging or a blockage in the valve using this data.

1. Procedure to follow after replacing the EGR valve:

– select the CLEAR menu, – run the clearing command RZ010 EGR valve fault adaptives: – display the parameters of the EGR circuit sub-function:

PR583 = PR584 = 0 %,

– switch off the ignition, – wait until power latch closes down for + 10 seconds i.e. 20 seconds minimum, – as soon as the ignition is switched on again the new EGR valve offset is automatically reinitialised, – display the parameters of the

EGR circuit sub-function:

0 % < PR583 < 20 % – start the vehicle to enable the latest EGR valve offset to be programmed, – switch off the ignition, – display the parameters of the EGR circuit sub-function:

0 % < PR088 = PR583 = PR584 < 20 %

2. Static test:

Exit fault finding mode and switch off the ignition, – wait 20 seconds, and switch on the ignition again, – clear any faults,

– start the engine, – let the engine idle for 1 min, – accelerate to 2,500 rpm for 5 s, and then return to idle speed, – repeat this procedure 5 times.Check for faults,If the fault does not recur, end the fault finding procedure.If the fault reappears, restart the procedure after disconnecting and reconnecting the EGR valve.If the fault is still present, replace the EGR valve.

*the engine immobiliser warning light will flash for a few seconds after switching the ignition off

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Vdiag No.: 04

REPLACING THE INJECTOR(s)

Procedure for programming the injector codes

– read the 6-figure alpha-numeric codes engraved on the upper section of the Bakelite body of the injector(s), – Select the COMMAND menu, then SPECIFIC COMMAND. – select the command SC004 Injector calibration data input, – on the CLIP tool, follow the instructions when the help button (depicted as a book) is clicked on. – when the command has finished, the modified code(s) is/are displayed in the CURRENT column.

Note:The IMA coding (individual injector correction) is a calibration made in production on each injector to adjustthe flow accurately.These correction values are etched onto the Bakelite body of each injector (6 alphanumeric characters) and thenentered into the computer which then controls each injector taking into account their manufacturing variation.

When replacing one (or more) injector(s), modify the IMA parameters on the injector outlet concerned. The systemcan be configured with the diagnostic socket using the RENAULT CLIP diagnostic tool. To do this, note down the IMA code(s) etched on the injector bodies, and enter these codes into the computer usingthe command SC004 Injector calibration data input, and follow the instructions given by the diagnostic tool.

IMPORTANT When the command is complete, switch off the ignition and exit fault finding mode.Wait 10 s.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 correspond, start the SC004 " Injector calibration data input" command procedure again.Then check the system faults, and clear any stored faults.If the computer does not have any faults, the operation is complete.If not, process any present faults.If necessary, clear fault DF173 Injector code programming.

*Note: – cylinder no. 1 is located at the timing end – the letters "Q" and "J" and the numbers "0" and "9" are not used in IMA coding, – each code must be allocated to the cylinder on which the injector is mounted.

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Fault finding - Fault summary table 13B

13B - 23V2MR-391-X24-13B000$300_eng.mif


Vdiag No.: 04

DIESEL INJECTION

Fault finding - Fault summary table

WARNING LIGHT MANAGEMENT:

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

FAULTSSystem

DTC

FAULT WARNINGLIGHT

LEVEL 1

(Orange preheatingindicator light)

FAULT WARNING LIGHT

LEVEL 2(Red overheating

warning light)

NO WARNINGLIGHT ON

DF001 Computer 606 6.DEF/8.DEF/12.DEF

1.DEF/2.DEF/3.DEF 4.DEF/5.DEF/7.DEF/10.DEF/

11.DEF/13.DEF/14.DEF...

DF002 Coolanttemperature sensor circuit

115 CO.1/CC.0 ... ...

DF012 Battery voltage 560 ... ... 1.DEF/2.DEF

DF015 Immobiliser C167 ... 1.DEF ...

DF016 Clutch contactcircuit

830 1.DEF/2.DEF ... ...

DF019 Air flow sensorcircuit

1001.DEF/2.DEFCO.0/CC.1

... ...

DF021 Fuel temperaturesensor circuit

180 ... ... CC.O/CO.1

DF022 Air temperature

sensor circuit110 CC.0/CO.1 ... ...

DF023 Engine speedsensor circuit

335 ... 1.DEF/2.DEF ...

DF024 Atmosphericpressure sensor circuit

105 1.DEF/2.DEF/3.DEF ... ...

DF027 EGR solenoidvalve circuit

400 ... ... 1.DEF

DF051 Brake pedalcontact circuit

571 1.DEF/2.DEF ... ...

DF061 Heater plug circuit 670 X ... ...

DF070 Camshaft/enginespeed sensor consistency

16 ... ... 1.DEF

MR-391-X24-13B000$300_eng.mif

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Vdiag No.: 04

FAULT WARNING LIGHT MANAGEMENT (CONTINUED):

FAULTS SystemDTC

FAULT WARNING

LIGHTLEVEL 1


FAULT WARNING

LIGHTLEVEL 2

(Red overheatingwarning light)

NO WARNING LIGHTON

DF071 Pedal sensorcircuit gang 1

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

DF073 Pedal sensorcircuit gang 2

2120 CO.0/CC.1/1.DEF ... ...

DF081 Preheating relaycircuit

380CC.0/CO/CC.1/

1.DEF... ...

DF082 Low pressurepump relay circuit 230 X ... ...

DF084 EGR valve positionsensor circuit

486 ... ... CO.0/CC.1

DF091 Sensor supplyvoltage no. 1

641 1.DEF/2.DEF ... ...


651 1.DEF/2.DEF ... ...

DF095 Vehicle speedsignal

500 ... 1.DEF ...

DF099 Cylinder 1 injectorcircuit

201 CO CC.1/CC/1.DEF ...


202 CO CC.1/CC/1.DEF ...


203 CO CC.1/CC/1.DEF ...

DF102 Cylinder injectorcircuit 4

204 CO CC.1/CC/1.DEF ...

DF113 Refrigerant

pressure sensor circuit.530 ... ... CO.0/CC.1

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Vdiag No.: 04

FAULT WARNING LIGHT MANAGEMENT (CONTINUED 2):

FAULTS SystemDTC

FAULT WARNING

LIGHTLEVEL 1


FAULT WARNING

LIGHTLEVEL 2

(Red overheatingwarning light)

NO WARNING LIGHTON

DF117 Rail pressuresensor circuit

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

DF118 Cruise control/speed limiter function

575 ... ... 1.DEF/2.DEF/3.DEF

DF125 Main relay controlcircuit

685 1.DEF/2.DEF ... ...

DF137 Rail pressureregulation function 89 3.DEF CO/CC.0/CC.1/1.DEF/2.DEF/4.DEF5.DEF/6.DEF

...

DF144 Compressor relaycontrol line

1605 ... ... X

DF146 Computer supplyvoltage

615 ... ... 1.DEF

DF163 EGR valve controlcircuit

403 1.DEF ... 2.DEF

DF173 Injector code

programming611 1.DEF/2.DEF ... ...

DF208 Turbochargingsolenoid valve controlcircuit

33CC.0/CC.1CO/1.DEF

... ...

DF209 Turbochargingpressure sensor circuit

235CC.1

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


697 ... 1.DEF/2.DEF ...

DF233 Turbochargingpressure regulation circuit

243 1.DEF/2.DEF ... ...

DF235 Camshaft sensorcircuit

340 1.DEF/2.DEF ... ...

DF244 Cruise controlfunction

575 ... ... 1.DEF/2.DEF/3.DEF

DF253 EGR solenoidvalve servo-control

409 2.DEF ... 1.DEF

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Fault finding - Interpretation of faults 13B

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Vdiag No.: 04

DIESEL INJECTION

Fault finding - Interpretation of faults

DF001PRESENT

ORSTORED

COMPUTER

1.DEF : permanent high signal2.DEF : permanent low signal

3.DEF : configuration absent or incorrect4.DEF : analogue/digital converter fault5.DEF : disrupted communication6.DEF : EEPROM fault7.DEF : watchdog activation8.DEF : signal outside upper limit10.DEF : injector control11.DEF : injector control condenser fault12.DEF : injection fault when decelerating13.DEF : initialisation fault

14.DEF : open circuit

WARNINGThis fault may appear if the wiring has been damaged.

Follow the procedure described in the Wiring Check in the Introduct ion.This check enables the condi tion and the conformity of the engine wiring harness to be checked.

NOTES

Conditions for applying the fault finding procedure to stored faults:The fault is declared present following an attempt to start engine or when the engine isrunning.

Special notes:

The level 1 warning light is lit if 6.DEF, 8.DEF or 12.DEF are present.The level 2 warning light is lit if 1.DEF, 2.DEF, 3.DEF, 4.DEF, 5.DEF, 7.DEF, 10.DEF,11.DEF, 13.DEF, 14.DEF are present.

Use bornier Elé. 1590 for all operations on the injection computer connectors.

Display the stored contexts for fault DF001.

1) Check the value of PR124 "Restart code" .If PR124 = 10, continue otherwise contact the Techline.

2) Check PR004 "Computer feed voltage" present and stored:

– If the two PR004 > 10 V, check the condition of the wiring harness between the computer and the battery,carry out any necessary repairs. Clear the faults. Start the vehicle. Check the faults: If DF001 is still present,contact Techline.

– If one of the two PR004 < 10 V, check that the vehicle conforms with the vehicle identification number (wiringfor any electrical consumers added). Check the charging circuit then the condition of the battery terminals.Carry out fault finding on the alternator. Recharge or replace the battery.If DF001 is still present, contact Techline.

AFTER REPAIRClear the faults, then switch off the ignition.Carry out a road test followed by another check with the diagnostic tool.Deal with any declared fault, or carry out a conformity check if there are none.

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DF002PRESENT

OR

STORED

COOLANT TEMPERATURE SENSOR CIRCUIT

CC.0 : short circuit to earthCO.1 : open circuit or short circuit to + 12 volts

NOTES

Conditions for applying the fault finding procedure to stored faults:

The fault appears after: – an attempt to start engine or engine running.

Special notes:

If the fault is declared present: – the coolant temperature: PR002 "Coolant temperature" is fixed at 119 ˚C, – the preheating phase is greater than 10 seconds, – fan assembly 1 is continuously run, – the level 1 warning light is lit.Use bornier Elé. 1590 for any work on the computer connectors.

CC.0 NOTES None

Check the coolant temperature sensor connections.

Repair if necessary.Measure the coolant temperature sensor resistance between terminals 1 and 2 of the black connector.Replace the sensor if the resistance is not: 12460 ± 112 ΩΩΩΩ at - 10 ˚C

2252 ± 112 ΩΩΩΩ at 25 ˚C811.4 ± 39 ΩΩΩΩ at 50 ˚C283 ± 8 ΩΩΩΩ at 80 ˚C

115 ± 3 ΩΩΩΩ at 110 ˚C

Check the injection computer connections.Check the continuity and insulation against earth of the following connections:

Injection computer brown 48-track connector B track H1 Track 1 coolant temperaturesensor

Injection computer brown 48-track connector B track F2 Track 2 coolant temperaturesensor

Repair if necessary.

If the fault is still present, replace the coolant temperature sensor.


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DF002CONTINUED

C0.1 NOTES None

Check the coolant temperature sensor connections.

Repair if necessary.Measure the coolant temperature sensor resistance between terminals 1 and 2 of the black connector.Replace the sensor if the resistance is not: 12460 ± 112 ΩΩΩΩ at - 10 ˚C

2252 ± 112 ΩΩΩΩ at 25 ˚C811.4 ± 39 ΩΩΩΩ at 50 ˚C283 ± 8 ΩΩΩΩ at 80 ˚C

115 ± 3 ΩΩΩΩ at 110 ˚C

Check the injection computer connections.Check the continu ity and insulation against the + 12 V feed on the following connection:

Injection computer brown 48-track connector B track H1 Track 1 coolant temperaturesensor

Check the continuity of the following connection:Injection computer brown 48-track connector B track F2 Track 2 coolant temperature

sensor


If the fault is still present, replace the coolant temperature sensor.


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Vdiag No.: 04

DF012PRESENT

OR

STORED

BATTERY VOLTAGE

1.DEF: excess voltage2.DEF: undervoltage

NOTES

Conditions for applying fault finding procedures to stored faults:

The fault is declared present after the engine starts.

Special notes:Computer operating voltage: 9 V < operating voltage < 16.5 V.

Use bornier Elé. 1590 for all operations on the injection computer connections.

1.DEF NOTES None

Check the charge circuit.Carry out the necessary repairs.


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DF012CONTINUED

2.DEF NOTES None

With the ignition off , measure the voltage across the battery terminals.

If the voltage is below 11.5 V, recharge and test the battery.If necessary replace the battery, then check the charge circuit.

With the ignition on, and the starter operating , measure the battery voltage across the terminals.If the voltage drops below 9 V, check the tightness and condition of the battery terminals.Recharge and test the battery.If necessary replace the battery, then check the charge circuit.

If the starter is driving the engine correctly, but the fault is still present: – Check for + 12 V after igni tion on:

Track G1 of the black 32-track A connector on the injection computer,Track E1 of the brown 48-track B connector on the injection computer

If there is no feed to these tracks, check the condition of fuse FM3 (30A) on the fuse board.Replace if necessary. – Check the condition of the injection computer supply voltage relay R8.

Repair the contacts or replace them if necessary. – Check the continu ity and absence of interference resistance of the following connections:

Injection computer brown 48-track connector B, track E1 Track 15 of relay R8Injection computer black 32-track connector A, track G1 Track 13 of relay R8Injection computer black 32-track connector A, tracks G1, G4 and H1 Battery earth



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Vdiag No.: 04

DF015PRESENT

OR

STORED

ENGINE IMMOBILISER

1.DEF: internal electronic fault

NOTES


The fault is declared present following an attempt to start engine or when the engine isrunning.

Special notes:

The level 2 warning light is lit if 1.DEF is present.It is impossible to start the vehicle.Use bornier Elé. 1590 for all operations on the injection computer connections.

Check the UCH connections.Check the injection computer connections.Repair if necessary.

Carry out a test on the multiplex network and a full fault finding procedure on the UCH (see 82A, Engineimmobiliser conformity check).If the fault is still present, contact the Techline.


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Vdiag No.: 04

DF016PRESENT

OR

STORED

CLUTCH SWITCH CIRCUIT

1.DEF: no signal2.DEF: signal incoherence

NOTES


The fault is declared present after a pedal is depressed or a road test.

Special notes:If the fault is present, cruise control is deactivated.

Use bornier Elé. 1590 for all operations on the injection computer connections.

WARNINGThis fault may appear if the wiring has been damaged.Follow the procedure described in the Wiring Check in the Introduct ion.

This check enables the condi tion and the conformity of the engine wiring harness to be checked.

Check the connections of the clutch pedal switch.Check the adjustment of the clutch switch.Repair if necessary.

Check the conformity of the clutch switch:

– clutch pedal depressed: continuity between tracks 1 and 2 of the switch – clutch pedal released: insulation between tracks 1 and 2 of the switch.If these controls do not comply, replace the clutch pedal switch.

Check for earth on track B3 of the clutch pedal switch.Repair if necessary.

Check the injection computer connections.Check for cont inuity and the absence of interference resistance on the following connection:

Injection computer connector A, black 32 tracks track C4 Track A1 Clutch pedal switchRepair if necessary.

If the fault is still present, contact the Techline.


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Vdiag No.: 04

DF019PRESENT

ORSTORED

AIR FLOWMETER CIRCUIT

CC.1 : short circuit to + 12 VCO.0 : open circuit or short circuit to earth

1.DEF: offset at minimum threshold2.DEF: offset at maximum threshold3.DEF: parameter at minimum limit.4.DEF: parameter at maximum limit

NOTES

Priority when dealing with a number of faults: Apply the procedure for dealing with fault DF211 Sensor feed vol tage no. 3 first if itis present or stored.

Conditions for applying fault finding procedures to stored faults:The fault is declared present following an attempt to start engine or when the engine isrunning.

Special notes:The level 1 warning light is lit.Use bornier Elé. 1590 for all operations on the injection computer connections.

CC.1 NOTES None

Check the air flowmeter connections.Check the injection computer connections.Repair if necessary.

Check the continu ity and insulation against the + 12 V feed of the following connection:Injection computer brown 48-track connector B track E2 Track 2 air flow sensor

If the fault is still present, replace the air flowmeter.


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Vdiag No.: 04

DF019CONTINUED 1

CO.0 NOTES None

Check the air flowmeter connections.

Check the injection computer connections.Repair if necessary.

Check for + 12 V after igni tion on track 4 of the air flow sensor connector.In the absence of + 12 V, check the condition and the conformity of fuse F1 20A on the passenger compartmentfuse and relay board.Replace it if necessary.Check that a supply of + 5 V is present on track 3 of the air flowmeter sensor connector.Check the continuity and insulation to earth of the following connection:

Injection computer brown 48-track connector B, track B4 Track 3 air flow sensor

If the fault is still present, replace the air flowmeter.


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Vdiag No.: 04

DF019CONTINUED 2

1.DEF

2.DEF

NOTES

Conditions for applying fault finding procedures to

stored faults:The fault is declared present after the ignition has beenswitched off for 30 seconds.

3.DEF

4.DEFNone

Check the air flowmeter connections.Check the injection computer connections.Repair if necessary.

Check the following connection for continuity and make sure that there is no interference resistance:Injection computer connector B track B4 track 3 air flow sensor connector.Injection computer connector B track G1 track 5 of the air flow sensor connector.Injection computer connector B track E2 track 2 of the air flow sensor connector.

Check for + 12 V after relay on track 4 of the air flow sensor connector.

Check for an earth on track 6 of the air flow sensor connector.

Check the entire air inlet circui t: – air filter unit inlet not blocked and filter not clogged, – no foreign bodies on the air flow sensor grille ( visual inspection only).Otherwise, replace the air flow sensor. – oil vapour recirculation circuit connected correctly, – no 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 open (valve control pressed against the body of the venturi unit).

Air flow sensor connected, vehicle ignition on and engine stopped:

– check the voltage between tracks 2 and 5 of the air flow sensor:If the value is not 0.6 V ± 0.1, replace the air flowmeter.

Check the EGR valve is no t jammed open: – switch off the ignition, disconnect the connector and remove the EGR valve. – if removal reveals that its valve is jammed in the open position, replace the EGR valve.In the event of replacing the EGR valve, use the command RZ010 Adaptives on EGR valve faults (see Replacement of components).


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Vdiag No.: 04

DF021PRESENT

OR

STORED

FUEL TEMPERATURE SENSOR CIRCUIT

CC.0 : short circuit to earthCO.1 : open circuit or short circuit to + 12 V

NOTES



Special notes:

– If the fault is present, the PR001 "Fuel temperature" parameter is frozen at 100 ˚C. – Use bornier Elé. 1590 for all operations on the injection computer connections.

CC.0 NOTES None

Check the fuel temperature sensor connectors.Check the injection computer connections.Repair if necessary.

Measure the fuel temperature sensor resistance across tracks 1 and 2.

Replace the fuel temperature sensor if the resistance is not: 3820 ΩΩΩΩ ± 282 at 20 ˚C2050 ΩΩΩΩ ± 100 at 25 ˚C810 ΩΩΩΩ ± 47 at 50 ˚C

Check the continuity and insulation to earth of the following connection:injection computer connector B, brown 48-track, track H2 Track 1 fuel temperature sensor

Check the continuity and insulation from earth of the following connection:Injection computer grey 32-track connector C, track F1 Track 2 fuel temperature sensor

If the fault is still present, replace the fuel temperature sensor.


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Vdiag No.: 04

DF021CONTINUED

CO.1 NOTES None

Check the fuel temperature sensor connectors.


Measure the fuel temperature sensor resistance across tracks 1 and 2.Replace the fuel temperature sensor if the resistance is not: 3820 ΩΩΩΩ ± 282 at 20 ˚C

2050 ΩΩΩΩ ± 100 at 25 ˚C

810 ΩΩΩΩ ± 47 at 50 ˚CCheck the following connections for insulation, continuity and interference resistance:

injection computer connector B, brown 48-track, track H2 Track 1 fuel temperature sensor Injection computer grey 32-track connector C, track F1 Track 2 fuel temperature sensor

If the fault is still present, replace the fuel temperature sensor.


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Vdiag No.: 04

DF022PRESENT

OR

STORED

AIR TEMPERATURE SENSOR CIRCUIT


NOTES


The fault is declared present after an engine start, or with the engine running.

Special notes:The level 1 warning light is lit.

If the fault is present: – parameter PR003 Air temperature is f ixed at 20 ˚C, – EGR regulation is deactivated, – there is light smoke at the exhaust.The air temperature will be determined according to the inlet manifold vacuum and theatmospheric pressure.Use bornier Elé. 1590 for all operations on the injection computer connections.

Check the air flow sensor.Check the injection computer connections.


Check for + 5 V on track 3 of the air flowmeter connector.Check the continui ty, the insulation to + 12 V and insulation to earth on the following connections:

Injection computer brown 48-track connector B, track G2 Track 1 of the air flow sensorconnector

Injection computer brown 48-track connector B, track E2 Track 2 of the air flow sensorconnector

Injection computer brown 48-track connector B, track B4 Track 3 of the air flow sensorconnector

Repair if necessary.Measure the air temperature sensor resistance between tracks 1 and 2 of the air flowmeter.Replace the air flowmeter if the resistance is not approximately: 3714 ΩΩΩΩ ± 161 at 10 ˚C

2488ΩΩΩΩ

± 90 at 20 ˚C1671 ΩΩΩΩ ± 59 at 30 ˚C


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Vdiag No.: 04

DF023PRESENT

OR

STORED

FLYWHEEL SIGNAL SENSOR CIRCUIT

1.DEF: no signal2.DEF: signal incoherence

NOTES


The fault is declared present after an attempt to start engine.

Special notes:If the fault is present:

– the level 2 warning light is lit, – engine start is impossible or engine stop is requested.Use bornier Elé. 1590 for any work on the computer connectors.The engine speed sensor is consistent with the camshaft sensor.

1.DEF

2.DEF NOTES None

Check the flywheel signal sensor connectors.Repair if necessary.

Check that the sensor/flywheel air gap is correct: 0.5 to 1.8 mm.

Measure the flywheel signal sensor resistance between terminals 1 and 2 of its connector.Replace the flywheel signal sensor if the winding resistance is not 800 ± 80 ΩΩΩΩ at an engine temperature of 20 ˚C.


Check the continuity, insulation and absence of interference resistance on the following connections:Brown 48-track connector B injection computer track B1 Track 1 of the flywheel signal sensor Brown 48-track connector B injection computer track C1 Track 2 of the flywheel signal sensor


Check the flywheel signal sensor using an oscilloscope:In the event of a fault, check that the flywheel signal sensor is mounted properly and that the flywheel target is notdamaged.



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Vdiag No.: 04

DF024PRESENT

OR

STORED

ATMOSPHERIC PRESSURE SENSOR CIRCUIT

1.DEF: signal incoherence2.DEF: signal outside lower limit

3.DEF: signal outside upper limit

NOTES


The fault is declared present following an attempt to start the engine or with the enginerunning.

Priority when dealing with a number of faults (for 2.DEF and 3.DEF):

Firstly, deal with the following faults:DF125 Main relay control circuit if it is present or stored.DF233 Turbocharger pressure sensor circuit if it is present or stored.

Special notes:The atmospheric pressure sensor is integrated into the injection computer, and cannotbe separated.If the fault is present: – the level 1 warning light is lit,

– the atmospheric pressure value changes to safe mode, – PR016 Atmospheric pressure = 750 mbar , – there is light smoke.Use bornier Elé. 1590 for any work on the computer connectors.

Check the following connections for continu ity and the absence of interference resistance:Injection computer, 48-track brown connector B, track E1 Track 15 of relay R8Injection computer black 32-track connector A , track G1 Track 13 of relay R8Injection computer black 32-track connector A, tracks G1, G4 and H1 Battery earth

Compare the PR016 Atmospheric pressure parameter with the PR150 Turbocharging pressure setpoint

IGNITION ON parameter.In case of deviation greater than ± 20 hPa (20 mBar), contact Techline.


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Vdiag No.: 04

DF027PRESENT

OR

STORED

EGR SOLENOID VALVE CIRCUIT

1.DEF: excessive EGR valve flow

NOTES


The fault is declared present after an attempt to start engine.


– the EGR function is inhibited, – vehicle performance is reduced and smoke could appear,Use bornier Elé. 1590 for all operations on the injection computer connectors.

Check the EGR valve connections.Check the injection computer connections.Repair if necessary.

Measure the resistance of the EGR valve motor between tracks 1 and 5.If the resistance is not 3 ± 0.3 ΩΩΩΩ, replace the EGR valve.Measure the resistance of the EGR valve potentiometer between tracks 2 and 4.If the resistance is not 6.5 ± 2.6 kΩΩΩΩ, replace the EGR valve.

Check for continuity and absence of interference resistance of the following connections:Injection computer brown 48-track connector B, track D2 Track 5 EGR valveInjection computer, 48-track brown connector B, track J2 Track 6 EGR valve

Check that there are no leaks on the EGR circuit.Reinitialise the EGR valve using command RZ010 EGR valve fault adaptives (see Replacement ofcomponents ).If the fault is still present, replace the EGR valve.


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Vdiag No.: 04

DF051PRESENT

OR

STORED

BRAKE PEDAL SWITCH CIRCUIT

1.DEF: fault finding outside the domain2.DEF: signal incoherence

NOTES


If the fault becomes present after starting the engine and depressing the brake pedal.


If the fault is present, cruise control is deactivated.Use bornier Elé. 1590 for all operations on the injection computer connectors.

1.DEF NOTES None

Check the brake light switch connectors.Check the condition and adjustment of the brake light switch.Repair if necessary.

Check the conformity of the brake light switch:

Brake pedal released:

Brake pedal depressed:

continuity between tracks 3 and 4 infinite resistance between tracks 1 and 2.infinite resistance between tracks 3 and 4 continuity between tracks 1 and 2.

Replace the switch if necessary.

Check the feeds to the switch:+ 12 V after ignition feed track 2 of the brake pedal switch connector (via the passenger

compartment fuse and relay box)+ 12 V battery feed track 4 of the brake pedal switch connector (via the UCH)


Check the continuity and insulation of the following connection:Injection computer black 32-track connector A, track E4 Track 3 of the brake light switch

connector Carry out the necessary repairs.


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Vdiag No.: 04

DF051CONTINUED

2.DEF NOTES None

Check the brake pedal switch connections.

Check the condition and adjustment of the brake-pedal switch.Repair if necessary.Check the continuity and make sure there is no interference resistance on the following connection:

Injection computer black 32-track connector A, track E4 Track 3 of the brake switchRepair if necessary.Check the conformity of the switch by consulting the interpretation of statuses ET013 Brake no. 1 switch

signal and ET014 Brake no. 2 switch signal (See Interpretation of statuses).If the fault is still present, carry out fault finding on the ABS computer.


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V2MR-391-X24-13B000$350_eng.mif


Vdiag No.: 04

DF061PRESENT

OR

STORED

HEATER PLUG CIRCUIT

NOTES


The fault becomes present after actuator command AC010 Preheating relay, or afteran attempt to start engine.

Special notes:

– If the fault is present, the level 1 warning light will be lit.It is difficult or even impossible to start the engine when cold.The heater plugs can be continuously controlled.The engine and the heater plugs may be damaged.Use bornier Elé. 1590 for all operations on the injection computer connectors.

Step 1:Using a multimeter fitted with an ampermetric clamp, gather the 4 heater plug leads together. Actuate the preheating relay via command AC010 Preheating relay and measure the current used by the4 heater plugs.If the current is not between 20 and 30A, go to step 2, otherwise end of fault finding.

Step 2:

Check the preheating unit connections.Check the connections on all the heater plugs.Repair if necessary.Measure the resistance of the heater plugs:Replace any plugs whose resistance is not less than 2 ΩΩΩΩ at + 20 ˚C.Check the continuity of the following connections:

preheating unit track 1 cylinder 3 heater plug,preheating unit track 2 cylinder 4 heater plug,preheating unit track 6 cylinder 1 heater plug,preheating unit track 7 cylinder 2 heater plug.

Check for + 12 V battery feed on track 3 of the preheating relay (via fuse).Check the engine earthing.


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Vdiag No.: 04

DF061CONTINUED

If the fault is still present:Check the injection computer connections.Repair if necessary.Check the continuity, insulation and absence of interference resistance of the following connections:

Injection computer grey, 32-track connector C, track A4 track 9 preheating unitconnector

Injection computer grey, 32-track connector C, track E2 track 8 of the preheating unitconnector

If the fault is still present, replace the pre-postheating unit.


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DIESEL INJECTION


V2MR-391-X24-13B000$350_eng.mif


Vdiag No.: 04

DF070PRESENT

OR

STORED

CAMSHAFT/ENGINE SPEED SENSOR CONSISTENCY

1 DEF: inconsistent signal

NOTES


The fault becomes present following an attempt to start the engine.

Special notes:Use bornier Elé. 1590 for all operations on the injection computer connectors.

Check the engine speed sensor and camshaft sensor connectors.Check the injection computer connections.Repair if necessary.Check the continuity of the following connections:

engine management computer, connector B track A1 track 1 of the camshaft sensor.engine management computer, connector B track D1 track 2 of the camshaft sensor.Engine management computer, connector B track B1 track 1 of the engine speed sensor.Engine management computer, connector B track C1 track 2 of the engine speed sensor.

Repair if necessary.Check that the engine earthing is in order (oxidation, tightness, etc.).Check the mounting, the air gap and the condition of the engine speed sensor.If one of the sensors is faulty, replace it.

Measure the camshaft sensor resistance between tracks 1 and 3.Replace the camshaft sensor if its resistance is not 10250 ± 500 ΩΩΩΩ.


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Vdiag No.: 04

DF071PRESENT

OR

STORED

PEDAL SENSOR CIRCUIT GANG 1

CO.0 : open circuit or short circuit to earthCC.1 : short circuit to + 12 V

1.DEF: signal incoherence

NOTES

Priorities when dealing wi th a number of faults:

Deal with DF091 Sensor feed vol tage no. 1 fault 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.

Special notes:

The turbocharging and cruise control functions are inhibited.The level 1 warning light is lit.The engine speed is limited to 3000 rpm only if the pedal sensor circuit gang 1 fault ispresent.If a pedal sensor circuit gang 2 fault is present at the same time as a pedal sensorcircuit gang 1 fault, the speed is then frozen at 1400 rpm.

Use bornier Elé. 1590 for any work on the computer connectors.

CO.0 NOTES

Priorities when dealing with a number of faults:

If there is a simultaneous occurrence of fault DF073 Pedalcircuit gang 2, check that the pedal sensor connector isconnected correctly.

Check the accelerator pedal sensor connectors.Check the injection computer connections.Repair if necessary.

Check the continui ty absence of interference resistance on the following connections:Injection computer black 32-track connector A track H2 Track 3 accelerator pedal sensor

connector Injection computer black 32-track connector A track G2 Track 4 of the accelerator pedal

sensor connector Repair if necessary.

Measure the accelerator pedal sensor resistance on gang 1 between tracks 4 and 2.Replace the sensor if the internal resistance is not 1.7 kΩΩΩΩ ± 0.9.


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Vdiag No.: 04

DF071CONTINUED 1

CC.1 NOTES None

Check the accelerator pedal sensor connectors.


Check for continui ty and the absence of interference resistance of the following connections:Injection computer black 32-track connector A track H2 Track 3 accelerator pedal sensor

connector Injection computer black 32-track connector A track H3 Track 2 of the accelerator pedal


Measure the accelerator pedal sensor resistance on gang 1 between tracks 4 and 2.Replace the sensor if the resistance is not: 1.7 kΩΩΩΩ ± 0.9.


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Vdiag No.: 04

DF071CONTINUED 2

1.DEF NOTES None

Check the connectors of the accelerator pedal sensor.


Check the continuity, insulation and absence of interference resistance on the following connections:Injection computer black 32-track connector A track H2 Track 3 accelerator pedal sensor


sensor connector Injection computer black 32-track connector A track H3 Track 2 of the accelerator pedal

sensor connector Injection computer black 32-track connector A track F3 Track 6 accelerator pedal sensor

connector Injection computer black 32-track connector A track F2 Track 5 of the accelerator pedal

sensor connector Injection computer black 32-track connector A track F4 Track 1 of the accelerator pedal


If the fault is still present, replace the accelerator pedal sensor.


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Vdiag No.: 04

DF073PRESENT

OR

STORED

PEDAL SENSOR CIRCUIT GANG 2

CO.0 : open circuit or short circuit to earthC1.1 : short circuit to + 12 V


NOTES


Deal with fault DF092 Sensor feed vol tage 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.

Special notes:

The turbocharging and cruise control functions are inhibited.The level 1 warning light is lit.The engine speed is limited to 3000 rpm only if the pedal sensor circuit gang 2 fault ispresent.If pedal sensor circuit gang 1 fault is present at the same time as a pedal sensor circuitgang 2 fault, the speed is then frozen at 1400 rpm.


CO.0 NOTES

Priorities when dealing with a number of faults:

If fault DF071 Pedal sensor circuit gang 1 is present at thesame time, check that the pedal sensor connector isconnected correctly.

Check the accelerator pedal sensor connectors.Check the injection computer connections.Repair if necessary.

Check the continu ity and absence of interference resistance of the following connections:Injection computer black 32-track connector A track F3 Track 6 accelerator pedal sensor



Measure the resistance of the accelerator pedal sensor on gang 2 between tracks 1 and 5.Replace the sensor if the resistance is not: 2.85 kΩΩΩΩ ± 2.05.


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Vdiag No.: 04

DF073 CONTINUED 1

CC.1 NOTES None



Check for continui ty and the absence of interference resistance of the following connections:Injection computer black 32-track connector A track F3 Track 6 accelerator pedal sensor

connector Injection computer 32-track black connector A track F4 Track 1 of the accelerator pedal


Measure the resistance of the accelerator pedal sensor on gang 2 between tracks 1 and 5.Replace the sensor if the resistance is not: 2.85 kΩΩΩΩ ± 2.05.


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Vdiag No.: 04

DF073 CONTINUED 2

1.DEF NOTES None



Check the continuity, insulation and absence of interference resistance on the following connections:Injection computer black 32-track connector A track F3 Track 6 accelerator pedal sensor


sensor connector Injection computer black 32-track connector A track F4 Track 1 of the accelerator pedal

sensor connector Injection computer black 32-track connector A track H2 Track 3 accelerator pedal sensor


sensor connector Injection computer black 32-track connector A track H3 Track 2 of the accelerator pedal


If the fault is still present, replace the accelerator pedal sensor.


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Vdiag No.: 04

DF081 PRESENT

OR

STORED

PREHEATING RELAY CIRCUIT

CC.1 : short circuit to + 12 VCC.0 : open circuit or short circuit to earth

CO : open circuit1.DEF: internal electrical fault

NOTES


The fault is declared present after actuator command AC010 Preheating relay, orafter an attempt to start the engine.

Special notes:

The level 1 warning light is lit.If the fault is present, it is difficult or even impossible to start the engine when cold.Use bornier Elé. 1590 for all operations on the injection computer connections.

CC.1 NOTES None

Check the preheating unit connections and the heating plug supply cables.Check the injection computer connections.Repair if necessary.

Check the continuity and insulation against + 12 V of the following connections:Injection computer grey 32-track connector C, track E2 Track 8 preheating unitInjection computer grey 32-track connector C, track A4 Track 9 preheating unit


If the fault is still present, replace the pre/postheating unit.


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Vdiag No.: 04

DF081CONTINUED 1

CC.0

CO NOTES

Special notes:

If the unit has a short circuit to earth there is a risk that theheater plugs will operate continuously. The heater plugs andthe engine may be damaged.

Step 1:

Using a multimeter fitted with a current clamp, group the 4 heater plug leads together. Actuate the preheating relay via command AC010 Preheating relay and measure the current used by the4 heater plugs.If the current is not between 20 and 30A, go to step 2, otherwise end of fault finding.

Step 2:Check the injection computer connections.Repair if necessary.Check the preheating unit connections and the heating plug supply cables.Measure the resistance of the heater plugs.Replace any heater plugs whose resistance is not less than 2 ΩΩΩΩ at + 20 ˚C.Check the continuity, absence of interference resistance and insulation against earth on the following

connections:Injection computer, grey 32-track connector C, track E2 Track 8 preheating unitInjection computer, grey 32-track connector C, track A4 Track 9 preheating unit

Repair if necessary.If the fault is still present, replace the pre/postheating unit.


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Vdiag No.: 04

DF081CONTINUED 2

1.DEF NOTES None

Check the preheating unit connections and the heating plug supply cables.


Check the following connection for continuity and make sure there is no interference resistance:Injection computer grey 32-track connector C, track E2 Track 8 preheating unit


If the fault is still present, check that the computer output is working correctly .With the preheating unit connected:

– connect the negative test pin of the voltmeter to track 8 of the preheating unit, – connect the positive test pin of the voltmeter to the + 12 V battery feed, – run command AC010 " Preheating unit" .If the voltmeter does not indicate the battery voltage while the command is running (ten one-second ON/OFFcycles), contact the Techline.


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Fault f inding - Interpretation of faults 13B

V2MR-391-X24-13B000$400_eng.mif


Vdiag No.: 04

DIESEL INJECTION

Fault f inding - Interpretation of faults

DF082PRESENT

OR

STORED

LOW PRESSURE PUMP RELAY CIRCUIT

NOTES


The fault is declared present after actuator command AC005 Low pressure pumprelay .

Special notes:

The level 1 warning light is lit.If the fault is present, it is difficult or even impossible to start the vehicle when coldUse bornier Elé. 1590 for all operations on the injection computer connections.

Check the low pressure pump relay and injection computer connections.Repair if necessary.Check the condition and the conformity of fuses F2 10A, F1 20A and F3 40A.Replace them, if necessary.Check the operation and conformity of the R15A relay: condition of the switches, winding resistances,operation of the after supply command stage.Replace it if necessary.Use command AC005 Low pressure pump relay .If the relay does not run on command, check for continuity and insulation to earth on the following connections:

+ battery feed Track A3 of relaymounting R15A.

+ after igni tion feed Track A1 of relaymounting R15A.

Injection computer grey 32-track connector C track C1 Track A2 of relaymounting R15A.

Repair if necessary.If the fault is still present, contact the Techline.


MR-391-X24-13B000$400_eng.mif

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Vdiag No.: 04

DF084PRESENT

OR

STORED

EGR VALVE POSITION SENSOR CIRCUIT


NOTES


Deal with fault DF092 Sensor feed vol tage no. 2 first if it is present or stored.

Conditions for applying fault finding procedures to stored faults:The fault is declared present after an attempted start, or with the engine running.

Special notes:If the fault is present: – there is smoke coming from the exhaust, – the EGR function and the turbocharging are deactivated.Use bornier Elé. 1590 for all operations on the injection computer connectors.

CO.0 NOTES None

Check the EGR valve connections.

Check the injection computer connections.Repair if necessary.Measure the resistance of the EGR valve potentiometer between tracks 2 and 6 of the EGR valve connector.If its resistance is not 6.5 ± 2.6 kΩΩΩΩ, replace the EGR valve.

Check the continuity and insulation to earth of the following connections:Injection computer 48-track brown connector B, track J2 Track 6 EGR valveInjection computer 48-track brown connector B, track F4 Track 2 EGR valve


Reinitialise the EGR valve using command RZ010 EGR valve fault adaptives (see Replacement ofcomponents ).

If the fault is still present, replace the EGR valve.


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Vdiag No.: 04

DF084CONTINUED

CC.1 NOTES None

Check the EGR valve connections.


Check the continuity and insulation to + 12 V on the following connections:Injection computer 48-track brown connector B, track J2 Track 6 EGR valveInjection computer grey 32-track connector C, track C2 Track 4 EGR valve


Reinitialise the EGR valve using command RZ010 EGR valve fault adaptives (see Replacement of

components ).If the fault is still present, check that the EGR valve is not blocked.Display the feedback parameter PR088 EGR valve posi tion feedback .If the value is not between 0 and 20 %: – remove the EGR valve, – in case of irreparable blockage, replace the EGR valve.


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Vdiag No.: 04

DF091PRESENT

OR

STORED

SENSOR FEED NO. 1 VOLTAGE

1.DEF: signal outside lower limit2.DEF: signal outside upper limit

NOTES


The fault is declared present after attempting to start the engine or with the enginerunning

Special notes:

If the fault is present: – the level 1 warning light is lit, – turbocharging and cruise control functions are deactivated, – engine torque is limited.Use bornier Elé. 1590 for all operations on the injection computer connections.


This check enables the condi tion and the conformity of the engine wiring harness to be checked.


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Vdiag No.: 04

DF091CONTINUED 1

1. Procedure to follow if the engine is equipped with a Turbocharger with Fixed Geometry:The sensor connected to feed no. 1 is the following: – accelerator potentiometer sensor, gang 1

To locate a possible internal sensor fault, disconnect one of these sensors then check if the fault becomesstored.If following a disconnection the fault becomes stored, replace the faulty sensor.Clear the faults created by the multiple disconnections.

If the fault is still present when the sensor has been disconnected: – Check the continu ity and insulation to earth and + 12 V on the following connections:

Injection computer black 32-track connector A, track G2 Track 4 accelerator pedalpotentiometer

Injection computer black 32-track connector A, track H2 Track 3 of the accelerator pedalpotentiometer

– Check the insulation of the following connections:Tracks 2 and 4 of the accelerator pedal potentiometer Repair if necessary.If the fault is still present, apply the fault finding procedure to the accelerator pedal potentiometer.


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Vdiag No.: 04

DF091CONTINUED 2

2. Procedure to follow if the engine is equipped with a Turbocharger with Variable Geometry:The following sensors are connected to supply no. 1: – Turbocharging pressure sensor,

– Accelerator potentiometer sensor, gang 1.To locate a possible internal sensor fault, disconnect one of these sensors then check if the fault becomesstored.If the fault remains present, repeat the operation with the other sensor (wait for a few seconds betweendisconnecting so that the computer can take its measurement).

Replace the faulty sensor if the fault becomes stored after a disconnection.Clear the faults created by the multiple disconnections.

If the fault is still present when both these sensors have been disconnected: – Check the continu ity and insulation to earth and + 12 V on the following connections:

Injection computer brown 48-track connector B, track B4 Track 3 air flowmeter Injection computer brown 48-track connector B, track G1 Track 5 air flowmeter Injection computer black 32-track connector A, track G2 Track 4 accelerator pedal

potentiometer Injection computer black 32-track connector A, track H2 Track 3 accelerator pedal

potentiometer – Check the insulation of the following connections:

Tracks 2 and 4 of the accelerator pedal potentiometer Track 2 and 3 of the air flowmeter Repair if necessary.If the fault is still present, apply the fault finding procedure to the air flowmeter and the accelerator pedalpotentiometer.


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Vdiag No.: 04

DF092PRESENT

OR

STORED

SENSOR FEED VOLTAGE NO. 2


NOTES


The fault is declared present after attempting to start the engine or with the enginerunning.

Special notes:

If the fault is present: – the level 1 warning light is lit, – the cruise control, turbocharging and the EGR are no longer commanded, – engine torque is limited.Use bornier Elé. 1590 for all operations on the injection computer connections.

WARNINGThis fault may appear if the wiring has been damaged. Follow the procedure described in the Wiring Check in the Introduct ion. This check enables the condi tion and the conformity of the engine wiring harness to be checked.


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Vdiag No.: 04

DF092 CONTINUED

The following sensors are connected to supply no. 2: – EGR valve posit ion sensor, – track 2 of the accelerator potentiometer sensor.

To locate a possible internal sensor fault, disconnect one of these sensors then check if the fault becomesstored.If the fault remains present, repeat the operation with the other sensor (wait for a few seconds betweendisconnecting so that the computer can take its measurement).Replace the faulty sensor if the fault becomes stored after a disconnection.

Clear the faults created by the multiple disconnections.

If the fault is still present when both these sensors have been disconnected: – Check the continu ity and insulation to earth and + 12 V on the following connections:

Injection computer brown 48-track connector B, track F4 Track 2 EGR valveinjection computer brown 48-track connector B, track G2 Track 4 EGR valveInjection computer black 32-track connector A, track F2 Track 5 accelerator pedal

potentiometer Injection computer black 32-track connector A, track F3 Track 6 accelerator pedal

potentiometer Injection computer black 32-track connector A, track F4 Track 1 accelerator pedal

potentiometer

– Check the insulation of the following connections:Tracks 2 and 4 of the EGR valve.Tracks 1 and 5 of the accelerator pedal potentiometer.Repair if necessary.If the fault is still present, apply the fault finding procedure to the EGR valve position sensor and to theaccelerator potentiometer.


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Vdiag No.: 04

DF095PRESENT

OR

STORED

VEHICLE SPEED SIGNAL

1.DEF: CAN connection fault

NOTES


The fault is declared present after a road test.


– the level 2 warning light is lit, – cruise control is deactivated, – performance is limited.Use bornier Elé. 1590 for all operations on the injection computer connections.

Check the ABS computer connections.Check the injection computer connections.Repair if necessary.

Run fault finding on the ABS.If there are no present or stored faults, carry out a multiplex network fault finding procedure.



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Vdiag No.: 04

DF099PRESENT

OR

STORED

CYLINDER 1 INJECTOR CIRCUIT

CC.1 : short circuit to + 12 voltsCO : open circuit

CC : short circuit1.DEF: injector control

NOTES


The fault is declared present after the engine has been started.

Special notes:If the fault is still present, the engine is unstable and performance is reduced.

Use bornier Elé. 1590 for all operations on the injection computer connections.Cylinder no. 1 is located at the timing end.



CC.1 NOTES Special notes: Level 2 warning light lit.

Check the connections on injector no 1.Check the injection computer connections.Repair if necessary.

Measure the resistance of injector no. 1.If the resistance is not approximately 0.33ΩΩΩΩ at 20 ˚C, replace injector no. 1.Check for continuity and insulation to + 12 V on the following connections:

Injection computer grey 32-track connector C, track G3 Track 2 injector no. 1Injection computer grey 32-track connector C, track H1 Track 1 injector no. 1

If the fault is still present, replace injector no. 1.


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Vdiag No.: 04

DF099CONTINUED 1

CO NOTES Special notes: Level 1 warning light lit.

Check the connections on injector no 1.


Measure the resistance of injector no. 1.If the resistance is not approximately 0.33ΩΩΩΩ at 20 ˚C, replace injector no. 1.Check the continu ity and absence of interference resistance of the following connections:

Injection computer grey 32-track connector C track G3 Track 2 injector no. 1Injection computer grey 32-track connector C track H1 Track 1 injector no. 1



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Vdiag No.: 04

DF099CONTINUED 2

CC NOTES Special notes: Level 2 warning light lit.


Check the injection computer connections (no conductive particles or bent pins).Repair if necessary.

Measure the resistance of injector no. 1.If the resistance is not approximately 0.33ΩΩΩΩ at 20 ˚C, replace injector no. 1.

Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals G3 and H1 on connector C.If this resistance is not approximately 0.33 ΩΩΩΩ at 20 ˚C, disconnect the injector and perform the measuring

procedure again.If the resistance equals 0 ΩΩΩΩ, the 2 injector cont rol wires are in short circuit.Repair if necessary.If the fault is still present, replace injector no. 1.

1.DEF NOTES Special notes: Level 2 warning light lit.

Measure the resistance of injector no. 1.If the resistance is not approximately 0.33ΩΩΩΩ at 20 ˚C, replace injector no. 1.Check the continu ity and absence of interference resistance of the following connections:Injection computer grey 32-track connector C track G3 Track 2 injector no. 1Injection computer grey 32-track connector C track H1 Track 1 injector no. 1

Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals G3 and H1 on connector C.

If this resistance is not approximately 0.33 ΩΩΩΩ at 20 ˚C, disconnect the injector and perform the measuringprocedure again.If the resistance equals 0 ΩΩΩΩ, the 2 injector cont rol wires are in short circuit.Repair if necessary.If the fault is still present, replace injector no. 1.


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Vdiag No.: 04

DF100PRESENT

OR

STORED




NOTES










Injection computer grey 32-track connector C, track G2 Track 2 injector no. 2Injection computer grey 32-track connector C, track G4 Track 1 injector no. 2



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Vdiag No.: 04

DF100CONTINUED 1








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Vdiag No.: 04

DF100CONTINUED 2





Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals G2 and G4 on connector C.If this resistance is not approximately 0.33 ΩΩΩΩ at 20 C, disconnect the injector and perform the measuring





Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals G3 and H1 on connector C.

If this resistance is not approximately 0.33 ΩΩΩΩ at 20 C, disconnect the injector and perform the measuringprocedure again.If the resistance equals 0 ΩΩΩΩ, the 2 injector cont rol wires are in short circuit. Repair if necessary.If the fault is still present, replace injector no. 2.


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Vdiag No.: 04

DF101PRESENT

OR

STORED




NOTES










Injection computer grey 32-track connector C, track H4 Track 2 injector no. 3Injection computer grey 32-track connector C, track H2 Track 1 injector no. 3



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Vdiag No.: 04

DF101CONTINUED 1





Injection computer grey 32-track connector C, track H4 Track 2 injector no. 3Injection computer grey 32-track connector C, track H2 Track 1 injector no. 3



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Vdiag No.: 04

DF101CONTINUED 2





Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals H2 and H4 on connector C.If this resistance is not approximately 0.33 ΩΩΩΩ at 20 C, disconnect the injector and perform the measuring





Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals H2 and H4 on connector C.

If this resistance is not approximately 0.33 ΩΩΩΩ at 20 C, disconnect the injector and perform the measuringprocedure again.If the resistance equals 0 ΩΩΩΩ, the 2 injector cont rol wires are in short circuit.Repair if necessary.If the fault is still present, replace injector no. 3.


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Vdiag No.: 04

DF102PRESENT

OR

STORED




NOTES










Injection computer grey 32-track connector C, track H3 Track 2 injector no. 4Injection computer grey 32-track connector C, track G1 Track 1 injector no. 4



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Vdiag No.: 04

DF102CONTINUED 1





Injection computer grey 32-track connector C, track H3 Track 2 injector no. 4Injection computer grey 32-track connector C, track G1 Track 1 injector no. 4



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Vdiag No.: 04

DF102CONTINUED 2



Check the injection computer connections. (no conducting particles or bent pins).Repair if necessary.


Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals H3 and G1 on connector C.If this resistance is not approximately 0.33 ΩΩΩΩ at 20 C, disconnect the injector and perform the measuring

procedure again.If the resistance equals 0 ΩΩΩΩ, the 2 injector cont rol wires are in short circuit.Repair if necessary.





Disconnect grey 32-track connector C from the injection computer and reconnect the injector.Measure the resistance between terminals H3 and G1 on connector C.If this resistance is not approximately 0.33 ΩΩΩΩ at 20 ˚C, disconnect the injector and perform the measuringprocedure again.If the resistance equals 0 ΩΩΩΩ, the 2 injector cont rol wires are in short circuit.Repair if necessary.If the fault is still present, replace injector no. 4.


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Vdiag No.: 04

DF113PRESENT

OR

STORED

REFRIGERANT PRESSURE SENSOR CIRCUIT

CC.1 : short circuit to + 12 VCO.0 : open circuit or short circuit to earth

NOTES


The fault is declared present when air conditioning is requested, engine running.

Special notes:If the fault is present, the air conditioning is inhibited.


CC.1 NOTES None

Check the refrigerant pressure sensor connectors.Check the injection computer connections.Repair if necessary.Check the continui ty and insulation against + 12 V of the following connections:

Injection computer connector B track F3 Track B of the refrigerant pressure sensor Injection computer connector B track F1 Track C of the refrigerant pressure sensor

Injection computer connector C track C3 Track A of the refrigerant pressure sensor Repair if necessary.


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Vdiag No.: 04

DF113 CONTINUED

CO.0 NOTES None

Check the refrigerant pressure sensor connectors.

Check the injection computer connections.Repair if necessary.Check the continuity and insulation from earth of the following connections:

Injection computer connector B track F3 Track B of the refrigerant pressure sensor Injection computer connector B track F1 Track C of the refrigerant pressure sensor Injection computer connector C track C3 Track A of the refrigerant pressure sensor



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Vdiag No.: 04

DF117PRESENT

OR

STORED

RAIL PRESSURE SENSOR CIRCUIT


1.DEF: offset at minimum threshold2.DEF: offset at maximum threshold

NOTES


Apply the procedure for dealing with fault DF211 Sensor feed vol tage no. 3 first if itis present or stored.


The fault is declared present after repeated engine starts or with the engine running.

Special notes:

The level 2 warning light is lit if CC.0, CO.1 is presentThe level 1 warning light is lit if 1.DEF, 2. DEF is present.Use bornier Elé. 1590 for any work on the computer connectors.If the fault is present, an immediate engine stop request is issued.

CC.0 NOTES None

Check the rail pressure sensor connectors.Check the injection computer connections.Repair if necessary.

Check the continuity and insulation to earth of the following connections:Brown injection computer 48-track connector B track G3 Track 2 rail pressure sensor Brown 48-track injection computer connector B track A4 Track 3 rail pressure sensor


If the fault is still present, replace the rail pressure sensor.Follow the safety instructions which apply to the system (see Introduction ).


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Vdiag No.: 04

DF117CONTINUED 1

CO.1 NOTES None

Check the rail pressure sensor connectors.


Check the continuity and insulation to + 12 V on the following connections:Brown 48-track injection computer connector B track C4 Track 1 rail pressure sensor Brown injection computer 48-track connector B track G3 Track 2 rail pressure sensor


If the fault is still present, replace the rail pressure sensor, and follow the safety instructions (see Introduction ).


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Vdiag No.: 04

DF117CONTINUED 2

1.DEF

2.DEF NOTES

Special notes:

The minimum value is 0.2 bar , and the maximum value is1,600 bar .

Check the rail pressure sensor connectors.Check the injection computer connections.


Check the continuity and absence of interference resistance of the following connections:Brown 48-track connector B Injection computer track G3 Track 2 rail pressure sensor Brown 48-track connector B injection computer track A4 Track 3 rail pressure sensor Brown 48-track connector B injection computer track C4 Track 1 rail pressure sensor


With the ignition on and the engine stopped for over 1 minute:Check the pressure value displayed on the diagnostic tool PR217 Rail pressure in the Fuel ci rcuit, Enginemanagement function tab, – If the value is below 50 bar , the sensor is in order.

In this case, contact the Techline. – If the pressure is above 50 bar , replace the rail pressure sensor.Observe the safety instructions (see Introduction).

AFTER REPAIRClear the fault memory, then switch off the ignition.Carry out a road test followed by another check with the diagnostic tool.Deal with any declared fault, or carry out a conformity check if there are none.

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Vdiag No.: 04

DF118

CRUISE CONTROL/SPEED LIMITER FUNCTION

1.DEF: Signal incoherence2.DEF: Inconsistent vehicle speed

3.DEF: Cruise control/Speed limiter steering wheel control

NOTES


The fault is declared present after the cruise control/speed limiter button is pressed, orwhen driving.

Special notes:

If the fault appears when driving, the cruise control/speed limiter function will beinhibited. Use bornier Elé. 1590 for all operations on the injection computer connectors.



1.DEF/ 3.DEF NOTES None

Display the status ET256 Cruise contro l/Speed limiter switch, and check that it varies according to presseson the ON/OFF cruise control or speed limiter button.Carry out the same test by pressing the "+" and " -" buttons and display status ET257 "Cruise control/speed

limiter function" .If it does not vary after pressing the button, consult the interpretation of status ET256.If the fault is present, check the connectors on the injection computers.Repair if necessary.If the fault is still present, check the continu ity and absence of interference resistance between thefollowing tracks:Engine management computer connector A, t rack A2 Track A3 of the button 6-track connector

Cruise control "ON/OFF"Engine management computer connector A, t rack C3 Track B1 of the button 6-track connector

Cruise control "ON/OFF"Repair if necessary.


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Vdiag No.: 04

DF118CONTINUED

2.DEF NOTES None

Check the ABS computer connections.

Check the injection computer connections.Repair if necessary.Carry out a multiplex network test.

Check whether the ABS computer is faulty.If faults are present (see 38C, Anti-lock Braking system).If the fault is still present, check the continu ity and the absence of in terference resistance between thefollowing tracks:

ABS computer track B1 Injection computer connector B track B3Repair if necessary.If the fault is still present, contact the Techline.

AFTER REPAIR

Clear the faults, then switch off the ignition.Carry out a road test followed by another check with the diagnostic tool.Deal with any declared fault, or carry out a conformity check if there are none.

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Vdiag No.: 04

DF125STORED

MAIN RELAY control CIRCUIT

1.DEF: relay cut out too soon2.DEF: relay cut out too late

NOTES


Apply the fault finding procedure for present or stored faults.

Special notes: level 2 warning light is lit if 1.DEF, 2.DEF present.

Check the condition of the main relay supply fuse FM3 30A.

Replace the fuse if necessary.Check the injection computer connections, and the injection computer supply relay R8.Repair if necessary.Remove the R8 relay and check it is working correctly.If this relay is defective, replace it and clear the faults.Check the condition and tightness of the battery terminals and its engine earth connection.Check the continuity and make sure there is no interference resistance on the following connection:

Injection computer 48-track brown connector B track E1 Relay mounting R8 track 15Repair if necessary.If the fault is still present, contact the Techline.


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Vdiag No.: 04

DF137PRESENT

ORSTORED

RAIL PRESSURE REGULATION FUNCTION

CC.1 : short circuit to + 12 VCC.0 : short circuit to earth

CO : open circuit1.DEF: internal electrical fault2.DEF: pressure measured too low3.DEF: pressure measured too high4.DEF: insufficient pressure5.DEF: pressure < minimum6.DEF: pressure > maximum7.DEF: infected pump command

NOTES

Priorities when dealing wi th a number of faults: Apply the interpretation of fault DF082 Low pressure pump relay first if it is presentor stored.

Conditions for applying the fault finding procedure to stored faults:The fault is declared present after repeated engine starts or with the engine running.

Special notes:The level 1 warning l ight is lit if 3.DEF is present.Otherwise, level 2 warning light is lit.Engine stop is requested and starting is impossible.Use bornier Elé. 1590 for any work on the computer connectors.

CC.1 NOTES None

Check the flow regulator connections.Check the injection computer connections.Repair if necessary.

Measure the resistance of the flow regulator between tracks 1 and 2.

If the resistance is not: 3 ΩΩΩΩ ± 0.1 at 20 ˚C, replace the fuel flow regulator.Check the insulation from the + 12 V feed of the following connection:

Injection computer brown 48-track connector B, track M4 Track 2 of the fuel flow regulator

If the fault is still present, replace the fuel flow regulator.


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Vdiag No.: 04

DF137CONTINUED 1

CC.0/CO NOTES None

Check the fuel flow regulator connections.


Measure the resistance of the flow regulator between tracks 1 and 2.If the resistance is not: 3 ΩΩΩΩ ± 0.1 at 20 ˚C, replace the fuel flow regulator.Check the continuity and insulation to earth of the following connection:


With the ignition on, check for the + 12 V after relay feed on track 1 of the fuel flow regulator.

If the fault is still present, replace the fuel flow regulator.


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Vdiag No.: 04

*Opening Cycli c Ratio

DF137CONTINUED 2

1.DEF NOTES None

Measure the resistance across tracks 1 and 2 of the flow regulator.

If the resistance is not: 3 ΩΩΩΩ ± 0.1 at 20 ˚C, replace the fuel flow regulator.Check for cont inuity and the absence of interference resistance on the following connection:


With the ignition on, check for the + 12 V after relay feed on track 1 of the fuel flow regulator.

If the fault is still present, check that the computer output is working correctly . Either using an ammeter:With the solenoid valve connected, connect the current clamp to the track 1 connection of the solenoid valve(in the direction of the current).Clear any fuel pressure solenoid valve fault, then run command AC624 Rail pressure regulator :

The ammeter should display ten cycles of two successive currents: ~ 0.6 A then ~ 2 A

Using a voltmeter:With the solenoid valve connected, connect the voltmeter earth lead to track 2 of the fuel pressure solenoidvalve and the positive cable to track 1. Clear any fuel pressure solenoid valve fault, then run command AC624Rail pressure regulator:

The voltmeter should display two successive values ~ = battery voltage X current OCR i.e.successively: AC 3.15 Volts for an OCR of 25 % then 9.45 V for an OCR of 75 % (ten cycles)

Or using an oscilloscope (range 5 V/division and with time base 1 ms/division):With the solenoid valve connected, connect the oscilloscope earth to the battery earth and the positive test pinto track 2 of the fuel pressure solenoid valve; clear any fuel pressure solenoid valve faults then run command AC624 Rail pressure regulator:

The oscilloscope should display a square pulse signal of an amplitude of 12.5 V at a frequency of185 Hz (with an OCR alternating from 25 to 75 %).


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Vdiag No.: 04

DF137CONTINUED 3

2.DEF at 7.DEF NOTES None

In the event of rail overpressure:

– check the operation of the injectors (see Test, Injector test), – check the operation of the rail pressure sensor (see Conformity check).

If these checks reveal no irregularities, replace the regulator.

In the event of rail underpressure: – check the priming of the low-pressure diesel circuit. – disconnect the diesel supply pipe from the diesel filter and run command AC005 Low pressure pump relay

several times. – check that the low pressure pump operates correctly and feeds the low pressure circuit, – 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 fuel circuit sealing (visual checks, odour, etc.): pump casing,

pressure relief valve, pipes, rail and injector unions, injector wells, etc. – check that the rail pressure sensor operates correctly by checking the conformity check values, – check the conformity of the seal fitting on the pressure regulator,

– check the operation of the injectors (See Test, Injector test),Carry out the required repairs.If the fault is still present, replace the fuel flow regulator.If the fault is still present, replace the high pressure pump.


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Vdiag No.: 04

DIESEL INJECTION

Fault f inding - Interpretation of faults

DF144PRESENT

OR

STORED

COMPRESSOR RELAY CONTROL LINE

NOTES


The fault is declared present when an air conditioning request is made, or after actuatorcommand AC599 Air condit ioning compressor has run.

Special notes:

If the relay is not supplied, the air conditioning is disabled.If the relay is continuously supplied, the battery is completely discharged.Use bornier Elé. 1590 for any work on the computer connectors.

Check the injection computer connections.Repair if necessary.Check the condition and operation of the relay R10A from the air conditioning compressor command. Replacethe relay if necessary.If the relay is in order, check the following connection for continuity and make sure there is no interferenceresistance:

Engine management computer, connector A t rack B1 Track A2 of the air conditioningcompressor control relay mounting.




MR-391-X24-13B000$450_eng.mif

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Vdiag No.: 04

DF146PRESENT

OR

STORED

COMPUTER SUPPLY VOLTAGE


NOTES



Special notes:

Computer operating voltage: 9 V < operating voltage < 16.5 V.Use bornier Elé. 1590 for all operations on the injection computer connections.

Check the condition of the fuses FM3 30A and FM6 10A.Replace if necessary.Remove the computer supply relay R8 and check that it is working properly.Ifit is faulty, replace it.Check the + 12 V after igni tion feed to the following tracks:Track G1 of the injection computer black connector ATrack D1 of the injection computer black connector AIf there is no feed on track G1 of the injection computer black connector A, check the continuity and makesure there is no i nterference resistance between:

Track G1 Relay mounting R8 track 13

Repair if necessary.If there is no feed on track D1 of the injection computer black connector A, check the continuity and make

sure there is no i nterference resistance between:Track D1 Engine fuse and relay box track 28

Repair if necessary.If all these checks have been carried out and there are no faulty components, check the continuity and that

there is no interference resistance between:Injection computer brown connector B track E1 Relay mounting R8 track 15

Repair if necessary.If the fault is still present, contact the Techline.


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Vdiag No.: 04

DF163PRESENT

OR

STORED

EGR VALVE CONTROL CIRCUIT

1.DEF: blocked valve open2.DEF: blocked valve closed

NOTES



Special notes:

– if 1.DEF the level 1 warning light is lit. – if 2.DEF the warning light is not lit, – there is a significant amount of smoke. – the EGR valve and the turbocharging are inhibited.Use bornier Elé. 1590 for all operations on the injection computer connectors.

Check the EGR valve connections.Check the injection computer connections.Repair if necessary.

Measure the resistance of the EGR valve motor between tracks 1 and 5.If the resistance is not 3 ± 0.3 ΩΩΩΩ, replace the EGR valve.Measure the resistance of the EGR valve potentiometer between tracks 2 and 4.

If the resistance is not 6.5 ± 2.6 kΩΩΩΩ, replace the EGR valve.

Check the continuity and insulation of the following connections:Injection computer brown 48-track connector B, track D2 Track 5 of the EGR valve

connector Injection computer brown 48-track connector B, track C2 Track 1 of the EGR valve

connector Repair if necessary.Reinitialise the EGR valve using command RZ010 EGR valve fault adaptives (see Replacement ofcomponents ).If the fault is still present and the valve remains blocked open, replace the EGR valve.Carry out a fault check; if the fault is still present, replace the EGR valve.


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Vdiag No.: 04

DF173PRESENT

INJECTOR CODE PROGRAMMING

1.DEF: internal electronic fault during programming2.DEF: no code stored

NOTES

Fault finding procedure application conditions:

This fault appears on any blank computer (new or recently reprogrammed).


– the level 1 warning light is lit, – engine speed is limited.

1.DEF NOTES None

Program the injector codes by using command SC004 Injector calibration data input (see Interpretation ofcommands).If the fault is still present, after the ignition is switched off and dialogue is established, contact the Techline.

2.DEF NOTES None

WARNING A computer wi thout the IMA option can be replaced by a computer with this opt ion. The codes have

therefore not been saved during command SC005 Computer replacement data save.In this case, fault DF173 "Injector code programming" is present and the engine runs in defect mode. – programme the injector codes by using command SC004 " Injection calibration data input" (follow the

procedure described in the Interpretation of commands) section. – after the codes have been written: – switch off the ignition,

– wait until power latch closes down and then switch the ignition back on, – establish dialogue and check that the fault is no longer present, – end of operation.If the fault is still present, contact the Techline.


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Vdiag No.: 04

DF208CONTINUED 1

CC.0 NOTES None

Check the continuity and insulation to earth of the following connection:

Injection computer grey 32-track connector C, track E1 Track 1 turbocharging solenoidvalve


CC.1 NOTES None

Check the continuity and insulation against + 12 V of the following connection:Injection computer grey 32-track connector C, track E1 Track 1 turbocharging solenoid

valveRepair if necessary.


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Vdiag No.: 04

DF208CONTINUED 2

1.DEF NOTES None

Check the turbocharging solenoid valve connections.


Measure the resistance of the turbocharging solenoid valve between its tracks 1 and 2:

Replace the solenoid valve if its resistance is not: 15.4ΩΩΩΩ ± 0.7 at 20 ˚C.

Check the injection computer connections.Check the continu ity, insulation, and the absence of interference resistance of the following connection:



Check for + 12 V after relay feed on track 2 of the turbocharging solenoid valve.

If the fault is still present, check that the computer output is working correctly .With the turbocharging solenoid valve connected:Using a voltmeter: – Connect the voltmeter earth lead to track 1o f the solenoid valve and the positive lead to track 2,

– Clear any solenoid valve faults then run command AC622 Turbocharging solenoid valve:The voltmeter should display ten cycles of two successive voltages ~ = battery voltage X current OCR*.

either: ~ 2.5 V (OCR of 20 %) then ~ 8.75 V (OCR of 70 %).Or using an oscilloscope (range 5 V/division and with time base 1 ms/division): – Connect the earth of the oscilloscope to the battery earth and the positive test pin to track 2 of the solenoid

valve, – Clear any solenoid valve faults then run command AC622 Turbocharging solenoid valve:

The oscilloscope should display a square pulse signal with an amplitude of 12.5 V (equal to the batteryvoltage) at a frequency of 140 Hz (with an OCR changing successively from ~ 20 to ~ 70 %).

– If the measurement is correct, replace the solenoid valve.

– If the measurement shows no actuation or a constant voltage, contact your Techline.


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Vdiag No.: 04

DF209PRESENT

OR

STORED

TURBOCHARGING PRESSURE SENSOR CIRCUIT



NOTES


The fault is declared present after an attempted start, or with the engine running.

Special notes:Use bornier Elé. 1590 for all operations on the engine management computer

connectors.If the fault is present: – the exhaust gas recirculation valve is cut off, – the turbocharging pressure enters defect mode, i.e.: PR082 = 750 mbar ,The level 1 warning light is lit.

CO.0 NOTES None

Check the turbocharger pressure sensor connections.Check the injection computer connections.


Check the continuity and insulation to earth of the following connections:Injection computer brown 48-track connector B, track K2 Track 3 turbocharging pressure

sensor connector Injection computer brown 48-track connector B, track G4 Track 1 turbocharging pressure


If the fault is still present, replace the turbocharger pressure sensor.


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Vdiag No.: 04

DF209CONTINUED 2

1.DEF NOTES None

Check the turbocharger pressure sensor connections.


Check the cont inuity , insulation and absence of interference resistance on the following connections:Injection computer brown 48-track connector B, track G4 Track 1 turbocharging pressure

sensor connector Injection computer brown 48-track connector B, track D4 Track 2 turbocharger pressure

sensor connector Injection computer brown 48-track connector B, track K2 Track 3 turbocharging pressure

sensor connector Repair if necessary.If these checks are carried out, and if fault DF209 is still present following clearance, replace the turbochargerpressure sensor.If the fault is still present, contact the Techline.


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Vdiag No.: 04

DF211PRESENT

OR

STORED

SENSOR FEED VOLTAGE No. 3


NOTES



Special notes:

If the fault is present: – the level 2 warning light is lit, – turbocharging and cruise control functions are deactivated, – engine torque is limited.Use bornier Elé. 1590 for all operations on the injection computer connections.


This test enables the condit ion and the conformity of the engine wiring harness to be checked.


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Vdiag No.: 04

DF211CONTINUED

The following sensors are connected to supply no. 3: – rai l pressure sensor, – air flowmeter.

To locate a possible internal sensor fault, disconnect one of these sensors then check if the fault becomesstored.

If the fault remains present, repeat the operation with the other sensor (wait for a few seconds betweendisconnecting so that the computer can take its measurement).

Replace the faulty sensor if the fault becomes stored after a disconnection.Clear the faults created by the multiple disconnections.If the fault is still present when both these sensors have been disconnected: – Check the continu ity and insulation to earth and + 12 V on the following connections:

Injection computer brown 48-track connector B, track A4 Track 3 rail pressure sensor Injection computer brown 48-track connector B, track C4 Track 1 rail pressure sensor Injection computer brown 48-track connector B, track B4 Track 3 air flowmeter Injection computer brown 48-track connector B, track E2 Track 2 of the air flowmeter

– Check the insulation of the following connections:Tracks 1 and 3 of the rail pressure sensor.Tracks 2 and 3 of the air flowmeter Repair if necessary.

If the fault is still present, apply the fault finding procedure to the air flowmeter and the rail pressure sensor.


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Vdiag No.: 04

DF233PRESENT

OR

STORED

TURBOCHARGING PRESSURE REGULATION CIRCUIT

1.DEF: pressure too low2.DEF: pressure too high

NOTES




– turbocharging is no longer authorised, – exhaust gas recirculation is deactivated, – the level 1 warning light is lit.Use bornier Elé. 1590 for all operations on the engine management computerconnectors.


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Vdiag No.: 04

DF233CONTINUED 1

1.DEF NOTES None.

Check the turbocharger pressure sensor connections.Check the connections of the turbocharging pressure relief solenoid valve.Check the engine management computer connections.Repair if necessary.

Check the conformity of the turbocharging pressure values by checking the conformity check values (Values fromPR082 Turbocharging pressure).

Check the sealing of the high pressure air circuit : – disconnected or pierced pipes, – pressure sensor disconnected or poorly fitted (seal present), – intercooler pierced (to check the intercooler: with the vehicle stationary, stabilise the engine speed at between

3500 and 4000 rpm and check that there are no leaks).

Check that the turbocharger and the control circuit are working: – With the engine stopped, make sure that the control rod is in the resting position. – Start the engine and check that the control shaft moves to its upper stop (when the engine is stopped, the control

shaft should return to its rest position).If the control rod movements do not conform, carry out the following checks:1) Vacuum pressure control check: – Disconnect the solenoid valve inlet hose and connect it to a pressure gauge, – start the engine and stabilise it at idle speed, – If the vacuum does not reach 800 mbar ± 100: check the vacuum pressure circuit from the vacuum pump, – stop the engine, reconnect the inlet hose and proceed to step 2.2) Solenoid valve control check: – Disconnect the solenoid valve outlet hoses, – Start the engine and keep it at idle speed, – place your hand on the solenoid valve and block the outlet connection with your thumb. – If there is no detectable vibration of the solenoid valve, check that the computer output is working correctly (see

DF208 Turbocharging solenoid valve control c ircuit ).

3) Solenoid valve operation check: – Attach the pressure gauge to the outlet union of the solenoid valve, – start the engine and keep it at idle speed.If the vacuum pressure does not reach 800 mbar ± 100, replace the solenoid valve.

Check that the exhaust gas recirculation valve is not stuck open.


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Vdiag No.: 04

DF233CONTINUED 2

2.DEF NOTES

Priority when dealing with a number of faults:Deal with fault DF209 Turbocharging pressure sensorcircuit first if it is present or stored.

Check the turbocharger pressure sensor connections.Check the connections of the turbocharging pressure relief solenoid valve.

Check the engine management computer connections.Repair if necessary.

Check the conformity of the turbocharging pressure values by checking the conformity check values (Valuesfrom PR082 Turbocharging pressure).

Make sure the turbocharging pressure relief solenoid valve is not jammed open: – with the engine switched off, disconnect the inlet and outlet hoses from the solenoid valve. – connect a vacuum pump to the inlet union and apply a vacuum pressure. – if the vacuum pressure is not maintained, replace the solenoid valve.

Check that the turbocharger control rod has not seized:

– with the engine stopped, check that the turbocharger control rod is in the rest position, – apply a vacuum pressure of 800 mbar ± 100, to the hose connected to the turbocharger control diaphragm, – if the diaphragm holds the vacuum, check the movement and setting of the turbocharger control rod

(see Technical Note 3818, Special Notes on the Master Propulsion Phase II, 12B, Turbocharger ).If the control rod is seized, replace the turbocharger.


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DIESEL INJECTION


V2MR-391-X24-13B000$450_eng.mif


Vdiag No.: 04

DF235PRESENT

OR

STORED

CAMSHAFT SENSOR CIRCUIT

1.DEF: signal incoherence2.DEF: no signal

NOTES


The fault is declared present following a road test or after attempting to start the engine.


If the fault is present with the engine stopped, starting the engine is impossible.Use bornier Elé. 1590 for all operations on the injection computer connectors.

Check the camshaft sensor connections.Check the camshaft sensor mounting and positioning. Also check the general condition (damaged housing, heating up, etc.).Carry out the necessary repairs.Measure the camshaft sensor resistance.If the resistance is not 10250 ± 500 ΩΩΩΩ, replace the sensor.

Check the injection computer connections.Check the continu ity and absence of interference resistance of the following connections:

Injection computer brown 48-track connector B, Track D1 Track 2 Camshaft sensor

Injection computer brown 48-track connector B, Track A1 Track 1 Camshaft sensor

With the ignition on and the camshaft sensor connected:Use a voltmeter to measure the voltage between tracks 1 and 3 of the camshaft sensor (This voltage mustequal the battery voltage): – If the voltage is outside permitted tolerance values, take the measurement again with the camshaft sensor

disconnected,

– if the voltage is still outside permitted tolerance values, check the continuity and make sure there is nointerference resistance on the following connection:

Camshaft sensor, track 3 + after ignition feed – if the voltage comes within the tolerance values, replace the camshaft sensor.

If the fault is still present, – check the timing belt tension, – check the timing setting.



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Vdiag No.: 04

DF253PRESENT

OR

STORED

EGR SOLENOID VALVE SERVO-CONTROL

1.DEF: insufficient EGR valve flow2.DEF: excessive EGR valve flow

NOTES


The fault is declared present after clearing the faults from the memory or following anengine start.

Special notes:

If there is a significant amount of smoke, the EGR valve and the turbocharger areblocked.If 2.DEF the level 1 warning light is lit.Use bornier Elé. 1590 for all operations on the injection computer connectors.

Check the resistance of the exhaust gas recirculation valve motor between tracks 1 and 5.If the resistance is not 3 ± 0.3 ΩΩΩΩ, replace the EGR valve.Measure the resistance of the exhaust gas recirculation valve potentiometer between tracks 2 and 4.If the resistance is not 6.5 ± 2.6 kΩΩΩΩ, replace the EGR valve.

Remove the exhaust gas recirculation valve.Check that nothing is blocking the valve piston in the open position.If the valve is blocked open or seized, remove the particle and clean the piston travel surface.

Refit the EGR valve and run command RZ010 Adaptives on EGR valve fault .Clear the faults when the command has finished.If the fault DF253 is still present, replace the EGR valve.


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Fault finding - Parameter summary table 13B

V2MR-391-X24-13B000$500_eng.mif


Vdiag No.: 04

DIESEL INJECTION

Fault finding - Parameter summary table

Tool Parameter Diagnostic tool title

PR001 Fuel temperature

PR002 Coolant temperature

PR003 Air temperature

PR004 Computer feed voltage

PR006 Engine speed

PR007 Inlet air flow

PR008 Pedal potentiometer voltage gang 1

PR009 Pedal potentiometer voltage gang 2

PR016 Atmospheric pressure

PR018 Vehicle speedPR020 Fuel flow setpoint

PR025 Air flowmeter feed voltage

PR033 Fuel flow

PR034 EGR vale opening setpoint

PR035 Idling speed correction

PR039 Air flow setpoint for the EGR

PR062 Engine idle speed setpoint.

PR082 Turbocharging pressure

PR088 EGR valve position feedback

PR089 EGR valve position feedback loop difference

PR095 EGR valve OCR

PR097 Rail pressure regulation valve OCR

PR100 Atmospheric pressure sensor voltage

PR104 Fuel temperature sensor voltage

PR107 Air temperature sensor voltage

MR-391-X24-13B000$500_eng.mif

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DIESEL INJECTION

Fault finding - Conformity check 13B

13B - 108V2MR-391-X24-13B000$550_eng.mif


Vdiag No.: 04

DIESEL INJECTION

Fault finding - Conformity check

AIR CIRCULATION (TURBOCHARGING - INLET)

*OCR: Opening cyclic ratio.

NOTES

Only check conformity after a complete check using the diagnostic tool. The valuesshown in this conformity check are given as a guide.Execution conditions: ENGINE STOPPED, IGNITION ON.

Order FunctionParameter or Statuschecked or Action

Display and Notes Fault finding

1 Engine speed PR006: Engine speed X = 0 rpm

In the event of a fault consult the interpretationfor fault DF023 "Enginespeed sensor circui t" .

2 Temperature PR003:Inlet air

temperature

Indicates the inlet airtemperature

Default value: 50 ˚C

In the event of a fault,refer to the interpretation

for parameter PR003.

3

Pressure

IMPORTANT:Parameters PR150

and PR082 onlyconcern engines

equipped withVariable Geometry

turbochargers.If this is not the

casePR150 = PR082 =

0 mbar

PR016: Atmospheric

pressure

Indicates theatmospheric pressure

in mbar The sensor is builtinto the computer.

Default value:

750 mbar

In the event of a fault consult the interpretation

of fault DF024 Atmospheric pressure

sensor circuit .

PR150:

Turbocharging

pressuresetpoint

X = 1000 mbar

Default value:750 mbar

In the event of a fault,

consult the interpretationof faults DF209

Turbocharger pressuresensor circuit and

DF208 Turbochargingsolenoid valve control

circuit.

PR082:Turbocharging

pressureX = PR150 ± 50 mbar

4 Sensor feed

PR107: Air temperaturesensor voltage

1.90 V < X < 2.10 VSafe value: 5 V

In the event of a fault,consult the interpretation

for fault DF022 "Air

temperature sensorcircuit" .

PR025: Air flowmeterfeed voltage

X = 0.6 V

Safe value: 5 V

In the event of a fault,consult the interpretationof fault DF019 Air flow

sensor circuit .

PR100:

Atmosphericpressure

sensor voltage3.80 V < X < 4 V



sensor circuit .

MR-391-X24-13B000$550_eng.mif

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Vdiag No.: 04

FUEL CIRCUIT

NOTES





In the event of a fault consult the interpretation forfault DF023 "Engine speed

sensor circuit" .

2 Injector codes ET235:Injector code

use

YESor

FAULTY

If status ET235 asDEFAULT, consult the

interpretation of thecommand SC004 Injector

calibration data input.

3 Temperature PR001:Fuel

temperature

Indicates the fueltemperature


In the event of a fault,consult the interpretation of

fault DF021 Fueltemperature sensor

circuit.

4 Pressure

PR216:Rail pressure

setpoint

Indicates the

theoretical pressurevalue for optimumengine operation

X = 680 bar Default value:

350 bar

NONE

PR097:

Rail pressureregulation valve

OCR

X = 15 %Default value: 50 %

In the event of a fault,consult the interpretation forfault DF117 "Rail pressure

sensor circuit" .PR217: Rail pressure X = 0 bar

PR548:Fuel pressure

difference

X = 680 bar PR548 = PR216 -

PR217

The calculated pressuredifference is the differencebetween the rail pressure

and the rail pressuresetpoint. In the event of a

fault, consult theinterpretation for fault DF117

"Rail pressure sensor

circuit" .

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Vdiag No.: 04

FUEL CIRCUIT (Continued)

NOTES




5 Flow

PR033: Fuel flow X = 40 mg/st

NONEPR020:

Fuel flowsetpoint

X = 40 mg/st

6 Rail current

PR598:Rail pressure

regulator current

X = 400 mA

Default value:1700 mA

In the event of a fault,consult the interpretation forfault DF117 "Rail pressure

sensor circuit" .

PR597:Rail pressure

regulator currentsetpoint

X = 400 mADefault value:

1700 mANONE

7 Rail supply

PR104:

Fueltemperature

sensor voltage

X = 3 VSafe value: 5 V


faults DF091 Sensor supplyvoltage No. 1, DF092

Sensor supply voltageNo. 2, DF211 Sensorsupply voltage No. 3.

PR556: Rail pressuresensor voltage

X = 0.5 VSafe value: 5 V

8Flow

correction

PR524:

Cylinder no. 1fuel flow

correction

X = 0 mg/st


test 1 Injectors test

PR589:Cylinder no. 2

fuel flowcorrection

PR590:


correction

PR525:


correction

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Vdiag No.: 04

EGR CIRCUIT

NOTES




1 Engine PR006: Engine speed X = 0 rpm


sensor circuit" .

2 EGR valve

PR095: EGR valve OCR 90 % < X < 95 %


of fault DF253 EGRsolenoid valve servo-

control system

PR034:EGR valve

opening setpoint0 % < X < 20 % NONE

PR088:

EGR valveposition

feedbackPR088 = PR034

In the event of a fault,consult the interpretation for

fault DF084 "EGR valve

position sensor circuit" .

PR089:

EGR valveposition

feedback loopdifference

PR089 = PR551 -

PR088

The EGR valve positionfeedback loop di fferencemust equal the difference

between the EGR valveposition and the position

feedback.

PR551:

EGR valveposition

correction0 % < X < 10 %


consult the interpretationof fault DF253 EGR

solenoid valve servo-control system

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Vdiag No.: 04

EGR CIRCUIT (Continued)

NOTES




3EGR valveContinued

PR039: Air flow setpoint

for EGRapproximately

750 mg/revNONE

PR550: Air flow

differencePR550 = PR039 NONE

PR506:EGR valve

position sensorvoltage

0.75 V < X < 1 V


fault DF084 "EGR valveposition sensor circuit" .

PR583:New EGR valve

offset0 % < X < 20 %

In the event of a fault, runcommand RZ010 EGR

valve fault adaptives.

PR584:Last EGR valve

offset0 % < X < 20 %

In the event of a fault, runcommand RZ010 EGRvalve fault adaptives.

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Vdiag No.: 04

DRIVER PARAMETERS

(*) PEDAL VOLTAGES - COLD, IGNITION ON (Average values given as examples).

NOTES






sensor circuit" .

2 Accelerator

pedal positionPR240:

Acceleratorpedal position

Indicates the pedalposition percentage

between no load andfull loadX = 0 %

(If no pressure isexerted on the pedal)

0 % < X < 100 %

In the event of a fault consult the interpretation offault DF071 Pedal sensor

circuit gang 1

or DF073 Pedal sensorcircuit gang 2.

3 Sensor feed

PR008:

Pedalpotentiometer

gang 1 voltage0.73 V no load

The voltage value of gang 2is approximately equal to halfthe voltage value of gang 1.

In the event of a fault,consult the interpretation offault DF071 Pedal sensorcircui t gang 1 or DF073

Pedal sensor circui t

equals gang 2.

PR009:

Pedalpotentiometer


Pedal load 0 % 25 % 50 % 100 %

Gang 1 voltage 0.73 V 1.60 V 2.79 V 3.93 V


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Vdiag No.: 04

DRIVER PARAMETERS (Continued)

NOTES




4 Brake contact

ET013:Brake contactno. 1 signal

Indicates recognitionof brake pedal

contacts

ACTIVEor

INACTIVE

In the event of a fault,consult the interpretation forstatus ET013 Brake contact

no. 1.

ET014:Brake contactsignal no. 2

In the event of a fault,consult the interpretation forstatus ET014 Brake switch

no. 2.

5 Clutch contact ET142: Clutch pedal

Indicates recognitionof the clutch pedal

contacts asRELEASED

or

DEPRESSED

In the event of a fault,consult the interpretation forstatus ET142 Clutch pedal.

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Vdiag No.: 04

PREHEATING

NOTES




1 Power supply

PR004:Computer feed

voltage9 V < X < 16 V

In the event of a fault consult the interpretation of

fault DF146 "Computersupply voltage" .

ET001:+ After ignitioncomputer feed

PRESENTor

ABSENT


status ET001 "Computer+ after igni tion feed"

2 Engine speed PR006: Engine speed 0 rpm


sensor circuit" .

3 Engine ET118: EngineSTALLED

or STOPPED

NONE

4 Temperature

PR002:Coolant

temperature

Displays the enginecoolant temperature

in ˚CDefault value: 105 C


fault DF002 "Coolant

temperature sensorcircuit" .

PR003:Inlet air

temperature




fault DF022"Air temperature sensor

circuit" .

5 Preheating ET239:Pre-postheating

control

ACTIVEor

INACTIVE


fault DF081 "Preheatingrelay circuit" .

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Vdiag No.: 04

AIR CONDITIONING

NOTES




1 Temperature PR002:Coolant

temperature

Shows the enginecoolant temperature

in ˚CDefault value: 105 ˚C


fault parameter DF002Coolant temperature

sensor circuit .

2 Programming

ET102: Air conditioning

request

YESor

NO

Status ET102 changes to"YES" when the driverpresses one of the airconditioning command

buttons.In the event of a fault,

consult the interpretationof s tatus ET102.


authorisationNO NONE

3 Refrigerant

PR192: Refrigerantpressure

X = 0 bar Default value: 35 bar

If there is a fault , consultthe interpretation for fault

DF113 "Refrigerantpressure sensor circui t" .PR203:

Refrigerantsensor voltage

0 V < X < 5 V

Safe value: 5 V

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Vdiag No.: 04

CRUISE CONTROL/SPEED LIMITER

NOTES

Only check conformity after a full check with the diagnostic tool. The values shown inthis conformity check are given as a guide.Execution conditions: ENGINE STOPPED, IGNITION ON.



1

Cruise control

ET256: Cruise control/speed limiter

CRUISE CONTROL orSPEED LIMITER

Test the operation of thecruise control/speed limiter

"ON/OFF" buttons,consulting the interpretation

of status ET256 "Cruise

control/speed limiter".

ET258:

Deactivation of

cruise control/speed limiter

Note: The cruisecontrol functioncan only beactivated ifV > 30 mph(50 km/h).

All these statuses canidentify a fault inhibiting thecruise control/speed limiter.If the cruise control/speedlimiter is faulty, consult the

interpretation of statusET258 Cruise control/

speed limiter deactivation.Test the operation of the

"ON/OFF" and "+" and " -"buttons, consulting the

interpretation of statusesET257 "Cruise cont rol/

speed limiter function" andET256 "Cruise cont rol/

speed limiter"

INACTIVE

STATUS 1: Tractioncontrol request

STATUS 2: Brakepedal depressed

STATUS 3: Cruisecontrol or speed limiterfault

STATUS 4: Engine/gearbox decoupling

STATUS 5: Faultdetected by injectioncomputer

STATUS 6: Vehiclespeed invalid

STATUS 7: Suspendbutton pressed

STATUS 8: Gear leverin neutral

STATUS 9:Inconsistency betweenthe request and thevehicle speed

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Vdiag No.: 04

CRUISE CONTROL/SPEED LIMITER (con td.)

NOTES

Only check conformity after a full check with the diagnostic tool. The values shown inthis conformity check are given as a guide.Execution conditions: ENGINE STOPPED, IGNITION ON.



2

Vehicle speed

PR018: Vehicle speed 0 mph with engine off

Test the multiplex network.If faults appear (see 38C,

Anti -lock Braking system).

ET257:Cruise control/speed limiter

function

"PLUS" or " MINUS"

indicates whether thedriver has selected acruising speed or if

he/she wishes toincrease it.

In the event of a fault, consultthe interpretation of status

ET257 Cruise control/speed limiter function.

3 Brake contact

ET013:Brake switchno. 1 signal Indicates recognition

of the brake pedalcontacts

ACTIVE or INACTIVE

In the event of a fault,consult the interpretation forstatus ET013 Brake contact

no. 1

ET014:

Brake switch

no. 2 signal


status ET014 "Brakecontact no. 2" .


Indicates recognition

of the clutch pedalcontacts as

RELEASED orDEPRESSED

In the event of a fault,consult the interpretation ofstatus ET142 Clutch pedal

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Vdiag No.: 04

STARTING

NOTES




1 Power supply


PRESENT


for status ET001"Computer + after

ignition feed"

PR004:Computer feed


In the event of a fault, consult the interpretationof fault DF146 Computer

supply voltage.

2 Starting ET238: Starting

AUTHORISED: Theinjection has given

starting authorisationor

PROHIBITED:The injection systemdoes not authorise

starting.

If status ET238 isPROHIBITED (see 82A,

Engine immobiliser .

3 Synchronisation ET157: Synchronisation NOT PERFORMEDIn the event of a fault,

consult the interpretationof status ET157.

4Engine

operation.ET118: Engine

STOPPED or STALLED NONE

5Engine

immobiliser

ET003:Engine

immobiliser

ACTIVE orINACTIVE

If status ET003 remains Active dur ing starting,

consult the

interpretation for statusET003.

ET133:Code

programmed

YES orNO

If status ET133 remainsNO, consult the

interpretation for statusET133.

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Vdiag No.: 04

STARTING (Continued)

NOTES




6Impact

detectedET207:

Impact detectedby the computer

YES orNO

If status ET207 is YES, referto the interpretation of ET207

Impact detected by thecomputer .

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Vdiag No.: 04

FEED VOLTAGE

NOTES




1 Power supply


PRESENT

In the event of a fault, consult the interpretation for

status ET001 Computer+ after ignition feed.

PR004:Computer feed



fault DF146 Computersupply voltage.


0.5 V < X < 1 VSafe value: 5 V

In the event of a fault, consult the interpretation of

fault DF019 Air f low sensorcircuit

2Sensor

voltages

PR470:Sensor

referencevoltage

3.4 V < X <3.8 V NONE

PR100:

Atmosphericpressure sensor

voltage3.7 V < X < 4 V

In the event of a fault, consult the interpretation offault DF024 Atmospheric

pressure sensor circuit.


2 V < X < 2.5 V

at 20 ˚CSafe value: 5 V


fault DF022 Air temperature

sensor circuit .

PR109:

Coolant

temperaturesensor voltage

2.5 < X < 3 V

at 20 ˚CSafe value: 5 V


fault DF002 Coolanttemperature sensor

circuit.

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Vdiag No.: 04

FEED VOLTAGE (Continued)

NOTES




2Sensor voltage

(continued)

PR104:

Fueltemperature

sensor voltage

2 V < X < 3 V

à 20 ˚C



circuit.

PR556:Rail pressure

sensor voltage0.2 V < X < 1 V

In the event of a fault, consult the interpretation offault DF117 Rail pressure

sensor circuit .

PR008:Pedal

potentiometervoltage gang 1

0.73 V no loadignition on

In the event of a fault, consult the interpretation offault DF071 Pedal sensor

circuit gang 1.

PR009:

Pedal

potentiometergang 2 voltage

0.37 V no load,

ignition on


fault DF073 Pedal sensorcircuit gang 2.

PR506:EGR valve

position sensorvoltage

0.2 V < voltage < 3 V


fault DF084 EGR valveposition sensor circuit.

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Vdiag No.: 04

POWER TAKE-OFF

NOTES




1 Power take-off

PR458:Maximum

vehicle speedX = 13 mph (22 km/h)

The power take-off

parameter values aredefined by default in the

computer.If the computer is replaced

or reprogrammed, they arestored by the command

SC005 Computer

replacement data save.For security reasons, none

of these values can bemodified.

If one of the values is notcorrect, consult the

interpretation of commandVP032 Commercial vehicle

specific parameters.

If the fault is still present,contact the Techline.

PR459:Minimum engine

speedX = 900 rpm

PR460:Maximum

engine speedX = 3500 rpm

PR461:Default engine

speed

X = 1200 rpmThis value must be

between PR459 andPR460

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Vdiag No.: 04

AIR CIRCULATION (TURBOCHARGING/INLET)

*OCR: Opening cyclic ratio.

NOTES

Only check conformity after a complete check using the diagnostic tool. The valuesshown in this conformity check are given as a guide.Execution conditions:

ENGINE AT IDLE SPEED AND WARM: ENGINE COOLANT TEMPERATURE> 80 ˚C.

Order FunctionParameter or Status

checked or ActionDisplay and Notes Fault finding


In the event of a fault consult the interpretationof fault DF023 Steering

wheel position sensorcircuit.

2 Temperature PR003:Inlet air

temperature


Default value: 50˚

In the event of a fault, refer to the interpretation

for parameter PR003.

3

PressureIMPORTANT:

Parameters PR150and PR082 only

concern enginesequipped with

Variable Geometry

turbochargers.Otherwise

PR150 = PR082 =0 mbar

PR016: Atmospheric

pressure

Indicates theatmospheric pressure

in mbar.The sensor is built into

the computer.Default value:

750 mbar



sensor circuit .

PR150:

Turbochargingpressuresetpoint

X = 1100 mbar Default value:

750 mbar


of faults DF209Turbocharger pressure

sensor circuit , andDF208 Turbochargingsolenoid valve control

circuit.

PR082:Turbocharging

pressureX = 1050 mbar

PR081:Turbochargingpressure loop

difference

0 mbar < X

< 50 mbar

4 Sensor feed

PR107:

Airtemperature

sensor voltage

2.2 V < X < 2.40 V

Safe value: 5 V

In the event of a fault, consult the interpretation

of fault DF022 Airtemperature sensor

circuit.

PR100: Atmospheric

pressuresensor voltage

3.80 V < X < 4 V

In the event of a fault, consult the interpretation


sensor circuit .


X = 0.6 VSafe value: 5 V


consult the interpretationof fault DF019 Air flow

sensor circuit .

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Vdiag No.: 04

FUEL CIRCUIT

NOTES


ENGINE AT IDLE SPEED AND WARM: ENGINE COOLANT TEMPERATURE> 80˚C.




In the event of a fault consult the interpretation offault DF023 Steering wheel

position sensor circuit.

2 Injector codes ET235:Injector code

use

YESor

FAULTY

If status ET235 asDEFAULT, consult the

interpretation of thecommand SC004 Injector

calibration data input.

3 Temperature PR001:Fuel

temperature

Indicates the fueltemperature




circuit.

4 Pressure

PR216:Rail pressure

setpoint

Indicates thetheoretical pressurevalue for optimumengine operation

X = 750 bar

Default value:350 bar

NONE

PR097:Rail pressure

regulation valveOCR

35 % < X < 40 %Default value: 50 %


sensor circuit.PR217: Rail pressure 700 bar < X < 800 bar

PR548:Fuel pressure

difference

0 bar < X < 50 bar PR548 = PR216 -

PR217

The calculated pressuredifference is the differencebetween the rail pressure

and the rail pressuresetpoint. In the event of a

fault, consult theinterpretation of fault DF117

Rail p ressure sensorcircuit.

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Vdiag No.: 04

FUEL CIRCUIT (Continued)

NOTES


ENGINE AT IDLE SPEED AND WARM: ENGINE COOLANT TEMPERATURE> 80˚C.



5 Flow

PR033: Fuel flow0 mg/st < X< 60 mg/st

In the event of a fault, consultthe interpretation of the fault

command AC624 Railpressure regulator .PR020: Fuel flow

setpointPR020 = PR033

6 Rail current

PR598:Rail pressure

regulator current

1390 bar < X< 1450 bar

Default value:

1700 mA

In the event of a fault, consultthe interpretation of fault

DF117 Rail pressure

sensor circuit .

PR597:

Rail pressureregulator current

setpoint

1390 bar < X< 1450 bar

Default value:1700 mA

NONE

7 Rail supply

PR104:Fuel


1.7 V < X < 3 VSafe value: 5 V


faults DF091 Sensor supplyvoltage No. 1, DF092

Sensor supply voltageNo. 2, DF211 Sensorsupply voltage No. 3.

PR556:Rail pressure

sensor voltage1.5 V < X < 2.5 VSafe value: 5 V

8Flow

correction

PR524:


correction

- 5 mg/st < X< + 5 mg/st


test 1 “Injector test”.

PR589:

Cylinder no. 2

fuel flowcorrection

PR590:Cylinder no. 3

fuel flowcorrection

PR525:


correction

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Vdiag No.: 04

EGR CIRCUIT

NOTES





1 Engine PR006: Engine speed X = 750 rpm

In the event of a fault consult the interpretation offault DF023 Steering wheel

position sensor circuit.

2 EGR valve

PR095: EGR valve OCR 90 % < X < 95 %

In the event of a fault, consult the interpretation offault DF253 EGR solenoid

valve servo-controlsystem

PR034:EGR valve

opening setpoint0 % < X < 30 %


fault DF163 EGR valvecontrol circuit.

PR088:EGR valve

positionfeedback

PR088 = PR034



PR089:

EGR valveposition

feedback loopdifference

PR089 = PR551 -PR088

The EGR valve positionfeedback loop di fference

must equal the differencebetween the EGR valve

position and the positionfeedback.

PR551:EGR valve

positioncorrection

0 % < X < 10 %


consult the interpretation offault DF253 EGR solenoid

valve servo-control

system

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Vdiag No.: 04

EGR CIRCUIT (Continued)

NOTES





3EGR valve

Continued

PR039: Air flow setpoint

for EGRapproximately1200 mg/rev

NONE

PR550: Air flowdifference

approximately450 mg/rev

NONE

PR506:

EGR valveposition sensor



fault DF084 "EGR valve

position sensor circuit" .

PR583:New EGR valve

offset0 % < X < 20 %

In the event of a fault, runcommand RZ010 EGRvalve fault adaptives.

PR584:Last EGR valve

offset 0 % < X < 20 %

In the event of a fault, run

command RZ010 EGRvalve fault adaptives.

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Vdiag No.: 04

DRIVER PARAMETERS

(*) PEDAL VOLTAGES - COLD, IGNITION ON (Average values given as examples).

NOTES







fault DF023 Flywheel signal

sensor circuit .

2 Accelerator

pedal positionPR240:

Acceleratorpedal position

Indicates the pedalposition percentage

between no load andfull loadX = 0 %

(if there is nopressure on the

pedal)0 % < X < 100 %


circuit gang 1 or DF073 Pedal sensor

circuit gang 2.

3 Sensor feed

PR008:Pedal

potentiometergang 1 voltage

0.73 V no loadThe voltage value of gang 2is approximately equal to halfthe voltage value of gang 1.

In the event of a fault consult the interpretation offault DF071 Pedal sensor

circuit gang 1 or DF073 Pedal sensor

circuit gang 2.

PR009:

Pedalpotentiometer


Pedal load 0 % 25 % 50 % 100 %



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Vdiag No.: 04

DRIVER PARAMETERS (Continued)

NOTES





4 Brake contact

ET013:Brake contactno. 1 signal

Indicates recognition

of brake pedalcontacts ACTIVE

or INACTIVE


status ET013 Brake

switch no. 1.

ET014:Brake contactsignal no. 2

In the event of a fault,consult the interpretation ofstatus ET014 Brake switch

no. 2.


Indicates recognitionof clutch pedal

contacts

RELEASEDor

DEPRESSED

In the event of a fault, consult the fault finding

procedure for status ET142Clutch pedal.

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Vdiag No.: 04

PREHEATING

NOTES





1 Power supply

PR004:Computer feed

voltage9 V < voltage < 16 V


fault DF146 Computer

supply voltage.


PRESENT


status ET001 Computer

+ after ignition feed.



fault DF023 Flywheel signal

sensor circuit .

3 Engine ET118: Engine RUNNING NONE

4 Temperature

PR002:Coolant

temperature

Displays the enginecoolant temperature

in ˚CDefault value: 105 C


fault DF002 Coolant

temperature sensorcircuit.

PR003:Inlet air

temperature




fault DF022 Air temperaturesensor circuit .

5 Preheating ET239: Pre-postheatingcontrol

INACTIVE


consult the interpretation offault DF081 Preheating

circuit relay.

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Vdiag No.: 04

AIR CONDITIONING

NOTES





1 Temperature PR002:Coolant

temperature

Shows the enginecoolant temperature

in ˚CDefault value: 105 ˚C

In the event of a fault, consult the interpretation forparameter DF002 Coolant


2 Programming


request

YESor

NO

Status ET102 changes to"YES" when the driverpresses one of the airconditioning command

buttons.In the event of a fault,

consult the interpretationof s tatus ET102.


authorisation

YESor

NO

Status ET117 becomesYES if the vehicle is not

under full load.In the event of a fault,

consult the interpretation

of s tatus ET117.

3 Refrigerant

PR192:Refrigerant

pressure2 bar < X < 35 bar

Default value: 35 bar In the event of a fault,

consult the interpretation offault DF113 Refrigerant

sensor circuit .PR203:Refrigerant

sensor voltage0 V < X < 5 V

Safe value: 5 V

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Vdiag No.: 04


NOTES

Only check conformity after a full check with the diagnostic tool. The values shown inthis conformity check are given as a guide.Execution conditions:ENGINE AT IDLE SPEED AND WARM: ENGINE COOLANT TEMPERATURE > 80˚C.



1 Cruise control

ET256: Cruise control/speed limiter

"CRUISE CONTROL" OR“ SPEED LIMITER”

Test the operation of thecruise control/speed limiter

"ON/OFF" buttons,consulting the

interpretation of status ET256 "Cruise contro l/

speed limiter".

ET258: Cruise control/speed limiter deactivation

Note:

Cruise control can only beactivated ifV > 30 mph (50 km/h) or V > 18mph (30 km/h) if“eco” cruise control/speedlimiter.

INACTIVE

All these statuses canidentify a fault inhibiting the

cruise control/speedlimiter.

If the cruise control/speedlimiter is faulty, consult the

interpretation of statusET258 Deactivation ofcruise control/speed

limiter .Test the operation of the"ON/OFF" and "+" and"-" buttons, consulting

the interpretation ofstatuses ET257 "Cruisecontrol/speed limiter"

funct ion and ET256"Cruise control/speed

limiter"

STATUS 1: Tractioncontrol

STATUS 2: Brake pedaldepressed

STATUS 3: Cruise controlor speed limiter fault

STATUS 4: Engine/gearbox decoupling

STATUS 5: Fault detectedby the injection computer

STATUS 6: Vehicle speedinvalid

STATUS 7: Cancel buttonpressed

STATUS 8: Gear lever inneutral position

STATUS 9: Inconsistencybetween the request and

the vehicle speed

ET257: Cruise control/speed limiter function

INACTIVE: no buttonpressed

In the event of a fault ,refer to the interpretation of

statuses ET257 Cruisecontrol/Speed limiterfunction and ET258

Cruise cont rol/Speedlimiter deactivation.

INCREASE: increasebutton pressed

DECREASE: decreasebutton pressed

SUSPEND: Suspendbutton pressed

RESUME: Resume buttonpressed

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Vdiag No.: 04

STARTING (Continued)

NOTES





6Impact

detected

ET207:Impact detectedby the computer

YES orNO

If status ET207 is YES, referto the interpretation of ET207

Impact detected by the

computer.

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Vdiag No.: 04

DIESEL INJECTION

Fault finding - Conformity check

FEED VOLTAGE

NOTES





1 Power supply


PRESENT


status ET001 Computer

+ after ignition feed.

PR004:Computer feed


In the event of a fault consult the interpretation of

fault DF146 "Computer

supply voltage" .


0.5 V < X < 3 V


fault DF019 Air f low sensor

circuit.

2 Sensor voltage

PR470:

Sensor

referencevoltage

3.4 V < X <3.8 V NONE

PR100: Atmospheric

pressure sensorvoltage

3.7 V < X < 4 V

In the event of a fault, consult the interpretation offault DF024 Atmosphericpressure sensor circuit.


1.5 V < X < 2.5 Vat 20 ˚C


fault DF022 Air temperaturesensor circuit .

PR109:

Coolanttemperature

sensor voltage

2 V < X < 3 V

à 20 ˚C


fault DF002 Coolanttemperature sensor

circuit.

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Vdiag No.: 04

FEED VOLTAGE (Continued)

NOTES





2Sensor voltage

(continued)

PR104:Fuel


1.5 V < X < 3 V

at 20 ˚C


fault DF021 Fuel


PR556:Rail pressure

sensor voltage1.5 V < X < 2.5 V


sensor circuit .

PR008:Pedal


0.73 V no load


circuit gang 1.

PR008:Pedal


0.37 V no load


circuit gang 2.

PR506:

EGR valveposition sensor

voltage0.2 V < X < 3 V



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Vdiag No.: 04

POWER TAKE-OFF

NOTES





1 Power take-off

PR458:Maximum

vehicle speedX = 13 mph (22 km/h)

The power take-offparameter values are

defined by default in the

computer.If the computer is replacedor reprogrammed, they are

stored by the commandSC005 Computer

replacement data save.For security reasons, none

of these values can bemodified.

If one of the values is notcorrect, consult the

interpretation of command

VP032 Commercial vehiclespecific parameters.

If the fault is still present,contact the Techline.

PR459: Minimum enginespeed

X = 900 rpm

PR460:Maximum

engine speedX = 3500 rpm

PR461:Default engine

speed

X = 1200 rpmThis value must bebetween PR459 and

460

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Fault finding - Status summary table 13B

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Vdiag No.: 04

DIESEL INJECTION

Fault finding - Status summary table

Summary of injection system statuses:

Tool status Diagnostic tool title

ET001 + After ignition computer feed

ET003 Engine immobiliser

ET013 Brake contact no. 1 signal

ET014 Brake contact signal no. 2

ET102 Air conditioning request

ET117 Air conditioning authorisation

ET118 Engine

ET133 Code programmed

ET142 Clutch pedal

ET157 Synchronisation

ET207 Impact detected by computer

ET235 Injector code use

ET238 Starting

ET239 Preheating unit control

ET256 Cruise control/Speed limiter

ET257 Cruise control/speed limiter function

ET258 Deactivation of cruise control/speed limiter

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Fault finding - Interpretation of statuses 13B

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Vdiag No.: 04

DIESEL INJECTION

Fault finding - Interpretation of statuses

ET001

COMPUTER + AFTER IGNITION FEED

ABSENT NOTES Ignition on

Check the FM3 (30A) supply fuse from the injection computer main supply relay.Use a multimeter to check for a + 12 V feed on the fuse holder with the ignition on.Repair if necessary.

Check the continuity and insulation to earth of the following connection:Computer main supply relay mounting (R8) track 15 Track E1 of injection computer

connector BCheck the following connection for continuity and make sure that there is no interference resistance:

Track G4 black 32-track connector A, injection computer Battery earthTrack H4 black 32-track connector A, injection computer Battery earthTrack H1 black 32-track connector A, injection computer Battery earth


PRESENT NOTES Ignition on

Normal operating conditions.With the ignition off check for a + 12 V feed on the injection computer connector B track E1 with a multimeter.Repair if necessary.

AFTER REPAIRCarry out another fault finding check on the system.Deal with any faults.

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Vdiag No.: 04

ET013

ET014

BRAKE CONTACT SIGNAL No. 1

IMPORTANTStatuses ET013 and ET014 must change at the same time. If there is inconsistency between these2 statuses, refer to the interpretation of fault DF051 Brake pedal contact c ircuit .

INACTIVE NOTES Brake pedal depressed

If the brake lights are working:

– Check the continuity and that there is no interference resistance between:Injection computer black 32-track connector A, track E4 Track B3 Brake light switch

Repair if necessary.If the brake lights are not working: – Check for an + after igni tion feed on tracks 2 and 4 of the brake light switch connector. – Check the condition and fitting of the brake light switch and brake lights fuse. – Remove the brake light switch and check that it is operating correctly:

Continuity between tracks Insulation between tracks

Switch depressed(Brake pedal released)

3 and 4 1 and 2

Switch released(Brake pedal depressed)

1 and 2 3 and 4

– Replace the brake light switch if necessary.


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Vdiag No.: 04

ET102

AIR CONDITIONING REQUEST

NOTESOnly perform the tests if the statuses do not correspond with the system programmingfunctions.

YES The air conditioning request has been made by the driver when pressing one of theair conditioning controls (Auto, or AC).Status ET102 becomes YES if the computer authorises air conditioning.If status ET102 does not change to YES after the control button is pressed, consultthe air conditioning fault finding procedure (see 62A, Air conditioning, conformity

check).

When the driver deactivates the air conditioning, the status ET102 must become NO.If this does not happen, consult the air conditioning fault finding procedure (see 62A,

air conditioning, conformity check).

NO


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Vdiag No.: 04

ET117

AIR CONDITIONING AUTHORISATION


YES The air conditioning authorisation only becomes YES if: – the air conditioning request was made by the driver, – the engine is not under full load, – air conditioning switch is in AC or AUTO position with minimum ventilation.If status ET117 does not become YES consult the air conditioning fault findingprocedure (see 62A, air condit ioning, conformity check).

IMPORTANT

Status ET117 remains at "NO" ignition on even if the air conditioning request switchis activated. The computer does not authorise air conditioning if the engine hasnot been started.

If status ET117 remains NO, switch released and engine started, check: – that the air conditioning compressor is activated correctly, – the supply fuses, – the presence of refrigerant in the air conditioning circuit, – that the refrigerant fluid pressure value seems consistent at idle speed.If this fault is still present, consult the fault finding procedure for the air conditioning(see 62A, Air conditioning, conformity check).

NO


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Vdiag No.: 04 Fault finding - Interpretation of statuses

ET118

Engine

STOPPEDThe status ET118 is "stopped" when the ignition is switched on but the starter motor isnot operating.

STALLEDStatus ET118 is stalled when the engine has stalled. The vehicle will still be under + afterignition feed.

RUNNING Status ET118 is running if the engine has started.

STARTER Status ET118 is starter when the engine is in its starting phase.

AFTER REPAIRCarry out another fault finding check on the system.Deal with any faults.Clear the stored faults.

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Vdiag No.: 04 Fault finding - Interpretation of statuses

ET133

CODE PROGRAMMED

YES Status ET133 becomes YES if dialogue is possible between the UCH computer and theinjection computer and the key code is recognised.

The engine is only authorised to start if the key code is recognised by the UCH computerand if status ET003 Immobili ser becomes INACTIVE.

NO Status ET133 becomes NO if dialogue is possible between the UCH computer and the

injection computer and the key code is recognised.

Authorisation for engine starting is only issued if the code is correctly recognised by the

UCH computer and status ET003 Engine immobiliser changes to ACTIVE.This fault may be caused by incorrect key programming or no key programming.

In this case, refer to the UCH fault finding note and follow the programming procedurefor the keys. If this fault is not due to programming, run a multiplex network test, andcheck that dialogue between the UCH and the injection computer can be established.

If dialogue is not established, contact Techline.


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Vdiag No.: 04

ET142

CLUTCH PEDAL

INACTIVE NOTES Clutch pedal depressed.

– Check the condition and fitting of the clutch switch. – Check for the earth connection on track B3 of the clutch switch connector. – Remove the clutch switch and check that it is operating correctly:


Switch pressed(Clutch pedal released)

1 and 2 -

Switch released(Clutch pedal depressed)

- 1 and 2

If the checks above are not in order, replace the switch.

– Check the continuity of the connection between track A1 of the clutch switch connector and track C4 of thecomputer's 32-track black connector A.



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Vdiag No.: 04

ET142CONTINUED

ACTIVE NOTES Clutch pedal depressed.

– Check the condition and fitting of the clutch switch. – Remove the clutch switch and check that it is operating correctly


Switch pressed(Clutch pedal released)

1 and 2 -

Switch released(Clutch pedal depressed)

- 1 and 2

– Replace the switch if necessary. – Check the continuity and insulation from earth of the connection between track A1 of the clutch switch

connector and track C4 of the computer's 32-track black A connector.


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Vdiag No.: 04

ET157

SYNCHRONISATION

NOTESSpecial notes: Perform these checks if the statuses are not consistent with the systemoperation programming.

NOT PERFORMED Status ET157 is NOT DONE with the ignition on.Engine synchronisation has not been carried out yet.

Status ET157 becomes “NOT DONE” when the starter is activated and the enginerunning.If engine synchronisation is never DONE, consult the interpretation of faults DF023

Flywheel signal sensor ci rcuit , and DF235 Camshaft sensor circuit .

DONE


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Vdiag No.: 04

ET207

IMPACT DETECTED BY THE INJECTION COMPUTER


YES When the vehicle has been involved in an accident, the injection computer detectsthe signal transmitted by the Ai rbag computer and status ET207 is YES.Switch off the ignition for 10 seconds, then switch it back on, so the engine can berestarted.Clear the Airbag circuit faults.

If the vehicle has not undergone any impact or the starting procedure describedabove has been established, status ET207 will be NO.

NO


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Vdiag No.: 04

ET235

INJECTOR CODE USE


YES Status ET235 is YES if the IMA option (individual injector correction) is activatedin the injection computer .

Al l the injectors have IMA codes etched on the bakelite body, but not allcomputers use them.In the case of a computer configured with the IMA option, the injector codes must be

entered into the injection computer in the following scenarios: – when one or more injectors is replaced, – when the injection computer is replaced, – when the injection computer is reprogrammed.If the injector codes are not programmed after these operations, fault DF173Injector code programming will be present, and the engine will operate in

defect mode.Use command SC004 " Injector code input" applying the procedure described

in the interpretation of this command.

Status ET235 is NO if the computer is not configured to interpret the IMA codes(individual injector correction).

WARNING A computer wi thout the IMA option can be replaced by a computer with this

option.In this case status ET235 changes to YES after replacing the computer.Fault DF173 Injector code programming is present and the engine runs indefect mode.

Use command SC004 " Injector code input" applying the procedure describedin the interpretation of this command.

NO


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Vdiag No.: 04

ET238

STARTING

AUTHORISED When the driver inserts the key and the code is recognised by the engine immobilisersystem, the ECU authorises the injection computer to start; status ET238 changes to AUTHORISED and the vehicle can be started.

PROHIBITED When the key code is no longer recognised by the UCH computer it prohibits enginestarting, status ET238 changes to PROHIBITED and the vehicle cannot be started.

Carry out a fault finding procedure on the UCH.


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Vdiag No.: 04

ET239

PREHEATING UNIT CONTROL


ACTIVE When the vehicle is started from cold, the injection computer controls the pre-postheating unit so that the vehicle can be started.The status becomes ACTIVE when switching on the ignition and during the startingphase.If the vehicle does not start and status ET239 becomes ACTIVE during the engine

starting phase or after switching on the ignition, check: – the supply fuse track 3 (70A) on the preheating unit, – the heater plug resistance and the continuity of the connections between the plugs

and the pre-postheating unit.If the vehicle starts and status ET239 remains at YES during the engine operatingphase, refer to the interpretation of faults: – DF081 Preheating relay ci rcui t, – DF061 Heater plug circu it .

After the vehicle starts, and after a variable postheating period, dependent on engine

coolant temperature, the injection computer should stop actuating the pre/postheating unit.

Status ET239 is INACTIVE during the operating phase.If the vehicle does not start or the status remains INACTIVE and preheating has notbeen carried out during the starting phase, check the following connections:Injection computerTrack A4 grey 32-track connector C Track 9 preheating unitInjection computerTrack E2 grey 32-track connector C Track 8 preheating unitRepair if necessary.

INACTIVE


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Vdiag No.: 04

ET256


NOTES

Special note:Only perform the tests if the statuses do not correspond with the system programmingfunctions.

Note: Vehicles equipped with the "eco" regulator function have an " ON/OFF" button for the cruisecontrol , and a "SET" increment button.Vehicles equipped with the "eco" regulator/limiter function have an " ON/OFF" button for the cruise

control /speed limi ter, and a "±" increment/decrement button.

INACTIVE

Status ET256 is INACTIVE if: – vehicle under + after igni tion feed, – no cruise control/speed limiter function pushbuttons are pressed, – no fault present inhibiting cruise control/speed limiter.

CRUISECONTROL

Status ET256 is CRUISE CONTROL if the cruise control on/off button is activatedby the user.

The cruise control is active, but no speed setpoint is saved.

If status ET256 never goes to CONTROL after several ON/OFF button presses,check: – The condition of the cruise control ON/OFF button (connections, damage,

oxidation of contacts). – The continuity between tracks A2 and A3 of the cruise control pushbutton in

pressed position. – The insulation between tracks A2 and A3 of the cruise control button in rest

position.

If the ON/OFF button is faulty, replace it.

Check the continuity and the absence of in terference resistance on the

following connection:Injection computer connector A track A2 Track A3 of the cruise controlbuttonCheck for + after igni tion feed on t rack A2 of the control button connector.

If there is no + 12 V after ign ition feed, repair the connection.

Check for earth on track A1 of the cruise control button connector.

If there is no earth, repair the electrical connection.


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Vdiag No.: 04

ET256

CONTINUED

SPEED LIMITER

Status ET256 is LIMITER if the speed limiter ON/OFF button is activated by theuser.

The speed limiter is active, but no speed setpoint is saved.

If status ET256 never goes to LIMITER after several ON/OFF button presses,check: – The condition of the ON/OFF button (connections, damage, oxidation of

contacts). – The continuity between tracks A2 and B1 of the speed limiter on/off button in

the pressed position. – The insulation between tracks A2 and B1 of the speed limiter ON/OFF button

in the OFF position.

If the ON/OFF button is faulty, replace it.

Check the continuity and the absence of in terference resistance on thefollowing connection:

Injection computer connector A, t rack C3 Track B1 of the ON/OFF button

Check for the + after igniti on feed on track A2 of the on/off button connector.

If there is no + 12 V after ign ition feed, repair the connection.

Check for earth on track A1 of the speed limiter ON/OFF button connector.

If there is no earth, repair the electrical connection.


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Vdiag No.: 04

ET257

CRUISE CONTROL/SPEED LIMITER FUNCTION

NOTES


Note: Vehicles equipped with the "eco" regulator funct ion have an "ON/OFF" button for the cruisecontrol , and a "SET" increment button .Vehicles equipped with the "eco" regulator/limiter function have an " ON/OFF" button for the cruise

control /speed limi ter, and a "±" increment/decrement button.

INACTIVE

Status ET257 is INACTIVE if: – vehicle under + after igni tion feed, – no cruise control/speed limiter function pushbuttons are pressed, – no fault present inhibiting cruise control/speed limiter.

PLUS

Status ET257 is PLUS if the increase button is activated by the user.The cruise control/speed limiter speed setpoint increases when the driver pressesthe pushbutton + (or SET).To be able to remove the driver's airbag and carry out the measures in

complete safety (see 88C, Airbag and pretensioners).If status ET257 never changes to PLUS after several button presses, check: – the condition of the + (or SET) button (connections, damage, oxidation of

contacts), – the continuity between tracks A2 and B1 of the ± (or SET) button of the cruise

control/speed limiter in pressed position, – the insulation between tracks A2 and B1 of the ± button of the cruise control in

rest position.Check the continuity and the absence of in terference resistance on thefollowing connections:Injection computer connector A track D3 Track A2 of the ± button

Injection computer connector A t rack D2 Track B1 of the ± button

If the connection is broken, repair it.Measure the resistance of the following connection, after pressing the± button:Injection computer connector A t rack D2 Track A2 of the ± button

If the resistance is not approximately 300ΩΩΩΩ,,,, check the continuity of the connectionwhen the button is not pressed.

If there is continuity, replace the ± control button; if the connection is broken, repairit.

AFTER REPAIRCarry out another fault finding check on the system.Deal with any other faults.Clear the stored faults.

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Vdiag No.: 04

ET257

CONTINUED 1

DECREASE

Status ET257 is MINUS if the decrease button is activated by the user.

The cruise control/speed limiter programmed speed is reduced when the driverpresses the " -" button.

To be able to remove the driver's airbag and carry out the measures in

complete safety (see 88C, Airbag and pretensioners).

If status ET257 never goes to MINUS after several button presses, check: – the condition of the "-" button (connections, damage, oxidation of contacts),

– the continui ty between tracks A2 and B1 of the cruise control/speed limiter"±" button in pressed position,

– the insulation between tracks A2 and B1 of the "±" button of the cruise controlin rest position.

Check the continuity and the absence of in terference resistance on thefollowing connections:Injection computer connector A track D3 Track A2 of the "±" buttonInjection computer connector A t rack D2 Track B1 of the "±" button

If the connection is broken, repair it.Measure the resistance of the following connection, after pressing the

"±" button:

Injection computer connector A t rack D2 Track A2 of the "±" button

If the resistance is not approximately 100ΩΩΩΩ, check the continuity of the connectionwhen the button is not pressed.

If there is continuity, replace the "±" control button.

If the connection is broken, repair it.


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ET258

CRUISE CONTROL/SPEED LIMITER DEACTIVATION

NOTES

Cruise control remains deactivated as long as the vehicle speed does not exceed30 mph (50 km/h).Status ET258 can have 9 different specifications.When status ET258 changes specification, the cruise control/speed limiter isimmediately deactivated.


INACTIVEStatus ET258 is INACTIVE if: – vehicle under + after ignition feed, – no cruise control/speed limiter function push buttons are pressed, – no fault present inhibiting cruise control/speed limiter.

STATUS 1

Traction control request

If the vehicle being diagnosed is fitted with a traction control system, the cruisecontrol/speed limiter function is deactivated each time the traction control isselected.Status ET258 only becomes STATUS 1 when driving.If this status appears with the ignition on and the vehicle stopped, (see 38C, Anti -lock braking system).

STATUS 2

Brake pedal depressed

If the driver depresses the brake pedal, the cruise control/speed limiter will becomeINACTIVE.Status ET258 changes to STATUS 2 when driving or during a cruise control/speedlimiter function test when stationary.If status ET258 remains locked on STATUS 2, refer to the interpretation of statusesET013 and ET014 Brake switch signal nos. 1 and 2

STATUS 3

Cruise control or speed limiter fault

If status ET258 is at STATUS3, consult the fault finding procedure for status ET257

Cruise control/speed limiter funct ion, to test the cruise control systemcomponents and find the faulty component.

STATUS 4

Disconnection of the engine/gearbox

The cruise control/speed limiter function is deactivated if the gearbox is no longerlinked to the engine (clutch pedal applied or gearbox in neutral).If status ET258 is locked at STATUS 4 with the vehicle stationary, contact theTechline.

AFTER REPAIR

Carry out another fault finding check on the system.Deal with any faults.Clear the stored faults.

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ET258

CONTINUED 1

STATUS 5

Fault detected by the injection computer

Status ET258 changes to STATUS 5 if the injection computer detects a fault on theinjection system.

Carry out a multiplex network test, and then an injection system test, and run faultfinding on any faults.

If the fault is still present, contact Techline.

STATUS 6

Invalid vehicle speed

Status ET258 becomes STATUS 6 if the vehicle speed received by the computer isinvalid. Consult the fault finding for fault DF095 Vehicle speed signal, and run faultfinding on the ABS computer .

If faults are present (see 38C, Anti-lock braking system).


STATUS 7

Suspend button pressed

N.B.: this status should not appear because the SUSPEND button is no tpresent on the vehicle.

Status ET258 becomes "STATUS7" if the driver presses the "0" button to the right

of the steering wheel.

This suspends the cruise control/speed limiter.

If the status ET257 never becomes “SUSPEND” after pressing the button severaltimes, check the status of the "0" button (connections, damage, oxidation ofcontacts).

If status ET258 remains locked at “STATUS7”, consult the information on ET257"Cruise control/speed limiter function" SUSPEND.

STATUS 8

Gear lever in neutral pos ition

If status ET258 becomes "STATUS8" if the driver moves the gear lever to neutralposition when driving.

This action deactivates the Cruise control/Speed limiter.

If status ET258 remains stuck at "STATUS8" when driving after engaging a gear,contact the Techline.


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ET258

CONTINUED 2

STATUS 9

Inconsistency between the request and the vehicle speed

If status ET258 changes to "STATUS9" if the computer detects a fault between thespeed requested by the driver and the vehicle speed.

The vehicle signal is getting interference or is wrong.

Consult the interpretation for fault DF095 "Vehicle speed signal" .

Run fault finding on the ABS circuit (see 38C, Anti-lock braking system).



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Fault finding - Command summary table 13B

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Vdiag No.: 04

DIESEL INJECTION

Fault finding - Command summary table

Summary of available commands

NOTESUse the commands to check that certain components are working properly or to carryout part replacement.

LC034: Air conditioningLC047: Type of turbocharger SC004: Injector calibration data inputSC005: Data save when replacing a computer SC007: Writing after computer replacementRZ001: Fault memoryRZ003: Engine parameter adaptives

RZ010: Adaptives on EGR valve fault AC005: Low pressure pump relay AC010: Preheating relay AC599: Air conditioning compressor AC622: Turbocharging solenoid valve AC624: Rail pressure regulator CF001: Passenger compartment heating resistor VP001: Write VINVP010: Reducing the idling speedVP011: Increase the idling speedVP026: Fuel supply inhibitionVP032: Special notes on commercial vehicles

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Vdiag No.: 04

SC005

DATA BACKUP FOR COMPUTER REPLACEMENT

NOTES This save is carried out before computer reprogramming or replacement.

Select the CLIP tool specific configurations mode, and choose command SC005.Confirming this command saves the following vehicle-specific data:

– vehicle-specific idling,

– injector calibration codes (if the vehicle is fitted with IMA), – programming the EGR valve data, – options available on the vehicle and managed by the computer (Example: Air conditioning). – the values of the power take-off function.

This information is saved in the Clip tool.Once the save is complete, use command SC007 Write data after replacing computer to reconfigure thecomputer.

AFTER REPAIR Repeat the conformity check from the start.

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SC007

DATA ENTRY AFTER COMPUTER REPLACEMENT

NOTES

The data must be saved using command SC005 Save data for computerreplacement to carry out this command.Writing is carried out after the computer has been reprogrammed or replaced.

Select the Clip tool specific configurations mode and then select SC007.Confirming this command writes the data saved using command SC005 Data backup for computer

replacement.The data is as follows:

– vehicle-specific idling, – injector calibration codes (if the vehicle is fitted with IMA), – the EGR valve data programming; – options available on the vehicle and managed by the computer (Example: Air conditioning). – the minimum and maximum fast idle speed if the vehicle has power take-off.

They configure the computer and enable it to avoid: – engine malfunction after reprogramming or replacing the computer, – faulty interpretation of information provided by the CLIP tool.


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RZ003

ENGINE PARAMETER ADAPTIVES

NOTES This command is only executed after replacing the computer.

Command RZ003 reconfigures the computer. When clearing data RZ003 is carried out, the computer is nolonger configured for air conditioning or for fast idle speed.The following configuration readings take on a default value:

LC001: Passenger compartment resistors becomes " None"LC034: Air condit ioning becomes " None"LC044: Water in diesel fuel detector becomes "None"Once the reset has finished, command the air conditioning to reconfigure the computer.The fast idle speed is stored again in the computer.


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Vdiag No.: 04

AC010

PREHEATING RELAY

NOTES

Carry out this fault finding check if a malfunction appears on the "Command" menu, orif there are starting faults. – See Mascott phase 2 Wiring diagrams, to locate the fuses and relays concerned.

Before applying the following fault finding procedure, check that the battery voltage is not below 12 V.

Step 1:Using a multimeter fitted with a current clamp, group the 4 heater plug supply wires together.Use the preheating relay via command AC010 and measure the current used by the 4 heater plugs.If the current consumed is not between 20 and 30 A inclusive, go to step 2, otherwise end of fault findingprocedure.

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 not 0.6 ± 0.1 ΩΩΩΩ replace the faulty heater plugs.Check the continui ty and for the absence of interference resistance between:

preheating unit track 1 cylinder 3 heater plug

preheating unit track 2 cylinder 4 heater plugpreheating unit track 6 cylinder 1 heater plugpreheating unit track 7 cylinder 2 heater plug

Check the condition of preheating unit supply fuse F01 (70A). Replace it if necessary. Check for + 12 V ontrack 3 of the preheating relay connector.Check the continuity and absence of interference resistance between:

Injection computer connector B track B3 Track 9 of the preheating unit connector Injection computer connector B track C3 Track 8 of the preheating unit connector

If the fault is still present, replace the preheating unit.


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Vdiag No.: 04

AC599

AIR CONDITIONING COMPRESSOR

NOTES

There must be no present or stored faults

Perform this fault finding procedure after a fault appears on the command menu orfollowing an air conditioning fault. – See Mascott phase 2 Wiring diagrams, to locate the fuses and relays concerned.

If during command AC599 the relay is not activated

– Check the insulation, continuity and the absence of interference resistance on the connection between:Engine management computer, connector A track B1 track 2 Compressor relaymounting

– Check the compressor relay coil power feeds:Compressor relay mounting Track 3 + 12 V after relay.

Check the operation of the compressor relay by the computer: – remove the compressor relay, – control the relay with command AC599, – check the + 12 V feed (10 "ON-OFF" cycles), on track 2 of the compressor relay mounting, – if the voltmeter indicates the battery voltage (10 "ON-OFF" cycles), replace the compressor relay. – if the voltmeter does not indicate the battery voltage (10 "ON-OFF" cycles), contact Techline.

If, when running command AC599, the compressor relay operates, but the compressor does not start:

– Check that the resistance of the compressor clutch coil is 3.5 ΩΩΩΩ ± 0.5, – Also check the insulation of the coil in relation to the compressor body. – Check for an earth on track B of the compressor connector, – Check the continuity and insulation of the following connection:

Compressor relay mounting, track 5 track A of the compressor connector, – Check the power supply of the normally open compressor relay contact:

Compressor relay mounting, track 3 + 12 V after ignition. – Check the conformity of the normally open compressor relay contact:

Continuity between tracks 3 and 5 when the relay is suppliedCarry out the necessary repairs.


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Vdiag No.: 04

AC622

TURBOCHARGING SOLENOID VALVE

NOTESConsult the interpretation for this command if one of the values from the conformitycheck is not correct.

WARNING

This command should only be used if the vehicle is equipped with a variable geometry turbocharger.

Introduction

1 - Check the high pressure air circui t sealing:Pipes not joined or pierced, pressure sensor disconnected or poorly fitted (seal present), intercooler pierced.To test the intercooler: stabilise the engine speed between 3,500 and 4,000 rpm with the vehicle stopped andcheck that there are no leaks.

Measure the resistance of the turbocharging limitation solenoid valve between its tracks 1 and 2.Replace the solenoid valve if the resistance is not: 15.4 ΩΩΩΩ ± 0.7 at 20 ˚C.

Check the injection computer connections.Check for continuity and make sure there is no interference resistance on the following connection:


Repair if necessary.Check for + 12 V after relay feed on track 2 of the turbocharging solenoid valve.


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AC622CONTINUED

2 - Turbocharger control circui t check – With the engine stopped, make sure that the control rod is in the resting position. – Start the engine and check that the control rod moves to its upper limit (when the engine is stopped, the

control rod should return to its rest position).If the control rod movements do not conform, carry out the following checks:

1) Vacuum pressure control check: – disconnect the solenoid valve inlet hose and connect it to a pressure gauge,

– start the engine and stabilise it at idle speed, – if the vacuum does not reach 800 mbar ± 100: check the vacuum pressure circuit from the vacuum pump, – stop the engine, reconnect the inlet hoses and go to step no. 22) Solenoid valve control check: – disconnect the solenoid valve outlet hose, – start the engine and stabilise it at idle speed, – place your hand on the solenoid valve and block the outlet connection with your thumb, – if you do not notice any solenoid valve vibration, check the operation of the computer output stage (step 5).3) Solenoid valve operation check: – attach the pressure gauge to the solenoid valve outlet union, – start the engine and stabilise it at idle speed,

If the vacuum pressure does not reach 800 mbar ± 100, replace the solenoid valve.


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AC622CONTINUED

Turbocharger control circuit check (continued)4) Turbocharger operation check:a) Attach a vacuum pump to the Hose connected to the turbocharger control diaphragm, – Apply a vacuum of 800 ± 100 mbar :

If there is a leak, replace the turbocharger (diaphragm included).b) Check the control rod displacement and setting (Workshop Repair Manual section 12B).

If the control rod is sticking, replace the turbocharger.c) Engine cold and stopped:

– Remove the turbocharger inlet duct and check that the compressor turns freely on the axis.d) If the fault is still present: – Check that the exhaust manifold is not leaking. – Check that the exhaust is not blocked.Carry out the necessary repairs.

5) Computer output stage check (solenoid valve connected) This operation can only be carried out if the checks listed in step no. 2 are not conclusive.Using a voltmeter: – connect the voltmeter earth to track 2 of the solenoid valve and the positive cable to track 1. – clear any solenoid valve fault then run command AC622:

The voltmeter should display ten cycles of two successive voltages ~ = battery voltage X OCR* in process.

Either: ~ 2.5 V (OCR of 20 %) then ~ 8.7 V (OCR of 70 %).Or using an oscilloscope (range 5 V/division and with time base 1 ms/division): – Connect the earth of the oscilloscope to the battery earth and the positive test pin to track 2 of the solenoid

valve, – Clear any faults in the solenoid valve, then run command AC622:

The oscilloscope should display a square pulse signal with an amplitude of 12.5 V at a frequency of 140 Hz (with an OCR* alternating from ~ 20 to ~ 70 %). – If the measurement is correct, replace the solenoid valve. – If the measurement does not show any control or continuous voltage, contact the Techline.


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AC624CONTINUED

Step 2In the event of rail overpressure:check the operation of the injectors (see Injector test).check that the rail pressure sensor is operating correctly.if these checks reveal no irregularities, replace the regulator.

In the event of rail underpressure: – check that the rail pressure sensor is operating correctly,

– check the priming of the low pressure diesel circuit, – 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 high pressure and low pressure diesel fuel circuit sealing, (visual checks + odours, etc.):

pump body, pressure release valve, pipes, rail and injectors unions, injector wells, etc. – check the conformity of the seal fitting on the pressure regulator, – check the operation of the injectors (see Injector test).

AFTER REPAIRCarry out a road test followed by a check with the diagnostic tool.Repeat the conformity check from the start.

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CF001

PASSENGER COMPARTMENT HEATING RESISTOR

NOTES

This command is used to configure the vehicle “WITH” or “WITHOUT” passengercompartment heating resistor.

Carry out this command:

– After reprogramming the injection computer, or – after replacing the injection computer, without having been able to use the scenario

SC003 " SAVE COMPUTER DATA" before reprogramming to save the computer

data.

To run this command, select configuration CF001 "PASSENGER COMPARTMENT HEATING RESISTOR"in the CLIP tool.

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Vdiag No.: 04

VP010

DECREASING THE IDLE SPEED

NOTES None

This command enables the idle speed value to be reduced.The idle speed will be decreased by 10 rpm every time this command is used.Parameter PR035 Idle speed cor rection enables the idle speed modification to be displayed.

WARNING:The idle speed cannot be reduced by more than 50 rpm from its initial value.


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VP011

INCREASING THE IDLE SPEED

NOTES None

This command enables the idle speed value to be increased.The idle speed will be increased by 10 rpm every time this command is used.Parameter PR035 Idle speed cor rection enables the idle speed modification to be displayed.

WARNING:The idle speed cannot be increased by more than 50 rpm from its initial value.


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VP026

INHIBIT FUEL SUPPLY

NOTESThis command restores fuel supply to the injectors.This command is carried out with the engine switched off, and ignition on.

WARNINGIf the ignition is switched off, or dialogue between the CLIP tool and the injection computer is lost, commandVP026 becomes ineffective.

Between engine starts, do not switch off the ignition for more than a few seconds.If communication is lost, run command VP026 again to run a safe compression test.

This command allows the injectors to be locked, so that starting is not possible.The command VP026 enables the cylinder compression to be checked in complete safety.

– use command VP026, – check the engine compression, – switch off the ignition once the 4 compression measurements have been taken and wait for the power-latch, – establish contact again and attempt to start.If an engine start is possible, command VP026 is deactivated.


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Vdiag No.: 04

VP032

SPECIAL NOTES ON COMMERCIAL VEHICLES

NOTES

Only use this command if command SC005 Save computer data has not workedbefore replacing an injection computer.Use this command with the engine stopped.

The power take-off function (fast idle speed) enables specific equipment to be used: – Main transmission power take off (crane,.etc.)

– Urban roadwork equipment (tipper, concrete mixer,.etc.).The driver has the following controls to operate the power take-off function: – on/off switch for cruise control and power take-off functions, – instrument panel R button permitting the last fast idle speed stored to be re-established, – instrument panel O button allowing the power take-off function to be deactivated momentarily, – instrument panel ± button allowing the fast idle speed to be increased or decreased.Command VP032 special features of commercial vehicles enables the default values of the power take-offand permanent speed limiter to be configured.Only use this command when replacing the computer and if commands SC005 Save data for computerreplacement or SC007 Write data after replacing computer do not work.The default values are as follows: – PR458 Maximum vehic le speed = 13 mph (22 km/h)

– PR459 Minimum engine speed = 900 rpm – PR460 Maximum engine speed = 3,500 rpm

– PR461 Engine default speed = 1,200 rpmThe value of the last parameter should always be between 900 rpm (PR459) and 3,500 rpm (PR460).


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Vdiag no.: 04


Fault f inding - Customer complaints

NO DIALOGUE WITH THE COMPUTER FAULT FINDING CHART 1

STARTING DIFFICULT OR IMPOSSIBLE FAULT FINDING CHART 2

INJECTION NOISE FAULT FINDING CHART 3

POOR PERFORMANCE FAULT FINDING CHART 4

IRREGULAR ENGINE OPERATION FAULT FINDING CHART 5

COMPONENT OPERATION TEST

INJECTOR TEST TEST 1

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Vdiag no.: 04


Fault finding - Fault Finding Chart

FAULTFINDINGCHART 1

No dialogue with the computer

NOTES

Before dealing with this customer complaint, check that there are no faults, and

the conformi ty (or otherwise) of the parameters and statuses using thediagnostic tool.If the customer complaint is not resolved, perform the following checks.

Check the conformity of the vehicle type and the domain selected on your 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 on track 16

+ after ignition on track 1Earth on tracks 4 and 5

Check (according to wiring diagram and equipment): – the conformity of the after ignition fuse, – the conformity of the injection relay mounting feeds, – the conformity of the impact sensor: continuity between tracks 1 and 3 at rest (before impact)

12 V battery feed track 3 (via the fuse)continuity between track 3 and track 1 of the injection relay.

– the conformity of the injection relay: 65 ΩΩΩΩ ± 5 ΩΩΩΩ between its tracks 1 and 2

infinite resistance between its tracks 3 and 5 (open contact)resistance < 0.2 ΩΩΩΩ between tracks 3 and 5 (closed contact)

Disconnect the injection computer and check that there are no conducting components on the computer pins.If its removal reveals any kind of contamination, clean it and try to establish dialogue.If the fault is still present, place the bornier Elé. 1590 on the engine wiring harness:Check the continu ity and the absence of interference resistance on the following connection:

Engine computer, 32-track connector A track B4 Diagnosticsocket track 7 (line K)

Ensure that the power supplies are in order:Engine computer, 32-track black connector A, track D1 + after ignition

feed ,Engine computer, 32-track black connector A, tracks G4, H4, and H1 Earth ,

By shunting the normally open injection relay contact, i.e. tracks 3 and 5 of the relay mounting: Engine computer, brown 48-track connector B, track M2 +12 V battery

(via test shunt)

Check the continuity of the connection between: Engine computer, brown 48-track connector B, track E track 2 of the

injectioncomputer supplyvoltage relaymounting

AFTER REPAIR Carry out a road test followed by a complete check with the diagnostic tool.

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FAULTFINDINGCHART 1

CONTINUED

Try to establish dialogue with another computer on the same vehicle.

If dialogue can be established with another computer on the same vehicle, go to step 2.If dialogue cannot be established with any other computer on the same vehicle, it could be that a faulty

computer is causing interference on line K. To locate it, carry out a process of elimination, disconnecting inturn all the computers linked to these lines (according to the wiring diagram and equipment): airbag, ABS, UCH,instrument panel.Try to establish dialogue after disconnecting each line:If, after a disconnection, you manage to establish dialogue, perform the fault finding procedure for the relevantcomputer.

If the fault is still present, reconnect the computers listed above and disconnect the enginecomputer. Try to establish dialogue with another computer.

If you manage to establish dialogue, go to step 2. If you still cannot establish dialogue, disconnect all the computers connected to line K and check

the insulation to +12 V and to earth on track 7 and track 15 of the diagnostic socket.Carry out the necessary repairs.

STEP 2Contact Techline.


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Vdiag no.: 04

FAULTFINDINGCHART 2

Starting faults (or starting impossib le)

NOTES

Before dealing with this customer complaint, check that there are no faults, andthe conformi ty (or otherwise) of the parameters and statuses using thediagnostic tool.If the customer complaint is not eliminated, perform the following checks.

impossible

Is starting difficult or impossible?

difficult

– Check the engine earths. – check that the engine speed reaches 250 rpm when the starter motor is operational in the parameters

screen, – check that the correct fuel is being used, – check the conformity of the fuel filter connections, – ensure that the fuel filter is not saturated with water. – check there are no air bubbles between the filter and the high pressure pump, – check that the heater plugs are actuated using command AC010 Preheating relay,

– check the condition of the air filter (clogging), – check the sealing of the high pressure diesel fuel circuit; pump, pipes, unions (visual inspection + odours), – check the position of the EGR valve: (jamming or mechanical seizure), – check the consistency of the signal from the engine coolant temperature sensor, – check the correct operation of the pressure regulator (see AC624 Rail pressure regulator ), – check the operation of the injectors (see 13B, Injector test). – check that the compressions are balanced, in accordance with the current consumption in the starting phase

(Compression test menu on the Clip tool).In the event of an imbalance, use a compression meter to complete the measurements. After the operation,clear the faults caused by disconnecting the regulator and the heater plugs.


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FAULTFINDINGCHART 2

CONTINUED

From the STATUS menu on your diagnostic tool, check the conformityof the immobiliser system: ET003 Engine immobiliser should be

INACTIVE.

ET003 in order (Immobiliser code

warning light switched off)

– Check the battery charge and the condition and tightness of theterminals.

– Ensure that engine speed reaches 250 rpm when the starter motor isoperated which is displayed on the parameter screen,

– check the engine earths, – check the conformity of the inertia switch (depending on equipment), – check the presence and conformity of fuel in the tank, – check for the presence of 12 V battery feed on track M2 of

connector B in the injection computer, – check the engine fuses (and their mountings, wires and terminals).

YEStest

Operate the starter:Does the pressure increase in the rail:

rail pressure = ~ 170 bar at ~ 250 rpm?

NO

Run a fault finding procedure on the regulator and high pressure pumpby applying the interpretation for command AC624 Rail pressure

regulator .

ET003 not correct , orimmobiliser warning lightcontinuously lit

Consult the engine immobiliserfault finding procedure(See 82A, Engineimmobiliser, conformity

check ).

Check the engine timing and theposition of the high pressurepump sprocket.Check the engine compression(see procedure in WorkshopRepair Manual if necessary).Check cylinder balancing usingthe Clip function, physicalmeasurement iconCompression test.


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Vdiag no.: 04

FAULTFINDINGCHART 3

Injection noise

NOTES


Does the injection noise occur after starting from cold? – Check the priming of the low pressure fuel circuit. – check the fuel heater supply,

– check the operation of the preheating system, – check that fuel and engine temperatures are consistent.

If the complaint is still present, check the rail pressure (Parameter menu) and apply the interpretation forcommand AC624 Rail pressure regulator .

Does the injection noise occur at idling speed?

– check the condition of the injector connector and pressure regulator terminals, – check the conformity of the air flow signal in the air circuit sub-function, – check the conformity of the EGR valve position (clogging, stuck, seized), – if the fault is still present, carry out a fault finding check on the injectors (see Injectors test).

Does the injection noise occur at all engine speeds? – perform the injector fault finding procedure (see Injector test),

– check the condition of the injector connector and pressure regulator terminals, – ensure that the correct fuel is being used, – check the conformity of the air flow signal in the air circuit sub-function, – if the complaint is still present, check the rail pressure (Parameter menu) and apply the interpretation for

command: AC624 Rail pressure regulator .

If the injection noise occurs at transitional speed:

If the engine races during gear changes, check the conformity of the clutch switch.When changing gear during a road test, display parameter PR033 Fuel flow. If it varies, without noticeableinfluence on the rail pressure, consult the fault finding procedure for the command AC624 Rail pressureregulator .If the fault is still present, carry out a fault finding check on the injectors (see Injector test).


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FAULTFINDINGCHART 4

Poor performance

NOTES

Before dealing with this customer complaint, check that there are no faults, andthe conformi ty (or otherwise) of the parameters and statuses using the

diagnostic tool.If the customer complaint is not eliminated, perform the following checks.

IMPORTANTIn the case of engine overheating to more than 110˚C, the computer voluntarily limits the fuel flow (ignitionoverheating warning light lit from 110˚C).

Is the poor performance accompanied by smoke?

YES NO

Check: – That the EGR valve is not stuck in the open position. – That the injectors are properly fitted (sealing washer fitted and correct).

YES

Is the engine running on all cyl inders?

NO

Check the operation of the injectors (see Injector test).

If the fault is still present:

Check conformity on the following components: – accelerator pedal position sensor, – brake pedal sensor, – rail pressure regulator, – EGR valve.Replace any faulty components.

– Check the condition of the air filter and the air inlet ducts, – check there are no foreign bodies on the air flowmeter grille (very sensitive to impurities).Check: – the correct operation of the turbocharger (no play in the shaft, and non seizing of the fins), – that the diesel filter is not clogged, – that there are no leaks in the low pressure and high pressure diesel circuits; – that the oil vapour rebreathing system is connected, – check the engine compression (Cylinder compression balance, with the Compression test function on the

CLIP tool), – check that the exhaust pipe is not blocked.


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Vdiag no.: 04

FAULTFINDINGCHART 5

Irregular engine operation

NOTES


If the engine hesitates or races during gear changes, check the conformity of the clutch switch.If the fault is still present: – check that the correct fuel is being used,

– check the priming of the low pressure fuel circuit (use of the command AC005 Low pressure pump relay), – check that the diesel filter is properly connected and that it is not saturated with water, – check that there are no air bubbles between the filter and the high pressure pump, – check the conformity of the rail pressure (warm engine):

± 25 bar around the rail pressure value at idle speed, (the minimum to maximum variations in the railpressure at idle speed should not exceed 50 bar ).~ 1600 bar under full load.In the event of a fault apply the interpretation of command AC624 Rail pressure regulator .

– Check the conformity of the air flow.If the fault is still present: – check the condition of the injectors using test 1 Injector test (see Injector test), – check cylinder balancing using the Clip function, physical measurement icon Compression test,

– check engine compression where necessary.


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Fault finding - Component operational test

TEST 1 Injector test

NOTES

Only apply this test after a complete check with the diagnostic tool.The injector test is only applied if all the diesel fuel low pressure circuit testshave been run.

A) Preliminary Checks: – Measure the resistance between tracks 1 and 2 of each injector: 0.33ΩΩΩΩ at 20˚C/2 ΩΩΩΩ max . – Check and ensure the insulation, continuity and absence of interference resistance on the following

connections:

Engine computer, connector C track G3 track 2 of the injector no. 1 connector Engine computer, connector C track H1 track 1 of the injector no. 1 connector Engine computer, connector C track G4 track 2 of the injector no. 2 connector Engine computer, connector C track G2 track 1 of the injector no. 2 connector Engine computer, connector C track H4 track 2 of the injector no. 3 connector Engine computer, connector C track H2 track 1 of the injector no. 3 connector Engine computer, connector C track H3 track 2 of the injector no. 4 connector Engine computer, connector C track G1 track 1 of the injector no. 4 connector

– Carefully check the clips , cables and tabs of the connections of each injector.

Check the flow correction on the following page


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Fault f inding - Component operational test 13BEDC16 InjectionProgram No.: C1

Vdiag no.: 04

TEST1

CONTINUED

B) Flow correction check on each injector Start the engine, and display the following parameters: – PR524 Cylinder no. 1 fuel f low correction – PR589 Cylinder no. 2 fuel f low correction – PR590 Cylinder no. 3 fuel f low correction – PR524 Cylinder no. 4 fuel f low correction

The normal fuel flow correction for an injector is approximately 1 mm3 (negative or positive according to theinjector requirements).Check the correction values for each injector.

– If at least one of these values is > 5 or -5 mm3:Carry out an engine compression test.If a cylinder indicates a compression value markedly lower than the others, carry out the necessaryengine repairs.If th 4 li d h th l ft th i t l th i j t ith

MR391X2413B000 master

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