DIESEL INJECTION

Fault finding – Replacement of components

COMPUTER REPLACEMENT, PROGRAMMING AND REPROGRAMMING OPERATIONS

The system can be programmed via the diagnostic socket using the diagnostic tool (see Technical Note 3585A
Computer programming and reprogramming procedure and Technical Note 9869A Computer programming
and reprogramming procedure and follow the instructions given by the diagnostic tool).

IMPORTANT
– Switch on the diagnostic tool (mains or cigarette lighter supply).
– Connect a battery charger.
– Switch off all electrical consumers (lights, interior lights, air conditioning, radio/CD, etc.).
– Wait for the engine to cool (engine coolant temperature below 60˚C and air temperature below 50˚C).

IMPORTANT
It is not possible to try an injection computer coming from the Parts Department because it will no longer be possible
to use it on another vehicle.

Before removing a computer in After-Sales, always save the computer data with the diagnostic tool by running
command SC003 Save computer data. This command saves the following information:
– C2I parameters (individual injector correction) and engine parameters,
– measuring system data,
– injection system reset data.
Any time the computer has been programmed:
– Switch off the ignition.
– Switch on the ignition and use the diagnostic tool to carry out the following steps:
– Use command SC001 Write saved data to restore the C2I and the engine adaptive programming.
– Run command VP010 Write VIN.
– Run command AC028 Static test.
– Run command AC154 Low speed fan assembly to test the operation of the 1st speed fan assembly.
– Run command AC153 High speed fan assembly to test the operation of the 2nd speed fan assembly.
– Run command AC250 Heating resistor 1 relay to test the operation of passenger compartment heating resistor 1.
– Run command AC251 Heating resistor 2 relay to test the operation of passenger compartment heating resistor 2.
– Run command AC100 Stop electrical consumer inhibition.
– Use command AC212 New pump chamber filling.
– Run the starter motor without releasing the key until the engine starts (the reprime time of the pump until the engine
starts can be up to 20 seconds).
– After the engine has started, refer to ET637 New pump chamber filling and check that it is Done. If not, repeat
the starting procedure.
– Stop the engine, switch off the ignition (to initialise the computer), and wait 30 seconds.
– After injection system programming, stored faults may appear in other computers.
– If DF1083 Water in diesel fuel warning light circuit appears in the injection computer: on a vehicle fitted with
a water in diesel fuel warning light, perform the fault finding operations described in DF1083 then run command
AC028 Static test again; on other vehicles, do not deal with the fault.
– Clear the computer memory RZ001 Fault memory.

IMPORTANT
AFTER A (RE)PROGRAMMING OPERATION, DO NOT DISCONNECT THE BATTERY FOR AT LEAST
30 MINUTES (to carry out other work on the vehicle).

Note:
If commands SC003 Save computer data and SC001 Write saved data do not work or were forgotten: after
programming the computer, write the C2I for each injector manually by reading the C2I on each injector
(see Replacement of injectors).
 Fault finding – Replacement of components

REPLACING THE INJECTORS

Note:
C2I (individual injector correction) is a calibration carried out in the factory on each injector to adjust the flow
of each injector precisely.
The correction values are written on a label affixed to each injector, then entered in the injection computer, which
can then actuate each injector by taking account of their manufacturing variation.

The system can be set up via the diagnostic socket using the diagnostic tool.

The C2I parameters must be replaced after replacing an injector/injectors.

To do this, reprogram C2I into the injection computer using the following commands:
- VP001 Cylinder 1 injector for the cylinder 1 injector (cylinder on the flywheel end),
- VP002 Cylinder 2 injector for the cylinder 2 injector,
- VP003 Cylinder 3 injector for the cylinder 3 injector,
- VP004 Cylinder 4 injector for the cylinder 4 injector.

It is also possible to enter the four C2I using command SC002 Enter injector codes.

Only after simultaneously replacing at least three injectors, reset the injector programming adaptives, using
command RZ004 Pressure regulation programming adaptives.

HIGH PRESSURE PUMP REPLACEMENT

IMPORTANT
When reprogramming the computer, carry out the following procedure only after command AC028 Static
test has been run (see Computer reprogramming operation).

PROCEDURE
– Switch on the ignition and use the diagnostic tool to re-establish dialogue with the injection computer.
– Use command AC212 New pump chamber filling.
– Run the starter (Important: the repriming time until the engine starts can be up to 20 seconds).
– After the engine has started, refer to ET637 Fill new pump chamber and check that it is Done; if not, repeat
the starting procedure.

REPLACING THE EGR VALVE

If the EGR valve is replaced, program the new valve's offset position.
Switch on the ignition and use the diagnostic tool to perform the following step:
– run command RZ002 EGR adaptives to clear the old offset using the EGR programming clearing procedure.

IMPORTANT
Do not use this command if the valve is not new.