Technical Note 3529a Xb07 - Xk07

8/14/2019 Technical Note 3529a Xb07 - Xk07

http://slidepdf.com/reader/full/technical-note-3529a-xb07-xk07 1/140

TECHNICAL NOTE 3529A

XB07 - XK07

Basic Manual: Workshop Repair Manual 325 - 337 - 345

DIRECT DIESEL INJECTION

HIGH PRESSURE COMMON RAIL

PROGRAM No.: BEVDIAG No.: 04 and 08

This note cancels and replaces Technical Note 3473A

77 11 305 642

"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which hisvehicles are constructed."

JUNE 2001

All copyrights reserved by Renault.

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 of Renault.

© RENAULT 2001



Contents

Page

13 DIESEL INJECTION

Introduction 13-1

Interpretation of faults 13-4

Conformity check 13-67

Interpretation of states 13-77Interpretation of parameters 13-78

Tests 13-79

Customer complaints 13-91

Fault finding chart 13-93



DIESEL INJECTION

Fault finding - Introduction 13

13-1

PROGRAM No.: BE

VDIAG No.: 04 and 08

113DIESEL INJECTION

Fault finding - Introduction

GENERAL APPROACH TO FAULT FINDING:

– Use one of the diagnostic tools to identify the system fitted to the vehicle (to read the computer group, the program

number, the Vdiag, etc.).

– Locate the Fault finding documents corresponding to the system identified.

– Take note of information contained in the introductory sections.

– Read the faults stored in the computer memory and use the Fault interpretation section of the documents.

Reminder : Each fault is interpreted for a particular type of storage (fault present, fault stored, fault present or

stored). The checks defined for handling each fault are therefore only to be performed if the fault shown by the

diagnostic tool is interpreted in the document for its type of storage. The storage type should be considered when

using the fault finding tool after the ignition has been switched off and switched back on.

If a fault is interpreted when it is declared stored, the conditions for applying the fault finding procedure appear in

the NOTES box. When these conditions are not satisfied, use the fault finding procedure to check the circuit of the

faulty part since the fault is no longer present on the vehicle. Follow the same procedure when a fault is declared

stored by the diagnostic tool but is only interpreted in the documentation for a present fault.

NOTE

– It is possible to consult the fault environment, using the diagnostic tool, to facilitate the fault finding procedure, i.e.

the conditions in which the fault appeared (different temperatures, pressures, gears etc.). To consult these

environmental conditions, just press the appropriate fault icon. Example: COOLANT TEMPERATURE SENSORCIRCUIT.

– Perform the conformity check (appearance of possible incorrect operations not yet declared by the system's self

diagnosis procedure) and apply the associated fault finding strategy according to results.

– Confirm the repair (disappearance of the problem reported by the customer).

– Use the fault finding strategy for each Customer complaint if the problem persists.

SPECIAL TOOLING REQUIRED:

– diagnostic tool (except XR25),

– Electrical bornier Elé. 1590, – multimeter.

This document contains the generic fault finding procedures applicable to all "LDCR" computers for thediesel injection function on CLIO/KANGOO vehicles with the K9K engine.

To undertake fault finding on this system, it is essential to have the following items available:

– The Fault finding Technical Note.

– The wiring diagram for the function on the vehicle concerned.

– The tools listed under Special tooling required.

CR DELPHI 1.0



DIESEL INJECTION


13-2

PROGRAM No.: BE


GENERAL OBSERVATIONS

1 - FAULT WARNING LIGHT MANAGEMENT

Pre/post heating and electronic fault warning light (level 1)

This warning light is used as an operating indicator light and as a system fault indicator light.

Steady lighting: the function is working normally (heating the plugs).

Flashing: after preheating and an automatic 3 second stop, flashing indicates a level 1 fault (the function is not

working to optimum standards and safety levels are reduced. The driver should carry out repairs as soon as

possible).

Coolant temperature warning light (level 2 fault):

This warning light is used as an operating indicator light and as a system fault indicator light. It lights up for

3 seconds when the ignition is switched on (automatic test procedure).

Steady lighting: this indicates engine overheating or a level 2 fault.

If the fault reaches critical level, the injection cuts off automatically after a few seconds.

In the event of overheating, it is the driver's choice to stop the car or continue driving.

OBD (On Board Diagnostics) excess pollution orange warning light

This warning light with engine symbol lights up when the ignition is switched on for about 3 seconds then goes out. It

is never lit when the engine is running.

2 - PROGRAMMING

Climate control and cruise control are the only options on the vehicle that are self-programmed.

These two systems control programming.

3 - REPLACING OR REPROGRAMMING THE COMPUTER

The system can be reprogrammed at the diagnostic socket using the RENAULT NXR and CLIP fault findingtools.

Before reprogramming or replacing the computer in after sales, the following must be saved in the fault finding

tool:

The C2I (individual injector correction) parameters and the configurations using the command SC005 Save

data for computer replacement if command SC005 has been run, reprogram or replace the computer then enter command SC008 Write data to memory to re-establish the C2I and the configurations.

NOTE: if command SC005 does not work, after replacing the computer, it will be necessary to write the C21 codesof each injector manually, by reading the C21 code on each injector and performing a static test with command

SC003 (see replacing injectors).

After reprogramming or replacing the computer, run a static/autoconfiguration test with command SC003 to

reconfigure the different elements (such as the power-assisted steering pump assembly, climate control and the

thermoplungers) and re-enter the C2I codes manually (see replacing injectors).

WARNING: it is not possible to test an injection computer from the parts stores because it will not be able to be fitted

to any other vehicle.

CR DELPHI 1.0



DIESEL INJECTION


13-3

PROGRAM No.: BE


Replacing the injectors

N.B.: the injectors are calibrated in the factory with C21 (individual injector correction), which allows the flow of each injector to be precisely adjusted. The correction values are written on a label affixed to each injector then

entered in the computer which can then control each injector by taking account of their dispense as manufactured.

The system can be configured at the diagnostic socket using the RENAULT NXR and CLIP fault findingtools.When replacing one or more injectors, it is necessary to replace the C2I parameters; to do this, rewrite the C2I codes

in the computer using the following commands:

– cylinder 1 injector: command VP021 – cylinder injector 2: command VP022 – cylinder injector 3: command VP023 – cylinder injector 4: command VP024

It is also possible to enter the four C2I codes using command SC004: enter injector calibration data.

The technician uses the appropriate command to reprogram the new C2I for the replaced injector and erase theold C2I.

4 - HIGH PRESSURE CIRCUIT TIGHTNESS TEST

There is a command that tests the high pressure circuit tightness when the engine is running.This command can only be used if the engine temperature is above 60˚C.

Activate the SC001 High pressure circuit tightness test command and the engine automatically performs four

cycles of accelerations up to 4000 rpm, then decelerates to raise the pressure in the rail. This is to check for leaks in

the high pressure circuit.

NOTE: The engine may stall during the first cycle of this operation due to the sharp increase and decrease in idle

speed.

Also be careful with any objects (tool or other) on the engine housing during the four cycles of theoperation (possible vibrations).

5 - SET-UP

There is a set-up section in the Command menu, which, if required, can inhibit varioius functions such as:

– VP004 INHIBIT ELECTRICAL CONSUMERS: this function inhibits preheating during an electrical test with the

ignition off in order not to discharge the battery.

– VP005 INHIBIT INJECTION: this function cuts off injection, e.g. for compression testing.

These functions are reactivated at the end of each timed supply (power latch) when the ignition is switched off.

– It is also possible for the driver to increase or decrease the idle speedVP010 DECREASE IDLE SPEED

VP011 INCREASE IDLE SPEED

CR DELPHI 1.0



DIESEL INJECTION

Fault finding - Fault Interpretation 13PROGRAM No.: BE

VDIAG No.: 04 and 08 Fault finding - Fault Interpretation

DF001

PRESENT

COMPUTER

1.DEF: Analogue converter

2.DEF : Write EEPROM memory

3.DEF: Read EEPROM memory

4.DEF : Injection calibration data

5.DEF: Memory self-test6.DEF: Non refreshed watchdog

7.DEF : Interference on the injector control line8.DEF: Watchdog activation

NOTES None.

7.DEFCheck the condition of the 48 track computer connector B.

Repair it if necessary.

Check the insulation, continuity and absence of interference resistance of the

connections:

computer connector B track A4 track 1 injector 1

computer connector B track B4 track 2 injector 1

computer connector B track G4 track 1 injector 2

computer connector B track H4 track 2 injector 2

computer connector B track C4 track 1 injector 3

computer connector B track D4 track 2 injector 3computer connector B track E4 track 1 injector 4

computer connector B track F4 track 2 injector 4

Repair if necessary.

If the fault persists, replace the computer

AFTER REPAIR Deal with any other possible faults.

Erase the stored faults.

CR DELPHI 1.0

13-4



DIESEL INJECTION

Fault finding - Fault Interpretation 13

13-5

PROGRAM No.: BE


DF001

Continued

4.DEF Check the condition of the 48 track computer connector B .

Repair it if necessary.

Check that the individual injection correction (C2I) matches the injectors. If notwrite the C2I codes (see first section).

If C2I corresponds correctly to the injectors, replace the computer.

1.DEF2.DEF3.DEF5.DEF6.DEF8.DEF

Replace the computer.

AFTER REPAIR

Follow the instructions to confirm repair.

Deal with any other possible faults.


CR DELPHI 1.0



DIESEL INJECTION


13-6

PROGRAM No.: BE


DF002PRESENT

COOLANT TEMPERATURE SENSOR CIRCUIT

CC.0 : Short circuit to earth

1.DEF : Permanently high level

NOTES Special notes:

if fault DF002 is present: run the fan assembly at low speed .

Check the condition of the coolant temperature sensor 2 track connector.Repair it if necessary.

Check the condition of the 48 track computer connector B and repair if necessary.

At the terminal, measure the resistance of the coolant temperature sensor, if it is not approximately

2252 Ω ± 112.16 Ω at 25 °C, replace the coolant temperature sensor.

Check the insulation, continuity and absence of interference resistance of the connections:

sensor connector track 2 track H3 computer connector Bsensor connector track 3 track H2 computer connector Bsensor connector track 1 instrument panel (non multiplex vehicle)

sensor connector track 4 earth (non multiplex vehicle)




CR DELPHI 1.0



DIESEL INJECTION


13-7

PROGRAM No.: BE


DF004

VEHICLE SPEED SENSOR CIRCUIT

1.DEF: Consistency

2.DEF: Signal Absent

NOTES

Fault finding procedure for the CLIO II (vdiag 04 non multiplex vehicle andvdiag 08 multiplex vehicle).None.

non multiplexvehicle

(vdiag 04)

Check the condition and connection of the vehicle speed sensor connector.Repair if necessary.

Check the condition of the 32 track computer connector C and replace it if necessary.

Check the continuity and absence of interference resistance of theconnections:

sensor connector track A + After ignitionsensor connector track B2 EARTH


Check the insulation against +12 volts of the connection:sensor connector track B1 track E1 computer connector C


multiplexvehicle

(vdiag 08)

Diagnose the multiplex network. (Refer to section 88 Multiplex network wiring).



CR DELPHI 1.0



DIESEL INJECTION


13-8

PROGRAM No.: BE


DF012STORED

BATTERY VOLTAGE

1.DEF: < Minimum threshold

2.DEF: > Maximum threshold

NOTES Conditions for applying the fault finding procedure to the fault stored::Fault declared present with the engine running above 1000 rpm.

Check the battery voltage when the ignition is switched on, if the battery voltage is < 10V recharge thebattery.

Check the condition of the battery terminals.


Check the vehicle's charge circuit.Repair if necessary.

Check the condition of the 32 track computer connector A and repair if necessary.


+ after ignition track D1 computer connector Achassis earth G1, H1 computer connector C


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-9

PROGRAM No.: BE


DF015PRESENT

IMMOBILISER

NOTES

Fault finding procedure for the CLIO II (vdiag 04 non multiplex vehicle and vdiag08 multiplex vehicle).None.

non multiplexvehicle

(vdiag 04)


Check the condition of the UCH connector and repair if necessary.

Check the insulation, continuity and absence of interference resistance of theconnection:

Computer connector A track B3 UCH track(see wiring diagram for the vehicle).


multiplexvehicle

(vdiag 08)




CR DELPHI 1.0



DIESEL INJECTION


13-10

PROGRAM No.: BE


DF021PRESENT

FUEL TEMPERATURE SENSOR CIRCUIT


1.DEF: Permanent high signal

NOTES None.

Check the condition of the 2 track fuel temperature sensor connector and repair it if necessary.


At the terminal, measure the resistance of the fuel temperature sensor, if it is not approximately 2.2K Ω at25 °C, replace the fuel temperature sensor.


sensor connector track 1 track G2 computer connector Bsensor connector track 2 track G3 computer connector B




CR DELPHI 1.0



DIESEL INJECTION


13-11

PROGRAM No.: BE


DF022PRESENT

AIR TEMPERATURE SENSOR CIRCUIT


1.DEF : Permanently high level

NOTES None.

Check the condition of the 2 track air temperature sensor connector and repair it if necessary.


At the terminal, measure the resistance of the air temperature sensor, if it is not approximately

2051 Ω ± 20Ω at 25 °C replace the air temperature sensor.


sensor connector track 1 track K2 computer connector Bsensor connector track 2 track K3 computer connector B




CR DELPHI 1.0



DIESEL INJECTION


13-12

PROGRAM No.: BE


DF023PRESENT

FLYWHEEL SIGNAL SENSOR CIRCUIT

1.DEF: Consistency

2.DEF: No tooth signal

3.DEF: Too many additional teeth

4.DEF: Teeth missing

5.DEF: Additional teeth6.DEF: Too many teeth missing

NOTES

If faults 3.DEF, 1.DEF, 4.DEF and 6.DEF are present, the engine will stop and

warning lights levels 1 and 2 will light up.

If faults 2.DEF and 5.DEF are present, performance will be reduced to 75 % with no

speed limitation and the warning light will not light up.

Check the condition of the flywheel signal sensor 2 track connector and repair if necessary.


At the terminal, measure the resistance of the flywheel signal sensor, if it is not approximately 760Ω replace

the flywheel signal sensor.

Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track A track F2 computer connector Bsensor connector track B track F3 computer connector B


Check that the flywheel ring gear is not faulty (missing teeth).



CR DELPHI 1.0



DIESEL INJECTION


13-13

PROGRAM No.: BE


DF024PRESENT

ATMOSPHERIC PRESSURE SENSOR CIRCUIT

CC.1 : Short-circuit to + 12 volts

1.DEF: Permanent low signal

NOTES None.




CR DELPHI 1.0



DIESEL INJECTION


13-14

PROGRAM No.: BE


DF027STORED

EGR SOLENOID VALVE CIRCUIT

CC.1 : Short circuit to +12 volts

1.DEF: At minimum stop

2.DEF: At maximum stop

3.DEF : Permanent low signal

4.DEF: > Maximum threshold5.DEF: Blocked component

NOTES

Conditions for applying the fault finding procedure to the fault stored:Fault declared present: at idle speed.

If fault DF027 is present warning light level 1 lights up.

Check the condition and connection of the 5 track EGR solenoid valve connector and repair it if necessary.


Measure the resistance between track 1 and 5 of the EGR solenoid valve, if it is not approximately 8Ω ± 0.5Ω at 25° replace the solenoid valve.

Check the insulation, continuity and absence of interference resistance of the connections:+ after ignition track 1 EGR solenoid valve

computer connector B track L3 track 5 EGR solenoid valveRepair if necessary.

AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-15

PROGRAM No.: BE


DF029PRESENT

ORSTORED

POWER-ASSISTED STEERING RELAY CONTROL CIRCUIT



NOTES

Conditions for applying the fault finding procedure to the fault stored:: – CC.1: fault declared present after the power-assisted steering pump assembly is

activated.

– 1.DEF: fault finding procedure applies only to the present fault.

Special note:This fault only affects vehicles fitted with electric power assisted steering.

Check the condition and connection of the electronic power-assisted steering assembly relay connector.Repair it if necessary.

Check the condition of the 32 track computer connector C and repair if necessary.

Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track C1 track 2 electronic power-assisted steering assembly relay

With the ignition on check for the presence of 12 volts supply on track 1 and track 3 of the relay.

Repair if necessary (see the vehicle's wiring diagram).

AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-16

PROGRAM No.: BE


DF037PRESENT

ORSTORED

STOP LIGHT SWITCH CIRCUIT

1.DEF: Consistency

2.DEF : Signal absent

NOTES

Conditions for applying fault finding procedure to a stored fault:

the fault is declared present in 3rd gear, on deceleration, when the brake pedal is

depressed.

Deal with the fault even if it is stored.

Check the switch connection and repair if necessary.

Check for the presence of + 12 volts on the switch supply.Repair if necessary.

Check the condition of the 32 track computer connector A and the 32 track computer connector C and

repair them if necessary.

Check that the switch is working.Change it if necessary.

Check the insulation, continuity and absence of interference resistance of the connections:stop light switch track B1 and A1 + After ignitionstop light switch track A3 track E4 computer connector Astop light switch track B3 track D4 computer connector C




CR DELPHI 1.0



DIESEL INJECTION


13-17

PROGRAM No.: BE


DF045PRESENT

PREHEATING RELAY CONTROL CIRCUIT



NOTES None.

Check the condition and connection of the preheating unit connector .Repair it if necessary.


Check the insulation, continuity and absence of interference resistance of the connections:+ after ignition track 3 pre-heating unit

computer connector C track D3 track 9 preheating unitcomputer connector C track F2 track 8 preheating unit




CR DELPHI 1.0



DIESEL INJECTION


13-18

PROGRAM No.: BE


DF048PRESENT

or STORED

FAN LOW SPEED CIRCUIT



NOTES

Conditions for applying the fault finding procedure to the fault stored: – CC.1: fault declared present after the low speed fan assembly is activated.


Check the condition and connection of the low speed fan assembly relay connector.Change it if necessary.


Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track B1 track 2 low speed fan assembly relay



AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-19

PROGRAM No.: BE


DF049PRESENT

ORSTORED

HIGH-SPEED FAN CIRCUIT



NOTES

Conditions for applying the fault finding procedure to the fault stored: – CC.1: fault declared present after the high speed fan assembly is activated.


Check the connection and condition of the high speed fan assembly relay connector and repair it if

necessary.


Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track B2 track 2 high speed fan assembly relay



AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-20

PROGRAM No.: BE


DF052STORED

INJECTION <--> CLIMATE CONTROL CONNECTION

1.DEF: Consistency



NOTES Conditions for applying the fault finding procedure to the fault stored:fault declared present: engine at idle speed, climate control engaged or not.


Check the condition of the computer connector or the climate control control relay and repair if necessary.

Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track E4 climate control control unit


If the fault persists, carry out a fault finding procedure on the climate control.

AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-21

PROGRAM No.: BE


DF055STORED

OBD WARNING LIGHT CIRCUIT (ON BOARD DIAGNOSTIC)



NOTES Warning light lights up for 3 seconds only on ignition then goes out.

None.

Enter command AC022 OBD warning light circuit and check that the warning light comes on correctly.

If the light comes on, replace the computer.

Check the OBD warning light connection.



Check the insulation, continuity and absence of interference resistance of the connection:computer connector A track F1 Instrument panel




CR DELPHI 1.0



DIESEL INJECTION


13-22

PROGRAM No.: BE


DF058PRESENT

SENSOR REFERENCE VOLTAGE



NOTES

If fault DF058 is present: engine speed maintained above 1000 rpm.Warning light level 1 lights up.

If faults DF058 and DF071 are present: engine speed fixed at 1300 rpm.Warning light level 1 lights up.

Special note:There are two different types of pedal potentiometer:

– a CTS sensor fitted in the engine compartment on the non multiplex CLIO(vdiag 04)

– a HELLA sensor fitted on the accelerator pedal on the multiplex CLIO (vdiag 08)

non multiplexvehicle CTS

sensor (vdiag 04)

CC.0

1.DEF

Check the connection and condition of the pedal potentiometer connector.Repair if necessary.


Check that potentiometer track 2 is correctly supplied on the sensor side.



connection:sensor connector track 3 track F2 computer connector A






Disconnect connector A from the computer and the connector from thepotentiometer and test the insulation between the two lines

Computer connector A track F2 track F3 computer connector ARepair if necessary.

Check the continuity of the connections:

sensor connector track 3 track F2 computer connector Acomputer connector track 5 track F4 computer connector A




CR DELPHI 1.0



DIESEL INJECTION


13-23

PROGRAM No.: BE


DF058

Cont'd

multiplexvehicle HELLA

sensor (vdiag 08)

CC.0

1.DEF






computer connector track 5 track F2 computer connector A




Check that potentiometer track 2 is correctly supplied on the sensor side.Repair if necessary.


Computer connector A track F2 track F3 computer connector ARepair if necessary.


computer connector track 5 track F2 computer connector Asensor connector track 1 track F4 computer connector A




CR DELPHI 1.0



DIESEL INJECTION


13-24

PROGRAM No.: BE


DF061PRESENT

HEATER PLUG CIRCUIT

CO : open circuit

NOTES None.

Check the condition and connection of the preheating unit connector.Change it if necessary.

Check the condition and connection of the heater plug connectors.

Change them, if necessary.


Measure the resistance of each heater plug. The resistance should be less than 1 Ohm. If not, replace the

faulty plugs.

Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track F2 track + pre-heating unit




CR DELPHI 1.0



DIESEL INJECTION


13-25

PROGRAM No.: BE


DF071PRESENT

PEDAL SENSOR CIRCUIT TRACK 1

1.DEF: Consistency



4.DEF: Signal absent

5.DEF: Blocked component

NOTES

Priority when dealing with a number of faults:If faults DF071 and DF127 are both present, deal with fault DF127 sensor voltagesupply first.






Be aware that state 5.DEF may be present after sports style driving, when the brake

pedal and accelerator pedal are depressed at the same time (heel and toe).


sensor (vdiag 04)

1.DEF

2.DEF

3.DEF4.DEF


Computer connector A track H2 track F3 computer connector ARepair if necessary.

Check the condition of the 32 track computer connector A and replace it if

necessary.

Measure the resistance at the pedal potentiometer terminal:

track 4 (earth) track 6 (+5 V)If it is not approximately 1.7 KΩ ± 0.9 KΩ, replace the pedal potentiometer.


connections:sensor connector track 6 track G2 computer connector Asensor connector track 2 track H2 computer connector Asensor connector track 4 track H3 computer connector A




CR DELPHI 1.0



DIESEL INJECTION


13-26

PROGRAM No.: BE


DF071(CONT. 1)

NOTES Be aware that state 5.DEF may be present after sports style driving, when the brake



sensor (vdiag 04)

5.DEF

Check that the accelerator pedal is not blocked with parameter PR240 Accelerator pedal position.

Replace the accelerator pedal potentiometer if necessary.

Check that the brake pedal is not blocked with state ET154 Brake pedal.Replace the stop light switch if necessary.

Let the customer know that heel and toe sports driving (pressing the brake and

accelerator pedal at once) may raise a fault.

DF071CONTINUED

Multiplex CLIO (vdiag 08)


sensor (vdiag 08)

1.DEF

Disconnect connector A from the computer and the connector from the pedal

potentiometer and test the insulation between the two lines:

Computer connector A track H2 track F3 computer connector ARepair if necessary.



CR DELPHI 1.0



DIESEL INJECTION


DF071(CONTINUED 2)

non multiplexvehicle HELLA

sensor (vdiag 08)

2.DEF3.DEF4.DEF

Check the condition of the 6 track pedal potentiometer connector and repair it if necessary.


necessary.

Measure the resistance at the pedal potentiometer terminals:track 2 (earth) track 4 (+5 V)

If it is not approximately 1.2 KΩ ± 0.5 KΩ, replace the pedal potentiometer.

Check the insulation, continuity and absence of interference resistance of theconnections:

sensor connector track 4 track G2 computer connector Asensor connector track 3 track H2 computer connector Asensor connector track 2 track H3 computer connector A


NOTES Be aware that state 5.DEF may be present after sports style driving, when the brake



sensor (vdiag 08)

5.DEF

Check that the accelerator pedal is not blocked by parameter PR240 Accelerator pedal position.

Replace the accelerator pedal if necessary.

Check that the brake pedal is not blocked by state ET154 Brake pedal.Replace the stop light switch if necessary.

Inform the customer that heel and toe sports driving (pressing the brake and

accelerator pedal at once) may raise a fault.

13-27

PROGRAM No.: BE




CR DELPHI 1.0



DIESEL INJECTION


13-28

PROGRAM No.: BE


DF073PRESENT

TRACK 2 PEDAL SENSOR CIRCUIT



NOTES







non multiplexvehicle CTSsensor

(vdiag 04)

1.DEF

Check the condition of the 6 track pedal potentiometer connector and repair it if necessary.


necessary.

Measure the resistance at the pedal potentiometer terminal:track 5 (earth) track 3 (+ 5 volts)


Check the insulation against the earth and the continuity of the connection:sensor connector track 1 track F3 computer connector A




CR DELPHI 1.0



DIESEL INJECTION


13-29

PROGRAM No.: BE


DF073

CONTINUED 1

Non multiplexvehicle CTS

sensor (vdiag 04)

2.DEF

Check the condition of the 6 track pedal potentiometer connector and repair it if

necessary.


necessary.

Measure the resistance at the pedal potentiometer terminals:track 5 (earth) track 3 (+ 5V)


Check the insulation against + 12 volts of the connections:sensor connector track 3 track F2 computer connector Asensor connector track 1 track F3 computer connector A



computer connector track 5 track F4 computer connector Asensor connector track 3 track F2 computer connector A

Disconnect connector A from the computer and the connector from the pedal

potentiometer and test the insulation between the two lines:computer connector A track F2 track F3 computer connector A


CR DELPHI 1.0





DIESEL INJECTION


13-30

PROGRAM No.: BE


DF073

CONTINUED 2


sensor (vdiag 08)

1.DEF


necessary.


necessary.

Measure the resistance at the pedal potentiometer terminals:track 1 (earth) track 5 (+5 V)


Check the insulation against the earth and the continuity of the connection:sensor connector track 6 track F3 computer connector A




CR DELPHI 1.0



DIESEL INJECTION


13-31

PROGRAM No.: BE


DF073

CONTINUED 3


sensor (vdiag 08)

2.DEF


necessary.


necessary.

Measure the resistance at the pedal potentiometer terminals:track 1 (earth) track 5 (+ 5V)



sensor connector track 6 track F3 computer connector ARepair if necessary.

Check the insulation against + 12 volts of the connections:computer connector track 5 track F2 computer connector Asensor connector track 6 track F3 computer connector A



sensor connector track 1 track F4 computer connector Acomputer connector track 5 track F2 computer connector A

Disconnect connector A from the computer and the connector from the pedalpotentiometer and test the insulation between the two lines:

computer connector A track F2 track F3 computer connector ARepair if necessary.



CR DELPHI 1.0



DIESEL INJECTION


13-32

PROGRAM No.: BE


DF084STORED

EGR VALVE POSITION SENSOR CIRCUIT


2.DEF: At maximum stop

3.DEF: < minimum threshold

4.DEF: > maximum threshold

NOTES

Priority when dealing with a number of faults::If faults DF084 and DF127 are both present, deal with fault DF127 Sensor voltagesupply first.

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

Check the condition of the 5 track gas recycling solenoid valve connector and replace it if necessary.

Check the condition of the 48 track computer connector B and replace it if necessary.

Measure the resistance at the gas recycling solenoid valve terminal, if it is not

approximately 4 KΩ ± 1.6KΩ at 20°C between tracks 2 and 4 and

approximately 1 KΩ ± 0.5KΩ at 20°C between tracks 4 and 6, replace the solenoid valve.

Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track 2 track B1 computer connector B

sensor connector track 6 track B2 computer connector Bsensor connector track 4 track B3 computer connector B


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-33

PROGRAM No.: BE


DF093STORED

MICROCONTROLLER

1.DEF: RAM memory defect

NOTES

Conditions for applying the fault finding procedure to the fault stored::The fault is declared present: with the engine running.

If fault DF093 is present: it is impossible to stop and restart the engine.

Levels 1 and 2 warning lights light up.

Re-enter C2I using the fault finding tool.

If the fault persists, replace the computer.

AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-34

PROGRAM No.: BE


DF099STORED

CYLINDER INJECTOR CIRCUIT 1

CO : Open circuit

CC : Short circuit


2.DEF: Combustion too strong

3.DEF: Permanent low signal4.DEF: Permanent high signal

NOTES

Conditions for applying the fault finding procedure to the fault stored::Fault declared present: engine at idle speedWarning light level 1 lights up.

CO4.DEF

With the ignition switched off, wait 15 seconds.

Check the connection and condition of the injector connector.Change it if necessary.

Check the continuity between the two injector terminals using a multimeter.

Replace the injector if necessary.

Check the condition of the 48 track computer connector B and replace it if

necessary.

Check the continuity and absence of interference resistance of the

connections:computer connector B track A4 track 1 injector 1

computer connector B track B4 track 2 injector 1


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-35

PROGRAM No.: BE


DF099

Cont'd

CC3.DEF

With the ignition switched off, wait 15 seconds.Check the connection and condition of the injector connector.Change it if necessary.

Disconnect the ignition, restart the ignition and check if the fault is stored.

Replace the injector if the fault is stored.


necessary.

Disconnect computer connector B and the connector from injector 1.

Check the insulation of the two lines:computer connector B track A4 computer connector B track B4


When the injector has been disconnected, check that the injector winding has not

short circuited with a multimeter.

NOTES

Conditions for applying the fault finding procedure to the fault stored:The fault is declared present with: the engine running and engine temperatureabove 80°C.Levels 1 and 2 warning lights light up.

Priority when dealing with a number of faults:If faults DF99 and DF130 are both present, deal with fault DF99: Cylinder 1 injector circuit first.

2.DEF Replace injector 1.

NOTES

Conditions for applying the fault finding procedure to the fault stored::

The fault is declared present when the car is being driven and after severalrecalibrations.Levels 1 and 2 warning lights light up.



AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-36

PROGRAM No.: BE


DF100STORED


CO : open circuit

CC : Short circuit




NOTES

Conditions for applying the fault finding procedure to the fault stored::Fault declared present: engine at idle speed.Warning light level 1 lights up.

CO4.DEF






necessary.

Check the continuity and absence of interference resistance of the

connections:computer connector B track G4 track 1 injector 2

computer connector B track H4 track 2 injector 2


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-37

PROGRAM No.: BE


DF100

Cont'd

CC3.DEF





necessary.


Check the insulation of the two lines:computer connector B track G4 computer connector B track H4Repair if necessary.

When the injector has been disconnected, using a multimeter, check that the

injector winding has not short circuited.

NOTES




NOTES

Conditions for applying the fault finding procedure to the fault stored:

The fault is declared present: when the car is being driven and after severalrecalibrations.Levels 1 and 2 warning lights light up.



AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-38

PROGRAM No.: BE


DF101STORED


CO : Open circuit

CC : Short circuit




NOTES

Conditions for applying the fault finding procedure to the fault stored:Fault declared present: engine at idle speed.Warning light level 1 lights up.

CO4.DEF





necessary.


computer connector B track C4 track 1 injector 3

computer connector B track D4 track 2 injector 3Repair if necessary.

CR DELPHI 1.0

AFTER REPAIR






DIESEL INJECTION


13-39

PROGRAM No.: BE


DF101

Cont'd

CC3.DEF

Ignition off.


Disconnect the injector and check to see if the fault is stored.



necessary.


Check the insulation of the two lines:computer connector B track C4 computer connector B track D4


When the injector has been disconnected, check that the injector winding has not

short circuited using a multimeter.

NOTES




1.DEF

NOTES


Fault declared present: when driving, after several recalibrations.Levels 1 and 2 warning lights light up


Replace injector 3.

AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-40

PROGRAM No.: BE


DF102STORED


CO : Open circuit

CC : Short circuit




NOTES

Conditions for applying the fault finding procedure to the fault stored::Fault declared present: engine at idle speed.Warning light level 1 lights up.

CO4.DEF






necessary.


computer connector B track E4 track 1 injector 4computer connector B track F4 track 2 injector 4


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-41

PROGRAM No.: BE


DF102

Cont'd

CC3.DEF





necessary.


Check the insulation of the two lines:computer connector B track E4 computer connector B track F4Repair if necessary.

With the injector disconnected, check that the injector winding has not shortcircuited using a multimeter.

NOTES

Conditions for applying the fault finding procedure to the fault stored:Fault declared present: with the engine running and engine temperature above80°C.

Levels 1 and 2 warning lights light up.



NOTES

Conditions for applying the fault finding procedure to the fault stored:Fault declared present: when driving, after several recalibrations.Levels 1 and 2 warning lights light up.



AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-42

PROGRAM No.: BE


DF110PRESENT

or STORED

MULTIPLEX NETWORK

1.DEF : Carry out the multiplex network fault finding procedure

NOTES None.




CR DELPHI 1.0



DIESEL INJECTION


13-43

PROGRAM No.: BE


DF111PRESENT

or STORED

COLD LOOP AIR CONDITIONING RELAY CONTROL CIRCUIT



NOTES

Conditions for applying the fault finding procedure to the fault stored: – CC.1: fault declared present after climate control is activated.

– 1.DEF: fault finding procedure to be applied only to the present fault.

Check the connection and condition of the air conditioning relay connector.Change it if necessary.

Check the condition of the 32 track computer connector A and replace it if necessary.

Check the insulation, continuity and absence of interference resistance of the connection:computer connector A track E2 climate control control unit


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-44

PROGRAM No.: BE


DF113STORED

COOLANT PRESSURE SENSOR CIRCUIT



NOTES

Conditions for applying the fault finding procedure to the fault stored:Fault declared present: engine running, climate control switched on, with coldloop.

Check the coolant pressure sensor connection.Repair if necessary.


Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track B track C4 computer connector Csensor connector track C track C3 computer connector Csensor connector track A track G3 computer connector C


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-45

PROGRAM No.: BE


DF115PRESENT

INLET MANIFOLD PRESSURE SENSOR CIRCUIT





5.DEF: Consistency

NOTES None.

Warning light level 1 lights up.

1.DEF2.DEF3.DEF4.DEF

5.DEF

Check the condition of the 3 track inlet pressure sensor connector and replace it

if necessary.


necessary.


sensor connector track A track C3 computer connector Bsensor connector track B track C2 computer connector Bsensor connector track C track C1 computer connector B


Visually check that the turbocharger circuit is leak tight.Repair if necessary.

Remove the air supply ducts and check that they are not blocked.


Check the consistency between the atmospheric pressure and inlet manifoldvacuum.

With the engine stopped, the pressure should be approximately the same between

the two sensors.

Replace the inlet manifold vacuum sensor if necessary.

Check the turbocharger .Repair if necessary.



CR DELPHI 1.0



DIESEL INJECTION


13-46

PROGRAM No.: BE


DF116STORED

CYLINDER REFERENCE SENSOR CIRCUIT

1.DEF: Consistency

2.DEF: Signal Absent

NOTES


Conditions for applying the fault finding procedure to the fault stored::The fault is declared present when the engine is started or at idle speed (600 rpm).

Check the condition of the 3 track cylinder reference sensor connector and replace it if necessary.


Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track 2 track E2 computer connector Bsensor connector track 1 track E3 computer connector Bsensor connector track 3 track H5 (+ after ignition) injection locking relay

If necessary, replace the sensor.

Check the timing gear setting using the appropriate Workshop Repair Manual.

AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-47

PROGRAM No.: BE


DF117STORED

RAIL PRESSURE SENSOR CIRCUIT

1.DEF: Consistency

2.DEF: Maximum threshold

3.DEF: Minimum threshold



NOTES

Priority when dealing with a number of faults:If faults DF117 and DF127 are both present, deal with fault DF127 Sensor voltagesupply first.

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

If DF117 is present, the engine stops and is impossible to restart.Levels 1 and 2 warning lights light up.

Check the condition of the 3 track connector of the rail pressure sensor and replace it if necessary.



sensor connector track 2 track D3 computer connector Bsensor connector track 1 track D2 computer connector Bsensor connector track 3 track D1 computer connector B


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION


13-48

PROGRAM No.: BE


DF118PRESENT

CRUISE CONTROL/SPEED LIMITER

1.DEF: Consistency

2.DEF: On/off switch

NOTES None.


Check the stop light switch connector.Repair if necessary.

Check for the presence of + 12 volts on the switch supply.


Check that the switch is working.Change it if necessary.

Check the insulation, continuity and absence of interference resistance of the connections:cruise control/limiter switch track track D2 computer connector Alimiter switch track track C3 computer connector Aearth switch track track D3 computer connector A

cruise control switch track track A2 computer connector ARepair if necessary.



CR DELPHI 1.0



DIESEL INJECTION


13-49

PROGRAM No.: BE


DF122PRESENT

THERMOPLUNGER RELAY CIRCUIT 3



NOTES None.

Check the condition and connection of thermoplunger relay connector 3.Change it if necessary.


Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track D1 track 2 thermoplunger relay 3

With the ignition on check for the presence of 12 volts supply on track 1 and track 3 of the relay.Repair if necessary (see the vehicle's wiring diagram).



CR DELPHI 1.0



DIESEL INJECTION


13-50

PROGRAM No.: BE


DF123PRESENT




NOTES None.



Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track D2 track 2 thermoplunger relay 2

With the ignition on check for the presence of 12 volts supply on track 1 and track 3 of relay 2.Repair if necessary (see the vehicle's wiring diagram).



CR DELPHI 1.0



DIESEL INJECTION


13-51

PROGRAM No.: BE


DF124PRESENT




NOTES None.



Check the insulation, continuity and absence of interference resistance of the connection:computer connector C track C2 track 2 thermoplunger relay 1

With the ignition on check for the presence of 12 volts supply on track 1 and track 3 of relay 1.Repair if necessary (see the vehicle's wiring diagram).



CR DELPHI 1.0



DIESEL INJECTION


13-52

PROGRAM No.: BE


DF125PRESENT

MAIN RELAY CONTROL CIRCUIT

1.DEF : Relay cut-off too soon

2.DEF : Relay cut-off too late

NOTES None.

Non multiplexvehicle

(vdiag 04)

Check the main relay supply fuse in the engine compartment: (fuse F1, 30A).

Change it if necessary.

Check the condition and connection of the 5 track main relay connector and replace

it if necessary.

Check the condition of the 32 track computer connector C and replace it if

necessary.


fuse F1 track 3 main relay

computer connector C track F1 track 2 main relay

inertia sensor track 3 track 1 main relay

computer connector C track H2, G2 track 5 main relay

computer connector C track G1 EARTH


Multiplexvehicle

(vdiag 08)

Check the main relay supply fuse in the engine compartment: (fuse F1, 30A).

Change it if necessary.

Check the condition and connection of the 5 track main relay connector and replaceit if necessary.

Check the condition of the 32 track computer connector C and replace it if

necessary.


fuse F1 tracks 3 and 1 main relay

computer connector C track F1 track 2 main relay

computer connector C track H2, G2 track 5 main relay

computer connector C track G1 EARTH




CR DELPHI 1.0



DIESEL INJECTION


13-53

PROGRAM No.: BE


DF126PRESENT

FUEL FLOW ACTUATOR CIRCUIT



NOTES

If fault DF126 is present with 1.DEF or CC.1, levels 1 and 2.warning lights light upThe fuel flow actuator is fully opened and the engine isstopped to prevent stalling.

Check the condition and connection of the flow actuator connector.Change it if necessary.


Measure the resistance between tracks 1 and 2 of the flow actuator, if it is not approximately 5.3 Ohms ± 0.5

at 20°C, replace the actuator.

Check the insulation, continuity and absence of interference resistance of the connection:

computer connector B track M4 track 1 fuel flow actuator Repair if necessary.



CR DELPHI 1.0



DIESEL INJECTION


13-54

PROGRAM No.: BE


DF127PRESENT

SUPPLY VOLTAGE SENSORS



NOTES

Order of priority in the event of more than one fault:If faults DF127 and DF071, DF084, DF116, DF117 are present, deal with DF27 sensor voltage supply first.

If fault DF127 is present, the engine stops immediately and cannot be restarted.

Check the condition and connection of all the sensor connectors supplied by an external track, as follows: – coolant pressure sensor

– turbocharging pressure sensor

– rail pressure sensor

– pedal sensor track 1

– EGR valve position sensor

– phase sensor


Check the condition of computer connectors A, B and C and replace them if necessary.

Connect the bornier in place of the computer and check the insulation, continuity and absence of interference resistance of the connections:

computer connector C track C4 track B of the coolant pressure sensor

computer connector B track C1 track C turbocharging pressure sensor

computer connector B track D1 track 3 rail pressure sensor

computer connector A track G2 track 4 pedal sensor track 1

computer connector B track B1 track 2 EGR valve position sensor

+ after ignition track 3 phase sensor


If the fault persists, apply the fault finding strategy to each sensor supplied by an external track.



CR DELPHI 1.0



DIESEL INJECTION


13-55

PROGRAM No.: BE


DF128PRESENT

INTAKE AIR TEMPERATURE SENSOR CIRCUIT



NOTES None.

Check the condition of the 2 track intake air temperature sensor connector and replace it if necessary.


At the terminal, measure the resistance of the air temperature sensor, if it is not approximately2051 Ω ± 120 Ω at 25 °C replace the intake air temperature sensor.

Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track 1 track J2 computer connector Bsensor connector track 2 track J3 computer connector B




CR DELPHI 1.0



DIESEL INJECTION


13-56

PROGRAM No.: BE


DF129PRESENT

ENGINE SPEED SIGNAL OUTPUT



NOTES

Priority when dealing with a number of faults:If faults DF023 and DF129 are both present, deal with fault DF023 Flywheel signal first.

Check the condition of the rev counter connector and replace it if necessary.


Check the insulation, continuity and absence of interference resistance of the connection:rev counter connector instrument panel track B2 computer connector A

Refer to the wiring diagram for the relevant vehicle and year.




CR DELPHI 1.0



DIESEL INJECTION


13-57

PROGRAM No.: BE


DF130STORED

CYLINDER No.1 COMBUSTION

NOTES

Conditions for applying the fault finding procedure to the fault stored::Fault declared present: engine at idle speed.

Priority when dealing with a number of faults:If faults DF99 (CC or CO) and DF130, are present, deal first with fault DF99 (CC or CO): Cylinder 1 injector circuit.

Priority when dealing with a number of faults:If faults DF137 (1.DEF, 2.DEF, 7.DEF) and DF130, are present, deal with fault DF137:

Pressure regulation. first.

Check the tightness of the cylinder and repair if necessary.

Check the valve clearances and adjust them if necessary.

Check the air inlet conduits and the EGR valve and clean them if necessary.

Replace the injector.


AFTER REPAIR




CR DELPHI 1.0



DIESEL INJECTION



DF131STORED

CYLINDER No. 2 COMBUSTION

NOTES


Priority when dealing with a number of faults:If faults DF100 (CC or CO) and DF131, are present, deal with fault DF100 (CC or CO):Cylinder 2 injector circuit.







If the fault persists, replace the computer.

AFTER REPAIR




CR DELPHI 1.0

13-58



DIESEL INJECTION



DF132STORED

CYLINDER No. 3 COMBUSTION

NOTES


Priority when dealing with a number of faults:If faults DF101 (CC or CO) and DF132, are present, deal first with fault DF101 (CC or CO): Cylinder 3 injector circuit.








AFTER REPAIR




CR DELPHI 1.0

13-59



DIESEL INJECTION



DF133STORED

CYLINDER N°4 COMBUSTION

NOTES


Priority when dealing with a number of faults:If faults DF102 (CC or CO) and DF133, are present, deal with fault DF102 (CC or CO):Cylinder 4 injector circuit. first.


Pressure regulation first.






AFTER REPAIR




CR DELPHI 1.0

13-60



DIESEL INJECTION



DF134STORED

ACCELEROMETER CIRCUIT

NOTES

Processing priority in the event of a number of faults:If faults DF134 and DF002, DF021, DF024 are present, first deal with faults DF002Coolant temperature, DF022 Air temperature, DF021 Fuel temperature, andDF024 Atmospheric pressure.

A fault on one of these sensors could lead to an incorrect diagnostic on the

accelerometer.


Fault declared present: engine at idle speed.

Check the conformity of the injectors fitted to the vehicle in relation to the type of vehicle and enginenumber (low injector, high or very high pressure).

Check the accelerometer connection. Repair if necessary.

Check the condition of the 48 track computer connector B and the sensor shielding on track K1 of connector B. Change it if necessary.

Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track A track F1 computer connector B

sensor connector track B track G1 computer connector BRepair if necessary.

AFTER REPAIR




CR DELPHI 1.0

13-61



DIESEL INJECTION



DF135PRESENT

LEVEL 2 WARNING LIGHT CIRCUIT



NOTES None.

Enter command AC213 level 2 warning light and check that it lights up correctly.If the light comes on, replace the computer.

Check the connector of the level 2 warning light.



Check the insulation, continuity and absence of interference resistance of the connection:warning light connector instrument panel track E1 computer connector A




CR DELPHI 1.0

13-62



DIESEL INJECTION



DF136STORED

INJECTOR COMMAND


CC.1 : Short circuit to + 12 volts



NOTES

Conditions for applying the fault finding procedure to the fault stored:Fault declared present: engine at idle speed.

Priority when dealing with a number of faults:If faults DF136 and DF099 (2.DEF), DF100 (2.DEF), DF101 (2.DEF) and DF102(2.DEF) are present, the fault finding procedure remains the same, but the faulty

injector has to be identified.

Switch off the ignition and check the injector connections.


Disconnect the injectors and switch the ignition back on.

Check to see if the fault is still present.

If the fault persists, an injector is faulty; switch of the ignition and reconnect one injector of the four. Restart

the ignition and if the fault disappears, replace the injector. If not follow the same procedure for the other injectors.

If the fault disappears when the injectors are disconnected, check the condition of the 48 track computer connector B and replace it if necessary.

Check the insulation, continuity and absence of interference resistance of the connections:injector 1 track 1 (+) track B4 computer connector Binjector 1 track 2 (earth) track B4 computer connector Binjector 2 track 1 (+) track G4 computer connector Binjector 2 track 2 (earth) track H4 computer connector Binjector 3 track 1 (+) track C4 computer connector Binjector 3 track 2 (earth) track D4 computer connector Binjector 4 track 1 (+) track E4 computer connector Binjector 4 track 2 (earth) track F4 computer connector B


AFTER REPAIR




CR DELPHI 1.0

13-63



DIESEL INJECTION



DF137

STORED

PRESSURE REGULATION FUNCTION

1.DEF: Pressure < minimum

2.DEF: Pressure > maximum

3.DEF: < minimum threshold

8.DEF: > maximum threshold

4.DEF : Weak flow current > maximum5.DEF : Strong flow current > maximum

6.DEF : Weak flow current < minimum7.DEF : Strong flow current < maximum

NOTES Conditions for applying the fault finding procedure to the fault stored::The fault is declared present: with the engine running.

3.DEF4.DEF5.DEF6.DEF8.DEF

Check the fuel flow actuator connection. Repair if necessary.

Measure the resistance between tracks 1 and 2 of the flow actuator, if it is not

approximately 5.3 Ohms ± 0.5Ω at 20°C, replace the actuator.


necessary.


connection:computer connector B track M4 track 1 fuel flow actuator


Check:

– that fuel is present in the tank,

– that there is no air in the fuel circuit,

– the condition of the diesel filter .Repair if necessary.

AFTER REPAIR




CR DELPHI 1.0

13-64



DIESEL INJECTION



DF137

Cont'd

1.DEF2.DEF7.DEF

Carry out a HIGH PRESSURE PUMP test (see TEST section).

AFTER REPAIR




CR DELPHI 1.0

13-65



DIESEL INJECTION



DF172STORED

WATER IN DIESEL DETECTOR CIRCUIT


1.DEF : above maximum threshold (presence of water)

2.DEF: permanent high signal

NOTES

Conditions for applying the fault finding procedure to the fault stored::The fault is declared present with the engine running.Warning light level 1 lights up.

Fault finding procedure for CLIOs fitted with a water detector on the diesel filter

Check the condition of the 3 track water detector connector and replace it if necessary.


Check the insulation, continuity and absence of interference resistance of the connections:sensor connector track 3 track A2 computer connector Csensor connector track 2 track B3 computer connector Csensor connector track 1 + after ignition


AFTER REPAIR




CR DELPHI 1.0

13-66



DIESEL INJECTION

Fault finding - Conformity check 13PROGRAM No.: BE

VDIAG No.: 04 and 08 Fault finding - Conformity check

NOTES

Only check the conformity after a complete check with the fault finding tool.

The values indicated in this conformity check are given as examples.

Test conditions: engine stopped, ignition on.

Order FunctionParameter or state

Check or actionDisplay and notes Fault finding

1 Battery voltage

PR241: battery voltage 12 < X < 12.5 V In the event of aproblem: perform the

charge circuit fault findingprocedure

2 Immobiliser

ET133: code programmed YES

Perform the engine

immobiliser system fault

finding procedure if theimmobiliser code is not

programmed.

ET151: computer locked NO

3 Accelerator

pedal

PR240: accelerator pedal

position

no load X = 0%

full load X = 100%In the event of a

problem:Carry out the fault finding

procedure for pedal

sensor circuit tracks 1 and

2 (DF071 and DF073) and

sensor reference voltage

DF058.

PR233: pedal sensor

track 2 voltage

no load 0.3V to 0.5V

full load 2V ± 0.3V

PR234: pedal sensor

track 1 voltage

no load 0.7V ± 0.2V

full load 4.1V ± 0.5V

4 Warning light

ET128: serious injection

fault warning light

control

ACTIVE

In the event of aproblem:

Consult the fault finding

procedure for states

ET128 and ET127.

ET127: injection fault

warning lightcontrol

ACTIVE

ET104: preheating

warning light

control

ACTIVE during the

preheating phase, then

INACTIVE


Refer to diagnostic for

state ET104

CR DELPHI 1.0

13-67



DIESEL INJECTION

Fault finding - Conformity check 13

13-68

PROGRAM No.: BE


NOTES






5Warning light

(continued)

ET129: coolant

temperature

warning lightcontrol

ACTIVE for 3 seconds

on ignition then goes

out


Refer to the fault findingprocedure for state

ET129.

ET197: on board

diagnostic

warning light

control

ACTIVE for 3 seconds

on ignition then goes

out


Refer to the fault finding

procedure for state

ET197.

6Gas

recirculation

PR034: EGR valve

opening

specification

X = 0% In the event of aproblem:

Apply the fault findingprocedure for the EGR

solenoid valve circuit fault

DF027.

PR088: EGR valve

position feedback

X = 0%


Carry out the fault findingprocedure on the EGR

valve position sensor

circuit DF084.

PR101: EGR valve

position sensor

voltage

1.5 V ± 0.5 V

7 Switches

ET154: brake pedal DEPRESSED when

the pedal is depressedIn the event of a

problem: Apply the fault findingprocedure for the stop

light switch circuit DF037.

ET155: secondary brake

pedal

ACTIVEwhen the

pedal is depressed

CR DELPHI 1.0



DIESEL INJECTION


13-69

PROGRAM No.: BE


NOTES






8 Relays

ET037: low speed fan

assembly relay

control

INACTIVE In the event of a problem: Apply the fault finding

procedure for the low-speed fan assembly circuit

DF048.

ET038: high speed fan

assembly relay

control

INACTIVE In the event of a problem: Apply the fault findingprocedure for the high

speed fan assembly circuit

DF049.

ET106: thermoplunger

relay control 1


procedure for

thermoplunger relay circuit 1

DF124.


relay control 2


procedure for

thermoplunger relay circuit 2DF123.


relay control 3


procedure for

thermoplunger relay circuit 3

DF122.

ET025: power-assisted

steering relay

control


procedure for the power-

assisted steering assemblyrelay control circuit DF029.

ET054: preheating relay

control

ACTIVE during the

preheating phase,

then INACTIVE

In the event of a problem: Apply the fault finding

procedure for the

preheating relay control

circuit DF045.

ET116: air conditioning

compressor relay

control


procedure for the air

conditioning cold loop relaycontrol circuit DF111.

CR DELPHI 1.0



DIESEL INJECTION


13-70

PROGRAM No.: BE


NOTES



Conditions for engine performance: warm at idle speed, no electrical consumers.



1 Battery voltage

PR241: battery voltage 13 < X < 14.4 V In the event of aproblem: perform the

charge circuit fault findingprocedure

3 Immobiliser

ET133: code programmed YES

Perform the engine

immobiliser system fault

finding procedure if theimmobiliser code is not

programmed.

ET151: computer locked NO

4

Coolant

temperature

sensor

PR002: coolant

temperature

90 to 100°C In the event of aproblem: Use the fault

finding procedure for the

coolant temperature

sensor circuit DF002.

5external air

temperature

sensor

PR212: external air

temperature

X = external

temperature ± 5˚C

In the event of a

problem: Use the faultfinding procedure for the

air temperature sensor

circuit DF022.

6

manifold air

temperature

sensor

PR213: manifold air

temperature

X = temperatureunder bonnet ± 5 ˚C

In the event of aproblem: Use the fault


intake air temperature


PR249: manifold

temperature

sensor voltage

2.0 V ± 0.2 V

CR DELPHI 1.0



DIESEL INJECTION


13-71

PROGRAM No.: BE


NOTES






8 Inlet

PR016: atmospheric

pressure

X = atmosphericpressure ± 10 mb


finding procedure for theatmospheric pressure


PR214: manifold pressure X = manifoldpressure ± 20 mb



inlet manifold pressure


PR243: estimated air flow 250..300 mg/stroke In the event of aproblem:Use the fault


atmospheric pressure

sensor circuit DF024 and

the manifold pressure

sensor DF115.

9 Accelerator

pedal

PR240: accelerator pedal

position

0%

In the event of aproblem:Use the faultfinding procedure for

pedal sensor circuit

tracks 1 and 2 DF071 and DF073 and sensor

reference voltage DF058.

PR233: pedal sensor track

2 voltageno load 0.3V to 0.5V

full load 2V ± 0.3V

PR234: pedal sensor

track 1 voltage

no load 0.7V ± 0.2V

full load 4.1V ± 0.5V

10 Climate control

PR192: refrigerant fluidpressure

1.5 > X >30 bar In the event of aproblem: carry out the

fault finding procedureon the coolant pressure


CR DELPHI 1.0



DIESEL INJECTION


13-72

PROGRAM No.: BE


NOTES






10Climate control

(continued)

ET006 : climate control

request

INACTIVEor

ACTIVE

None.

ET116: air conditioningcompressor relay

control

ACTIVEor

INACTIVE

In the event of aproblem: perform the

fault finding procedure

on the cold loop air

conditioning relay control

circuit DF111.

PR044: power used by the

AC compressor

250 to 300 Wattswithout climate control

250 to 5000 Wattsclimate control on

None.

See operation PR044.

11 Fuel

PR001: fuel temperature X = fuel temperature

± 5°CIn the event of a

problem: Carry out the

fault finding procedure

on the fuel temperaturesensor circuit DF021.

PR033: fuel flow 2 to 5 mg/stroke In the event of aproblem: Carry out the

fault finding procedureon the fuel flow actuator

circuit DF126.

PR103: fuel pressure

sensor voltage

1.2 V ± 0.2 V In the event of aproblem:carry out the

fault finding procedureon the rail pressure

sensor DF117 and on the

sensor voltage supply

DF127.

PR215: advance 0° to 1° flywheelNone.

CR DELPHI 1.0



DIESEL INJECTION


13-73

PROGRAM No.: BE


NOTES






11 Fuel (continued)

PR217: rail pressure

230 ± 5 bar In the event of a

problem: Carry out thefault finding procedure

on the rail pressuresensor circuit DF117.

PR216: rail pressurespecification

230 bar

ET138: high pressure

pump control

ACTIVE

In the event of aproblem: Carry out the

fault finding procedurefor the fuel flow actuator

circuit DF126.

12 Warning light

ET104: preheating

warning light

control

ACTIVEduring the

preheating phase, then

INACTIVE

In the event of aproblem: Consult the

fault finding procedure for

state ET104.

ET129: coolanttemperature

warning light

control

ACTIVE for 3 secondsafter the ignition is

switched on, then INACTIVE

If the state remains ACTIVE, check the

conformity of parameter

PR002 coolant

temperature

CR DELPHI 1.0



DIESEL INJECTION


13-74

PROGRAM No.: BE


NOTES






13Gas

recirculation

PR034: EGR valve

opening

specification

X = 16 ± 5 % In the event of aproblem: Carry out the

fault finding procedureon the EGR solenoid

valve circuit DF027.

PR088: EGR valve

position feedback

specification ± 2 %In the event of a


fault finding procedureon the EGR valve position


PR101: EGR valve

position sensor

voltage

1.5 V ± 0.5 V

ET021: EGR solenoid

valve control

ACTIVE In the event of aproblem: Carry out the

fault finding procedureon the EGR solenoid

valve circuit DF027.

14 Relays

ET037:

ET144:

low speed fan

assembly relay

control

low speed fan

assembly request

The low speed fanassembly switcheson at 99˚C and runsuntil the temperaturedrops to 96˚C

In the event of a


fault finding procedureon the low speed fan

assembly circuit DF048.

ET038: high speed fan

assembly relay

control

The high speed fanassembly switches

on at 102˚C and runsuntil the temperaturedrops to 99˚C


fault finding procedureon the high speed fan

assembly circuit DF049.ET143: high speed fan

assembly request

It is only active if thevehicle is fitted withclimate control

CR DELPHI 1.0



DIESEL INJECTION


13-75

PROGRAM No.: BE


NOTES






14Relays

(continued)


relay control 1

INACTIVE In the event of aproblem: Carry out the

fault finding procedureon thermoplunger relay

circuit 1 DF124.


relay control 2

INACTIVE In the event of aproblem: Carry out the


circuit 2 DF123.


relay control 3

INACTIVE

active only withextreme cold option



circuit 3 DF122.

ET025: power-assistedsteering

assembly relay

control

INACTIVE

present only onvehicles fitted with

climate control


fault finding procedureon the power assisted

steering assembly relay

control circuit DF029.

ET054: preheating relay

control

ACTIVE during the

preheating phase

(warning light comes on)

then for 8 seconds after

the light goes out


fault finding procedureon the preheating relay

control circuit DF045.

15Vehicle and

engine speeds

PR006: engine speed specification ± 5 rpm In the event of aproblem: Carry out the

fault finding procedureon the flywheel sensor

circuit DF023.

PR011: idle speed

regulation

specification

X = 850 rpmNone.

CR DELPHI 1.0



DIESEL INJECTION


13-76

PROGRAM No.: BE


NOTES






15

Engine speed

and speed

(continued)

ET145: fast idle speed

request

INACTIVEexcept for electrical

consumer None.

PR018: vehicle speed X = 0 mph In the event of a problem: Carry out the fault findingprocedure on the vehicle

speed sensor circuit

DF004.

16 EngineET152: engine running

None.

17Speed limiter/

cruise control

ET140: speed limiter INACTIVEor

ACTIVEdepending on the

switch

In the event of a problem: Carry out the fault findingprocedure on the cruise

control/speed limiter

function DF118.

ET141: cruise control INACTIVE

or ACTIVE

depending on the

switch

ET146: speed checking

mode

none

limiter

cruise controldepending on the

switch

ET147: cruise control /speed limiter

function selector

on the steering

wheel

moreless

restart

canceldepending on the

switch

18Heated

windscreen

ET153: electric

windscreen

INACTIVENone.

CR DELPHI 1.0



DIESEL INJECTION

Fault finding - Interpretation of states 13PROGRAM No.: BE

VDIAG No.: 04 and 08 Fault finding - Interpretation of states

ET104

PREHEATING WARNING LIGHT CONTROL

Enter command AC212 Preheating warning light and check that it lights up correctly.If the light comes on, replace the computer .

Check the preheating warning light connection.



Check the insulation, continuity and absence of interference resistance of the connection:

warning light connector instrument panel track A1 computer connector ARepair if necessary.

CR DELPHI 1.0

13-77



DIESEL INJECTION

Fault finding - Interpretation of parameters 13

13-78

PROGRAM No.: BE

VDIAG No.: 04 and 08 Fault finding - Interpretation of parameters

PR044

POWER CONSUMED BY THE CLIMATE CONTROL COMPRESSOR

NOTES The values listed below are examples only.

Whether the variable capacity compressor is pneumatic or electrically controlled, the power consumed by the

compressor can be anything from several hundred watts to approximately 3 KW depending on weather

conditions, car speed and compressor rotation speed.

The power consumed signal is a function of two parameters:

– continuous high pressure readings, – compressor rotation speed.

The power consumed value calculated by the climate control computer is transmitted to the engine computer.

This allows the engine computer to anticipate the effect that the load variations induced by the compressor will

have on the car at idle speed and when in motion.

CR DELPHI 1.0



DIESEL INJECTION

Fault finding - Tests 13PROGRAM No.: BE

VDIAG: 04 and 08 Fault finding - Tests

Some specific checks are grouped under the << tests >> heading and are used as required

in different fault finding charts.

TEST 1: low pressure circuit check

TEST 2: electrical circuit check

TEST 3: injector check

TEST 4: parameter check

TEST 5: air inlet circuit check

TEST 6: computer check

TEST 7: high pressure pump check

TEST 8: high pressure circuit tightness check

TEST 9: injector tightness check

TEST 10: Test with the plugged rail tool

NOTES Only consult the tests after following the fault finding chart procedure.

CR DELPHI 1.0

13-79



DIESEL INJECTION

Fault finding - Tests 13

13-80

PROGRAM No.: BE


TEST 1 LOW PRESSURE CIRCUIT CHECK

Check the conformity of the connections.

Is the low pressure circuit connectioncorrect?

YES

Look for leaks on the unions.

Are there leaks in the hoses and unions?

NO

Check the correctness of the diesel filter.

Is the diesel filter correct?

YES

NO

YES

NO

Carry out the required repairs.


Replace the filter with an original part.

CR DELPHI 1.0



DIESEL INJECTION


13-81

PROGRAM No.: BE


TEST 1

Cont'd

Check for water in the diesel.

Is there water in the diesel?

NO

Check for air bubbles in the diesel.

Are there any air bubbles in the lowpressure circuit?

NO

Low pressure circuit OK.

YES

YES

Drain the diesel filter.

Bleed the low pressure circuit.

Place a container under the filter: – Disconnect the return hose at the

filter and block the filter. – Pump using the vacuum pump until

there is no air left. – Reconnect the return hose

immediately.

CR DELPHI 1.0



DIESEL INJECTION


13-82

PROGRAM No.: BE


TEST 2 ELECTRICAL CIRCUIT CHECK

Check the battery charge and ensure that

the alternator is working properly.

Is the charge circuit correct?

YES

Check the fuses.

Are the fuses correct?

YES

Check that the injection locking relay is inworking order.

Is the injection locking relay workingproperly?

YES

Check the earth strap.

Is the earth strap correct?

YES

The electrical circuit is OK.

NO

NO

NO

NO



Replace the dual relay.

Replace the earth strap.

CR DELPHI 1.0



DIESEL INJECTION


13-83

PROGRAM No.: BE


TEST 3 INJECTOR CHECK

Visually inspect the injector wells.

Is there diesel in the injector wells?

NO

Run the ISO injector cycle.

Can you hear the valve moving?

YES

Compare the return flow of the four injectors when hot using a measuringcylinder. See TEST 9.

Does one of the four injectors have agreater return flow than the others?

NO

YES

NO

YES

Injector ice leak, replace the injector.


Replace the injector with an unusuallyhigh return flow (leak at the valve).

CR DELPHI 1.0



DIESEL INJECTION


13-84

PROGRAM No.: BE


TEST 3

Cont'd

Disconnect and reconnect injector i.

Is there a noticeable change in enginenoise?

YES and i=4

The injector is sound.

NO

i=1

YESand i<4

i = i+1Replace injector iwith a new part.

CR DELPHI 1.0



DIESEL INJECTION


13-85

PROGRAM No.: BE


TEST 4 PARAMETER CHECK

Use the fault finding tool to check that C2I

corresponds to the injectors.

Is C2I correctly programmed?

YES

Do the electrical consumer statesdisplayed on the fault finding toolcorrespond to the actual states?

YES

Check the consistency of the engine

parameters.

NO

NO

Use the fault finding tool to programC2I into the memory, paying attention

to the cylinder numbers.

Perform the fault finding procedureand any necessary repairs.

CR DELPHI 1.0



DIESEL INJECTION


13-86

PROGRAM No.: BE


TEST 5 AIR INLET CIRCUIT CHECK

Check for the presence of a leak/intake of

air.

Presence of a leak/intake of air.

NO

Check the condition of the air filter.

Air filter ok.

YES

Check that the inlet manifold is notobstructed (dirty).

Is the inlet manifold blocked?

NO

Air circuit ok.

YES

NO

YES


Replace the air filter with a new part.

Clean the inlet manifold.

CR DELPHI 1.0



DIESEL INJECTION


13-87

PROGRAM No.: BE


TEST 6 COMPUTER CHECK

Check that the computer connectors are

locked correctly.

Are the connectors poorly locked?

NO


YES Lock the connectors correctly.

CR DELPHI 1.0



DIESEL INJECTION


13-88

PROGRAM No.: BE


TEST 7 HIGH PRESSURE PUMP CHECK

It is possible to check the flow of the highpressure pump without electrical consumers

as follows: – disconnect the fuel flow actuator

– electrically disconnect the four injectors

– connect the fault finding tool and check the

PR217 Rail pressure parameter screen

– run the starter motor for 10 seconds while

checking the pressure on the tool.

Does the rail pressure exceed 280 bar?

NO

Check the diesel fuel in the diesel filter

– disconnect the diesel supply and return

hoses from the filter. Block the filter inlets

and outlets straight away with appropriate

plugs.

– remove the filter from its support andshake it well keep the plugs in place and

empty the contents of the filter into a glass

container by lifting up a protective plug and

slackening the bleed screw.

Is there residue visible in the bottom of the container?

YES

Replace the entire injection system.

YES

NO

The pump is correct, carry out a fault

finding procedure on the injectors bychecking the return flow on the four

injectors.

(See TEST 9 checking injector tightness).

Carry out a fault finding procedure on the

injectors by checking the return flow of the

four injectors.

(See TEST 9 checking injector tightness).

Is test 9 correct?

NO YES

Replace the faulty

injector(s)

Replace the high

pressure pump.

CR DELPHI 1.0



DIESEL INJECTION


13-89

PROGRAM No.: BE


There is a command that tests the high pressure circuit tightness when the engine is running.This command can diagnose a leak on the high pressure circuit if a union is improperly fitted or bolted, but cannot

detect a small leak if a union is not torque tightened.

This command can only be used if the engine temperature is above 60˚C.

Activate command SC001 High pressure circuit tightness test and the engine automatically performs a cycle of

four accelerations up to 4000 rpm, then decelerates to raise the pressure in the rail. This is to check for leaks in the

high pressure circuit.

Be careful with any objects (tool or other) on the engine housing during the four cycles of the operation(possible vibrations).

Command SC001 can also check the leak flow of each injector to detect an internal leak from one or more

injectors. To do this, the engine temperature must be above 60 °C, and you must disconnect:

– The return hoses from the four injectors.

– Connect four 20 cm hoses in place of the return hoses.

– Immerse these four hoses in four graduated measuring cylinders.

Having made these preparations, start the engine, then let it run for 2 minutes at idle speed.

Activate command SC001 High pressure circuit tightness test.The engine automatically performs a cycle of four accelerations up to 4000 rpm then decelerates to raise the pressure

in the rail. This is to check for internal leaks in the injector return circuit.

When the cycle has ended, it is necessary to run it again to get a correct reading of the flow from each injector.

At the end of the two cycles, the flow from each injector should be approximately 16 ml. If the flow from one of the

injectors is over 16 ml, replace the faulty injector.

Be careful with any objects (tool or other) on the engine housing during the four cycles of the operation(possible vibrations).

TEST 8 HIGH PRESSURE CIRCUIT TIGHTNESS TEST

TEST 9 INJECTOR TIGHTNESS CHECK

CR DELPHI 1.0



DIESEL INJECTION


13-90

PROGRAM No.: BE


The plugged rail test enables the diagnostic tool to show, the performance of the high pressure pump whenstarting to give a precise diagnostic.

NOTE:IMPORTANT: before carrying out any work, connect the diagnostic tool, set up communication with the injection

computer and check that the injection rail is not under pressure (see parameter screen).

Wait until the fuel temperature drops.

Order the special high pressure injection circuit plug kit.

Fit the plugged rail – Remove the high pressure pipe linking the pump to the rail (see K9K engine Technical Note).

– Block the high pressure pump outlet and rail inlet, while preparing the tool . – Insert the test pipe olive into the taper of the high pressure pump outlet and finger tighten. – Insert the test pipe olive into the taper of the plugged rail inlet and finger tighten.

– Tighten the pipe union on the rail side to a torque of 2 daN.m. – Tighten the pipe union on the pump side to a torque of 2 daN.m.

– Disconnect the injector leak return pipe on the venturi then block it.

– Disconnect the pressure sensor on the rail, then reconnect it to the plugged rail one. – Connect a pipe to the discharge outlet of the plugged rail, then immerse it in a container

TEST: – Run the starter motor for a maximum of 10 seconds then read the rail pressure value on the parameter screen of

the fault finding tool.

During the test, the pump should maintain a pressure of approximately 1200 bar on starting.

If the pressure value is less than 1200 bar, the pump is faulty.

NOTE: Before dismantling depressurise using the discharge screw on the plugged rail.

Plugged rail removal

– Disconnect the pressure sensor on the plugged rail, then reconnect it to the one on the rail.

– Remove the high pressure test pipe.

– Block the high pressure pump outlet and rail inlet, while preparing the new high pressure pipe. – Fit the new pump rail high pressure pipe(see K9K engine technical note).

TEST 10 TEST WITH PLUGGED RAIL TOOL

CR DELPHI 1.0



DIESEL INJECTION

Fault finding - Customer complaints 13PROGRAM No.: BE

VDIAG No.: 04 and 08 Fault finding - Customer complaints

NOTES Only consult this customer complaint after a complete check using thediagnostic tool.

No communication with the computer CHART 1

Starting fault

The engine does not start CHART 2

The engine starts with difficulty or starts then stalls CHART 3

Starting difficult with warm engine CHART 4

Idle speed fault

Rough idle speed (pumping) CHART 5

Idle speed too high or too low CHART 6

Behaviour while driving

Unexpected acceleration/deceleration and engine stalling CHART 7

Response fault CHART 8

Engine stop (timing) CHART 9

Engine jerking CHART 10

Lack of power CHART 11

Too much power CHART 12

CR DELPHI 1.0

13-91



DIESEL INJECTION

Fault finding - Customer complaints 13

13-92

PROGRAM No.: BE


Road holding (continued)

Excessive consumption CHART 13

Overspeed when lifting off accelerator or changing gear CHART 14

Engine dies when pulling away CHART 15

The engine does not stop CHART 16

noise, odours or smoke

Clanking engine, noisy engine CHART 17

Squalling noise CHART 18

Varied mechanical noise CHART 19

Exhaust odours CHART 20

Diesel odours CHART 21

Blue, white or black smoke CHART 22

Smoke (blue, white or black) on acceleration CHART 23

CR DELPHI 1.0



DIESEL INJECTION

Diagnostic - Fault finding charts 13

13-93

PROGRAM No.: BE

VDIAG No.: 04 and 08 Diagnostic - Fault finding charts

CHART 1 NO DIALOGUE WITH THE COMPUTER


Try the diagnostic tool on another vehicle.

Check the computer earth point on the left hand front shock absorber cage.

Check: – the connection between the diagnostic tool and the diagnostic socket (wiring in good condition),

– the engine and passenger compartment fuses.

Check for the presence of + 12 volts before ignition on track 16, + 12 volts after ignition on track 1 and an

earth on tracks 4 and 5 of the diagnostic socket.


Connect the bornier and check the insulation, continuity and absence of interference resistance of theconnections:

computer connector C track G2 track 5 main relay

computer connector C track H2 track 5 main relaycomputer connector A track D1 + after ignition (fuse box)

computer connector C track F1 track 2 main relay (relay control)

computer connector C track G1 earthcomputer connector C track H1 earthcomputer connector A track B4 track 7 of the diagnostic socket (line K)


CR DELPHI 1.0



DIESEL INJECTION


13-94

PROGRAM No.: BE


CHART 2 THE ENGINE DOES NOT START


Check that the fuel tank is correctly filledand that the fuel type is suitable.

Is the fuel type suitable and the tankcorrectly filled?

YES

Is the starter motor working properly?

YES

Check the low pressure circuit: TEST 1.

Check for leaks in the high pressurecircuit.

Check the electrical circuit: TEST 2.

NO

NO

Refill the fuel tank correctly.


CR DELPHI 1.0



DIESEL INJECTION


13-95

PROGRAM No.: BE


CHART 2

CONTINUED 1

Check the engine parameters: TEST 4.

Check the air inlet circuit: TEST 5.

Is the high pressure actuator blocked?

NO

Is the engine wiring harness cut off or

jammed?

NO

Check that the heater plugs are workingproperly.

Is the heater plug resistance above1 Ohm?

NO

YES

YES

YES



Replace the heater plugs.

CR DELPHI 1.0



DIESEL INJECTION


13-96

PROGRAM No.: BE

VDIAG No. 04 and 08

CHART 2

CONTINUED 2

Are the compressions correct?

YES

Check the injectors: TEST 3.

Check the high pressure pump: TEST 7.

Check the computer: TEST 6.

End of fault finding.

NO Carry out the required repairs.

AFTER REPAIR Check that the system is operating correctly.

CR DELPHI 1.0



DIESEL INJECTION


13-97

PROGRAM No.: BE


CHART 3THE ENGINE STARTS WITH DIFFICULTY OR STARTS THEN

STALLS



Is the fuel type suitable and the tankcorrectly filled?

YES




NO Refill the fuel tank correctly.

CR DELPHI 1.0



DIESEL INJECTION


13-98

PROGRAM No.: BE


CHART 3

CONTINUED 1




NO

Is the engine oil level correct?

YES

Is the catalytic converter sealed off or damaged?

NO

YES

NO

YES


Top up the oil.

Replace the catalytic converter.

CR DELPHI 1.0



DIESEL INJECTION


13-99

PROGRAM No.: BE


CHART 3

CONTINUED 2


jammed?

NO


Is the heater plug resistance over 1 Ohm?

NO


YES




YES

YES

NO




CR DELPHI 1.0



DIESEL INJECTION


13-100

PROGRAM No.: BE


CHART 4 STARTING DIFFICULT WITH WARM ENGINE







NO


YES

YES

NO



CR DELPHI 1.0



DIESEL INJECTION


13-101

PROGRAM No.: BE


CHART 4

Cont'd


jammed?

NO



YES Carry out the required repairs.

CR DELPHI 1.0



DIESEL INJECTION


13-102

PROGRAM No.: BE


CHART 5 ROUGH IDLE SPEED (PUMPING)




Is the engine wiring harness cut off or jammed?

NO


NO


YES

YES



CR DELPHI 1.0



DIESEL INJECTION


13-103

PROGRAM No.: BE


CHART 5

Cont'd

Check that the heater plugs are working

properly.


NO


YES




YES

NO



CR DELPHI 1.0



DIESEL INJECTION


13-104

PROGRAM No.: BE


CHART 6 IDLE SPEED TOO HIGH/TOO LOW




Is the clutch linkage correct?

YES



NO Carry out the required repairs.

CR DELPHI 1.0



DIESEL INJECTION


13-105

PROGRAM No.: BE


CHART 7UNEXPECTED ACCELERATION/DECELERATION AND ENGINE

STALLING





NO


Check that the engine has not aspiratedits oil (engine stalls).

NO

YES

YES



CR DELPHI 1.0



DIESEL INJECTION


13-106

PROGRAM No.: BE


CHART 7

Cont'd



CR DELPHI 1.0



DIESEL INJECTION


13-107

PROGRAM No.: BE


CHART 8 RESPONSE FAULT




Check that the turbocharger is workingproperly.

Is the turbocharger correct?

YES



YES

NO

NO



CR DELPHI 1.0



DIESEL INJECTION


13-108

PROGRAM No.: BE


CHART 8

Cont'd

Check for leaks in the high pressure

circuit.


NO





CR DELPHI 1.0



DIESEL INJECTION


13-109

PROGRAM No.: BE


CHART 9 ENGINE STOP/STALLING



Is the fuel type suitable and the tank

correctly filled?

YES


Check for leaks in the high pressure

circuit.



NO

NO Refill the fuel tank correctly.

CR DELPHI 1.0



DIESEL INJECTION


13-110

PROGRAM No.: BE


CHART 9

CONTINUED 1



NO


NO


NO


NO

YES

YES

YES

YES





CR DELPHI 1.0





DIESEL INJECTION


13-112

PROGRAM No.: BE


CHART 10 ENGINE JERKING



Is the fuel type suitable and the tank

correctly filled?

YES




NO

NO

YES

Refill the fuel tank correctly.


CR DELPHI 1.0



DIESEL INJECTION


13-113

PROGRAM No.: BE


CHART 10

CONTINUED 1


properly.


NO


YES

Is the valve clearance properly adjusted?

YES


YES

NO

NO



Make the necessary adjustments.

CR DELPHI 1.0



DIESEL INJECTION


13-114

PROGRAM No.: BE


CHART 10

CONTINUED 2



CR DELPHI 1.0



DIESEL INJECTION


13-115

PROGRAM No.: BE


CHART 11 LACK OF POWER





YES


NO



YES

NO

YES

NO

Top up the oil.



CR DELPHI 1.0



DIESEL INJECTION


13-116

PROGRAM No.: BE


CHART 11

Cont'd




YES


YES


NO

NO



CR DELPHI 1.0



DIESEL INJECTION


13-117

PROGRAM No.: BE


CHART 12 Too much power





NO





CR DELPHI 1.0



DIESEL INJECTION


13-118

PROGRAM No.: BE


CHART 13 EXCESSIVE CONSUMPTION



Does the high pressure actuator have: aleak?

NO

Is the diesel temperature sensor leaking?

NO




YES

YES


Replace the diesel temperature

sensor.

CR DELPHI 1.0



DIESEL INJECTION


13-119

PROGRAM No.: BE


CHART 13

CONTINUED 1



YES

Is the catalytic converter clogged or damaged?

NO



YES


YES

NO

YES

NO

NO

Top up the oil.




CR DELPHI 1.0



DIESEL INJECTION


13-120

PROGRAM No.: BE


CHART 13

CONTINUED 2



CR DELPHI 1.0



DIESEL INJECTION


13-121

PROGRAM No.: BE


CHART 14OVERSPEED WHEN LIFTING OFF ACCELERATOR OR

CHANGING GEAR



Is the engine wiring harness cut or

pinched?

NO

Is the clutch linkage properly adjusted?

YES


NO



YES

YES

NO

YES

NO





CR DELPHI 1.0



DIESEL INJECTION


13-122

PROGRAM No.: BE


CHART 14

Cont'd




CR DELPHI 1.0



DIESEL INJECTION


13-123

PROGRAM No.: BE


CHART 15 ENGINE DIES ON PULLING AWAY






NO


YES

YES

NO



CR DELPHI 1.0



DIESEL INJECTION


13-124

PROGRAM No.: BE


CHART 15

Cont'd


pinched?

NO


NO



YES

YES



CR DELPHI 1.0



DIESEL INJECTION


13-125

PROGRAM No.: BE


CHART 16 THE ENGINE DOES NOT STOP



Check that the engine has not aspirated

its oil (engine stalls).

NO




CR DELPHI 1.0



DIESEL INJECTION


13-126

PROGRAM No.: BE


CHART 17 CLANKING ENGINE, NOISY ENGINE






NO


YES


YES

NO



CR DELPHI 1.0



DIESEL INJECTION


13-127

PROGRAM No.: BE


CHART 17

Continued



CR DELPHI 1.0



DIESEL INJECTION


13-128

PROGRAM No.: BE


CHART 18 SQUALLING NOISE



Is the engine wiring harness cut or pinched?

NO


NO



YES

YES



CR DELPHI 1.0



DIESEL INJECTION


13-129

PROGRAM No.: BE


CHART 19 VARIOUS MECHANICAL NOISES


Check that the injectors are not making abuzzing noise (injector discharge).

NO

Are the mounting clips on the injector pipes broken or missing?

NO



NO


YES

YES

YES




CR DELPHI 1.0



DIESEL INJECTION


13-130

PROGRAM No.: BE


CHART 19

Cont'd



YES



YES


YES


NO

NO

NO




CR DELPHI 1.0



DIESEL INJECTION


13-131

PROGRAM No.: BE


CHART 20 EXHAUST ODOURS





NO



YES


YES

YES

NO

NO



Top up the oil.

CR DELPHI 1.0



DIESEL INJECTION


13-132

PROGRAM No.: BE


CHART 20

Cont'd

Is the catalytic converter clogged or

damaged?

NO




YES Replace the catalytic converter.

CR DELPHI 1.0



DIESEL INJECTION


13-133

PROGRAM No.: BE


CHART 21 DIESEL ODOURS



Is the high pressure actuator leaking?

NO

Is the diesel temperature sensor leaking?

NO




YES

YES


Replace the diesel temperaturesensor.

CR DELPHI 1.0



DIESEL INJECTION


13-134

PROGRAM No.: BE


CHART 22 BLUE, WHITE OR BLACK SMOKE





NO


YES



NO

YES

NO

YES


Top up the oil.


CR DELPHI 1.0



DIESEL INJECTION


13-135

PROGRAM No.: BE


CHART 22

Cont'd

Check that the engine has not aspirated

its oil (engine stalls).

NO


properly.


NO


YES



YES

YES

NO




CR DELPHI 1.0



DIESEL INJECTION


13-136

PROGRAM No.: BE


CHART 23 BLUE, BLACK OR WHITE SMOKE WHEN ACCELERATING






YES



YES

NO

NO

Top up the oil.


CR DELPHI 1.0



DIESEL INJECTION


13-137

PROGRAM No.: BE


CHART 23

CONTINUED 1

Is the catalytic converter clogged or

damaged?

NO


NO


Is the heater plug resistance above

1 Ohm?

NO


YES

Check for leaks in the high pressurecircuit

YES

YES

YES

NO





CR DELPHI 1.0



DIESEL INJECTION

Diagnostic - Fault finding charts 13PROGRAM No.: BE


CHART 23

Cont'd


pinched?

NO





Technical Note 3529a Xb07 - Xk07

Documents