Chevrolet

TABLE OF CONTENTS
SPECIAL FEATURES OF THE SYSTEM I
REMOVING / REFITTING SYSTEM COMPONENTS II
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APPENDICES III
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Produced and published by:

Delphi France SAS
Diesel Aftermarket
12 - 14 Boulevard de l’industrie Tel: (+33) (0) 2 54 55 39 39
41042 Blois Cedex Fax: (+33) (0) 2 54 55 39 12
France http://www.delphi.com/am
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 i

I SPECIAL FEATURES OF THE SYSTEM
TABLE OF CONTENTS
1. CHEVROLET Z20D Z22D ENGINE SPECIFICATIONS

1.1 Z20D/Z22D Engine Specifications................................................................................................................................1-1
2. PARTS SUPPLIED BY DELPHI
2.1 High pressure pump ....................................................................................................................................................2-3
2.1.1 DFP3.2 high pressure pump........................................................................................................................2-3
2.1.2 Inlet metering valve (IMV)...........................................................................................................................2-4
2.1.3 HP outlet........................................................................................................................................................2-4
2.1.4 Pressure limiter............................................................................................................................................2-5
2.1.5 LP unions......................................................................................................................................................2-5
2.1.6 Venturi...........................................................................................................................................................2-6
2.2 Rail .................................................................................................................................................................................2-7
2.2.1 Tubular rail....................................................................................................................................................2-7
2.2.2 Rail pressure sensor (HPS)..........................................................................................................................2-8
2.3 Injectors..........................................................................................................................................................................2-8
2.4 DCU..............................................................................................................................................................................2-10
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3. PARTS NOT SUPPLIED BY DELPHI
3.1 HP pipes.......................................................................................................................................................................3-11
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3.2 Filter..............................................................................................................................................................................3-11
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3.2.1 Diesel filter..................................................................................................................................................3-12
3.2.2 Fuel temperature sensor............................................................................................................................3-12
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3.2.3 Water detector............................................................................................................................................3-12

3.2.4 Heater..........................................................................................................................................................3-13
3.3 Electric Priming Pump................................................................................................................................................3-13
4. SPECIAL FEATURES OF THE COMMON RAIL SYSTEM
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4.1 Fuel Supply/Air Supply...............................................................................................................................................4-15

4.2 Electrical supply..........................................................................................................................................................4-16
4.2.1 Switch on DCU...........................................................................................................................................4-16
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4.2.2 Sensor supply.............................................................................................................................................4-17

4.3 The Immobiliser..........................................................................................................................................................4-17
4.3.1 Function......................................................................................................................................................4-17
4.3.2 Communication between the immobiliser and the DCU........................................................................4-17
4.3.3 Functional description...............................................................................................................................4-18
4.3.4 Replacing the DCU.....................................................................................................................................4-18
4.3.5 Synchronising the DCU and the immobiliser..........................................................................................4-18
4.3.6 Reading immobiliser faults.......................................................................................................................4-18
4.4 Diagnostics..................................................................................................................................................................4-19
4.4.1 Diagnostic communication........................................................................................................................4-19
4.4.2 Diagnostic socket.......................................................................................................................................4-19
4.5 Dashboard warning LEDs...........................................................................................................................................4-20
4.5.1 Description..................................................................................................................................................4-20
4.5.2 The fault LED..............................................................................................................................................4-20
4.5.3 Preheating LED...........................................................................................................................................4-21
4.5.4 Immobiliser light........................................................................................................................................4-21
4.5.5 Presence of water in the diesel filter LED.................................................................................................4-21
4.6 DCU Inputs/Outputs....................................................................................................................................................4-23
© Delphi
ii DDNX384(EN) - Issue 1 of 12/2011

TABLE OF CONTENTS
4.7 Pre-post heating..........................................................................................................................................................4-26
4.7.1 Function......................................................................................................................................................4-26
4.7.2 Control circuit.............................................................................................................................................4-26
4.7.3 Preheating...................................................................................................................................................4-26
4.7.4 Postheating.................................................................................................................................................4-26
4.7.5 Diagnostics.................................................................................................................................................4-27
4.8 Engine cooling.............................................................................................................................................................4-27
4.8.1 Function......................................................................................................................................................4-27
4.8.2 Control circuit.............................................................................................................................................4-27
4.8.3 Control strategy..........................................................................................................................................4-28
4.9 Particle filter.................................................................................................................................................................4-28
4.9.1 Particle filter................................................................................................................................................4-28
4.9.2 Particle filter differential pressure sensor................................................................................................4-29
4.10 EGR management.......................................................................................................................................................4-29
4.10.1 Principle......................................................................................................................................................4-29
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4.10.2 Function......................................................................................................................................................4-29
4.10.3 EGR setting.................................................................................................................................................4-30
4.10.4 EGR valve....................................................................................................................................................4-30
4.10.5
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Throttle Valve.............................................................................................................................................4-31
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4.10.6 Swirl valve..................................................................................................................................................4-31
4.10.7 EGR Cooler Bypass....................................................................................................................................4-32
4.10.8 Air flowmeter..............................................................................................................................................4-32
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4.11 Air conditioning (AC) checks......................................................................................................................................4-32

4.11.1 Function......................................................................................................................................................4-32
4.11.2 Components...............................................................................................................................................4-32
4.11.3 Compressor control circuit........................................................................................................................4-33
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4.11.4 Compressor activation...............................................................................................................................4-34

4.11.5 Air conditioning request............................................................................................................................4-34
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4.12 The water heaters........................................................................................................................................................4-34

4.12.1 Function......................................................................................................................................................4-34
4.12.2 Control circuit.............................................................................................................................................4-34
4.13 The CAN.......................................................................................................................................................................4-35
4.13.1 Function......................................................................................................................................................4-35
4.13.2 Description..................................................................................................................................................4-35
4.13.3 Fault type....................................................................................................................................................4-36
4.14 Camshaft sensor..........................................................................................................................................................4-37
4.15 Crankshaft sensor........................................................................................................................................................4-37
4.16 Accelerometer sensor.................................................................................................................................................4-37
4.17 Pedal sensor Double track..........................................................................................................................................4-39
4.17.1 Function......................................................................................................................................................4-39
4.17.2 Measuring circuit........................................................................................................................................4-39
4.17.3 Pedal position calculation..........................................................................................................................4-40
4.18 Vehicle Cruise Control / Speed Limiter......................................................................................................................4-40
4.18.1 Function......................................................................................................................................................4-40
4.18.2 Control circuit.............................................................................................................................................4-40
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 iii

TABLE OF CONTENTS
4.19 Clutch switches............................................................................................................................................................4-42
4.19.1 Function......................................................................................................................................................4-42
4.20 Brake pedal switch(es)................................................................................................................................................4-42
4.20.1 Function......................................................................................................................................................4-42
4.20.2 Description..................................................................................................................................................4-42
4.21 Turbocharging Pressure Control................................................................................................................................4-43
4.21.1 VGT boost pressure control......................................................................................................................4-43
4.22 Temperature sensors..................................................................................................................................................4-44
4.22.1 Coolant temperature..................................................................................................................................4-44
4.22.2 Fuel temperature........................................................................................................................................4-45
4.22.3 Boost air temperature................................................................................................................................4-45
4.22.4 Pre - VGT exhaust gas temperature..........................................................................................................4-46
4.22.5 Pre - catalyser exhaust gas temperature..................................................................................................4-46
4.22.6 Pre - DPF exhaust gas temperature..........................................................................................................4-47
4.23 Oxygen probe..............................................................................................................................................................4-47
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4.23.1 Oxygen probe.............................................................................................................................................4-47
4.23.2 Oxygen probe heater.................................................................................................................................4-47
5. COMPONENT PLACEMENT
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5.1 Component location ...................................................................................................................................................5-49
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5.1.1 Engine compartment.................................................................................................................................5-49
5.1.2 Passenger compartment ...........................................................................................................................5-50
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© Delphi
iv DDNX384(EN) - Issue 1 of 12/2011

TABLE OF CONTENTS
6. SUMMARIES
6.1 Cleanliness conditions................................................................................................................................................6-51
6.2 Plugs and Caps............................................................................................................................................................6-52
6.3 Fuel Filter.....................................................................................................................................................................6-53
6.4 Rail/Injector high pressure pipe.................................................................................................................................6-54
6.5 Injector.........................................................................................................................................................................6-55
6.6 Rail................................................................................................................................................................................6-57
6.7 Pump/Rail high pressure pipe....................................................................................................................................6-58
6.8 High pressure pump...................................................................................................................................................6-59
6.9 Venturi..........................................................................................................................................................................6-61
6.10 Inlet metering valve (IMV)..........................................................................................................................................6-62
6.11 Fuel temperature sensor.............................................................................................................................................6-64
6.12 DCU..............................................................................................................................................................................6-65
6.13 Torque settings............................................................................................................................................................6-66
6.14 Schedule......................................................................................................................................................................6-67
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7. PRELIMINARY OPERATIONS
8. REMOVING/REFITTING THE FUEL FILTER
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8.1 Removing the filter......................................................................................................................................................8-71
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8.1.1 SUV..............................................................................................................................................................8-71
8.1.2 Saloon/PCV.................................................................................................................................................8-72
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8.2 Preparing the filter......................................................................................................................................................8-72

8.3 Refitting the filter.........................................................................................................................................................8-72
9. REMOVING/REFITTING THE RAIL/INJECTOR HIGH PRESSURE PIPES
9.1 Removing the rail/Injector high pressure pipe ........................................................................................................9-73
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9.2 Preparing the rail/Injector high pressure pipe .........................................................................................................9-74

9.3 Refitting the rail/Injector high pressure pipe............................................................................................................9-74
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10. REMOVING / REFITTING AN INJECTOR

10.1 Removing the injector...............................................................................................................................................10-75
10.2 Preparing an injector.................................................................................................................................................10-76
10.3 Refitting the injector..................................................................................................................................................10-77
11. REMOVING / REFITTING RAIL
11.1 Removing the rail......................................................................................................................................................11-79
11.2 Preparing the Rail......................................................................................................................................................11-80
11.3 Refitting the Rail........................................................................................................................................................11-80
12. REMOVING/REFITTING THE HIGH PRESSURE PUMP AND ASSOCIATED COMPONENTS
12.1 Removing/Refitting the HP pump/Rail HP pipe.......................................................................................................12-81
12.1.1 Removing the pump/rail HP pipe ...........................................................................................................12-81
12.1.2 Preparing the pump/rail HP pipe.............................................................................................................12-82
12.1.3 Refitting the pump/rail HP pipe...............................................................................................................12-82
12.2 Removing/Refitting the Venturi................................................................................................................................12-82
12.3 Removing/Refitting the IMV.....................................................................................................................................12-82
12.3.1 Removing the IMV....................................................................................................................................12-83
12.3.2 Preparing the IMV....................................................................................................................................12-84
12.3.3 Refitting the IMV.......................................................................................................................................12-84
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 v

II REMOVING / REFITTING SYSTEM COMPONENTS
TABLE OF CONTENTS
12.4 Removing/Refitting the fuel temperature sensor...................................................................................................12-85
12.4.1 Removing the fuel temperature sensor..................................................................................................12-85
12.4.2 Preparing the fuel temperature sensor..................................................................................................12-85
12.4.3 Refitting the fuel temperature sensor.....................................................................................................12-85
12.5 Removing/refitting the High Pressure Pump. ........................................................................................................12-87
12.5.1 Removing the HP pump...........................................................................................................................12-87
12.5.2 Preparing the HP pump ..........................................................................................................................12-90
12.5.3 Refitting the HP pump..............................................................................................................................12-90
13. REMOVING/REFITTING THE DCU
13.1 Removing the DCU....................................................................................................................................................13-93
13.2 Preparing the DCU....................................................................................................................................................13-93
13.3 REFITTING THE DCU.................................................................................................................................................13-94
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© Delphi
vi DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
TABLE OF CONTENTS
14. REFERENCE VALUES

14.1 Reference values.......................................................................................................................................................14-95
15. WIRING DIAGRAM
15.1 Wiring diagram........................................................................................................................................................15-101
15.1.1 Wiring diagram - 96 pin connector.......................................................................................................15-101
15.1.2 Wiring diagram - 58 pin connector.......................................................................................................15-102
16. TOOLING
16.1 Tooling required......................................................................................................................................................16-103
16.1.1 Special tooling........................................................................................................................................16-103
16.1.2 Standard tooling.....................................................................................................................................16-103
16.1.3 Consumables summary.........................................................................................................................16-105
16.1.4 Repair harness range.............................................................................................................................16-105
17. ABBREVIATIONS
17.1 Abbreviations/Descriptions....................................................................................................................................17-107
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© Delphi
DDNX384(EN) - Issue 1 of 12/2011 vii

III APPENDICES
TABLE OF CONTENTS
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© Delphi
viii DDNX384(EN) - Issue 1 of 12/2011

CHEVROLET Z20D Z22D ENGINE SPECIFICATIONS

This manual presents the specific features of the Common Rail injection system fitted on the Z20D and Z22D engines
fitted to CHEVROLET vehicles and all information relating to fault finding.
The DELPHI Common Rail injection system is described in the Common Rail Manual "Operating Principles" binder :
DDGX200B".
1.1 Z20D/Z22D Engine Specifications
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CAPTIVA Z22D Euro V

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© Delphi
DDNX384(EN) - Issue 1 of 12/2011 1-1

CHEVROLET Z20D Z22D ENGINE SPECIFICATIONS
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CRUZE Z20D Euro V / ORLANDO Z20D Euro V
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Z20D Z22D
Layout 4 in-line cylinders with direct injection
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Layout Transverse
Cubic capacity 1,998 cm3 2,231 cm3
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Bore x stroke 86 x 86 mm 86 x 96 mm
Number of valves 4
per cylinder
Timing Two overhead camshafts driven by a chain
Inlet air cooling Air/Air exchanger
Turbocharging By variable geometry turbocharger
Maximum power 130(bhp) at 3800 163(bhp) at 3800 rpm 163(bhp) at 3800 rpm 184(bhp) at 3800 rpm
rpm
Maximum torque 315 Nm at 2750 rpm 360 Nm at 2750 rpm 360 Nm at 2750 rpm 400 Nm at 2750 rpm
Maximum no load 4800 rpm
engine speed
Compression ratio 16.3
© Delphi
1-2 DDNX384(EN) - Issue 1 of 12/2011

PARTS SUPPLIED BY DELPHI

DELPHI supplies the following original fitment parts:
• The HP pump with a filling actuator(IMV), a venturi and a pressure limiter.
• A tubular rail with a rail pressure sensor.
• Four injectors.
• A DCU.
2.1 High pressure pump
Operation:
The fuel sent to the pump is controlled by a filling actuator known as the Inlet Metering Valve (IMV). High pressure is
generated by a DFP3.2 type HP pump. The pressure is then stored in a rail and sent to the injectors via HP pipes.
The filling actuator (IMV) is fed by an electric priming pump in the fuel tank.
A venturi incorporated in the pump body regulates the vacuum in the injector return circuit.
The integrated high pressure pump :
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• A pressure stage managed by an IMV.
• A pressure limiter
• A venturi.
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2.1.1 DFP3.2 high pressure pump
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The pump has the following inlets/outlets :

• Fuel inlet.
• High pressure outlet (rail supply).
• Low pressure outlet (fuel return).
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Specifications :
High pressure pump
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• Pumping chamber : 0.97 cm3/pump

revolution.
• High pressure regulation by the IMV.
• Integrated pressure limiter (see paragraph
on Pressure limiter).
• Oldham coupling.
• Drive ratio 1/2.
• Maximum speed 2700 rpm (peaks to 3500
rpm).
• External temperature range : -30°C to +120°C.
The high pressure fuel generated by the HP pump is stored in the tubular injection rail and redistributed via HP
pipes to the injectors.
It is driven via an Oldham coupling on the pump drive shaft.
The pressure can be checked using the H3PI kit YDT278, YDT410 and the HP-T kit YDT465.
CAUTION
For all operations, all openings must be plugged using clean plugs from the dispenser YDT480.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 2-3


2.1.2 Inlet metering valve (IMV)
The IMV regulates the quantity of fuel delivered to

the HP pump pumping elements to control the
pressure in the rail.
Specifications :
• Supply voltage : +Vbat.
• Control signal : PWM between 300 Hz and
2000 Hz depending on rpm.
• Nominal control current : between 0 and 1.3
A.
• Maximum current : 1.6 A.
• Resistance : 5.3 Ω at 20 .
It is located on the pump. Diagnostics can be carried

out with the kit YDT330B.
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The pressure can be checked using the H3PI kit
YDT278, YDT410 and the HP-T kit YDT465.
2.1.3 HP outlet
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The pump has a high pressure connector to connect
it to the rail via a 1/4 inch (6.35 mm external) HP pipe.
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HP outlet diameter : M14 x 1.5 mm.

It is fitted in the main housing.
CAUTION
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This part should only be manipulated in accordance

with the relevant safety, cleanliness and torque
recommendations (see specific operations).
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A counter torque is required for all tightening/

slackening operations on the HP tube.
This part does not require any network intervention.
© Delphi
2-4 DDNX384(EN) - Issue 1 of 12/2011


2.1.4 Pressure limiter
This unit mechanically limits the pressure to 2150

bar +/- 100 bar.
It discharges the pressure on an ad hoc basis if
IMV regulation is no longer active or if discharge via
the injectors is not being managed.
The fuel is returned to the tank via the LP backleak
circuit.
This component does not require any network
intervention.
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2.1.5 LP unions
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The pump has several LP connectors (screwed into the main housing) :
• An inlet feed from the electric priming pump.
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• A return for the fuel returning to the tank.
Z20D engine
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• The inlet diameter is 9.89 mm. It is straight

with respect to the pump body.
• The return diameter is 8 mm.
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These are quickfit type connectors with flexible

plastic locking tabs.
These parts do not require any network
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intervention.
Z22D engine
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 2-5


• The inlet diameter is 7.89 mm. It is elbowed
with respect to the pump body.
• The return diameter is 8 mm.
These parts do not require any network

intervention.
These are quickfit type connectors with metal
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locking tabs (4). These connectors can be
disconnected with the YDT597 tool.
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2.1.6 Venturi
It is integral with the pump body.

The venturi creates a vacuum in the injector return
circuit. It reduces any variation in flow to injectors
(stroke to stroke).
The injector return is connected to the venturi
double canal system.
© Delphi
2-6 DDNX384(EN) - Issue 1 of 12/2011

2.2 Rail
The rail is a high pressure accumulator. It is supplied by the HP pump and functions as a high pressure reserve for the
injectors.
It is made up of the following elements :
• A tubular body.
• A rail pressure sensor (HPS)
• A pump inlet.
• 4 injector outlets with integral jets.
The jets help absorb the pressure waves to limit instability. They cannot be removed from the rail body.
2.2.1 Tubular rail
Specifications :
• Dry weight : 1.185 kg.
• Volume : 17.5 cm3.
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• Maximum operating pressure 2200 bar.
• Burst pressure > 7000 Bar.
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CAUTION
For all operations, all openings must be plugged using clean plugs from the dispenser YDT480.
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CAUTION
When the engine is stopped, fuel is still pressurised in the rail. It is vital to wait before working on the system.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 2-7


2.2.2 Rail pressure sensor (HPS)
The HP sensor transmits the rail pressure value to

the DCU. This value is used to calculate the flow and
injection advance.
It consists of a membrane that deforms due to the
fuel pressure. The deformation is converted into an
electrical value representing the rail pressure level.
It supplies a voltage proportional to the fuel
pressure.
CAUTION
It is not permitted to remove it as there is a risk of
contaminating the system.
Specifications :
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• Supply voltage : 5 V ±0.1 V.
• Measurement range : from 0 to 1800 bar.
• Maximum pressure : 2300 bar.
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• Sensor type : KOSTAL
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It is located on the end of the rail. Diagnostics can
be carried out with the kit YDT330C.
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2.3 Injectors
The injector is a DFI1.5 type and conforms to Euro V standards.

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© Delphi
2-8 DDNX384(EN) - Issue 1 of 12/2011


The DFI1.5 incorporates several design changes :
• The valve and adaptor plate are combined in a
single unit.
• There is a radial inlet.
• The individual calibration uses a 20 alphanumeric
C3I.
Specifications :
Injector :
• Opening controlled by electric pulse.
• Peak pull current : 22 A min to 24 A max.
• Peak holding current: 6 A min to 8 A max.
• Pull duration : approximately 260 μs (indicative
value for a battery voltage of 12 V).
• Resistance : between 0.155 Ω and 0.185 Ω at 20 .
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• Multiple injection possible: separate pilot, close
pilot, main, close post and separate post.
• Maximum pressure : 1800 bar.
• Number of holes : 8.
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• Vacuum : 300 mbar.
• Sealing washer : a copper washer is fitted between
the cylinder head and the injector contact face.
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- Z20D : thickness 3 mm.

- Z22D : thickness 2 mm.
They are located in the cylinder head wells with a specific position for the correct orientation of the injection jets and are
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supplied with fuel by the HP pipes.

Electrical supply is ensured by a connector (2 pin) locked
to the injector body. Each injector has its own connector.
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Diagnostics can be carried out using the YDT479 kit.

For ease of assembly in the body plant, the n°4 injector
is connected to the main engine harness via a sub-
harness.
No fuel can be injected if the DCU is off or if a control
wire is cut.
CAUTION
During an operation, the connections and surrounding area must be protected from fuel spills. All openings to be plugged
using clean plugs from the dispenser (YDT480) .
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 2-9

2.4 DCU
The DCU is a DCM3.7 type. It manages the engine by

applying various strategies depending on running
conditions (idle, full load...).
Main characteristics are:
• Normal operating voltage: from 10V to 16V.
• 96 way connector.
• 58 way connector.
• Motorola 32 bit microprocessor.
The DCU controls the following functions :

• Voltage supply.
• Immobiliser.
• Pre-post heating.
• Engine cooling.
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• EGR. DCU DCM3.7 - 154 pins
• Air conditioning cut-out.
• Water heater control.
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• Boost pressure control
• Cruise control.
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• The fuel flow and the advance.

• System diagnostics.
It is fitted vertically next to the battery. It can be connected using the kit YDT374 (YDT375 + YDT376) with the kit
YDT175 (terminal box) to gain access to the DCU pins.
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© Delphi
2-10 DDNX384(EN) - Issue 1 of 12/2011

PARTS NOT SUPPLIED BY DELPHI

DELPHI does not supply the following original fitment parts:
• The HP pipes.
• The fuel filter.
3.1 HP pipes
The DELPHI injection systems for the GMDAT

applications Z20D and Z22D have 5 HP pipes. Each
injector has a specific HP pipe.
Pump/Rail pipe
• It feeds high pressure fuel from the pump to the
rail.
- Internal diameter : 3 mm.
- External diameter : 6.35 mm.
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- Length : 295.1 ± 0.5 mm.
- Maximum operating pressure : 1800 bar.
- Max peak pressure : 2100 bar.
Rail / injector pipes
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• They distribute fuel from the rail to the injectors.
- Internal diameter : 3 mm.
- External diameter : 6.35 mm.
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- Length : 190.6 ± 0.5 mm.

- Maximum operating pressure : 1800 bar.
- Max peak pressure : 2100 bar.
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CAUTION
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Operations on the HP pipes must follow the safety and cleanliness instructions and the correct sequence(see specific
operations). For all operations, all openings must be plugged using clean plugs from the dispenser YDT480.
3.2 Filter
The DELPHI injection system for the GMDAT

applications Z20D and Z22D are fitted with a fuel filter.
There are 2 versions depending on the engine type.
For the 2 applications Z20D and Z22D, the filter
integrates :
• A fuel temperature sensor.
• A water detector.
• A heater.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 3-11


3.2.1 Diesel filter
The filter is located under the vehicle on the right hand side near the rear wheel.
Specifications :
• Filtration efficiency:
> 4 μm 84.26 %.
> 5 μm 96.47 %.
> 6 μm 99.92 %.
> 10 μm 99.99 %.
> 20 μm 99.99 %.
> 30 μm 100 %.
3.2.2 Fuel temperature sensor
The diesel temperature sensor is in the HP pump

low pressure circuit. It is used in the injection
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control strategy to apply corrections for fuel
temperature. It is also used to protect the system in
cases of excessively high fuel temperatures.
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This is a combination sensor with the fuel heater on
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the filter.
Specifications :
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• Supply voltage : +5 V ±0.25 V.

• Thermistor type : negative temperature
coefficient (resistance decreases as
temperature increases).
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• Resistance : 2.057 kΩ at 25 °C.

• Measurement range : -30 to +110 .
• Equivalent impedance range : 26.114 kΩ at 144
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Ω.
The sensor can be electrically checked with the

YDT538C kit.
3.2.3 Water detector
It is integral with the filter and protects the injection

system by detecting the presence of water in the
fuel.
Specifications :
• Detection level: 170 ml.
• Maximum current : less than 200 mA.

YDT529C kit.
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3-12 DDNX384(EN) - Issue 1 of 12/2011


3.2.4 Heater
It is integral with the filter and can heat the fuel to

the correct operating temperature for the injection
system.
The heater control is integrated with the
combination temperature sensor on the filter.
Specifications :
• Z20D heater : 210W.
• Z22D heater : 250W.
• Maximum current : 21 A.

YDT538C kit.
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3.3 Electric Priming Pump
The system includes an external priming pump. It is located in the tank and supplies the HP pump.
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It has an integrated regulator to maintain the fuel pressure at the correct level for the engine speed.
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Specifications :
• Z20D : Bosch.
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• Z22D : Kafus.
• Fuel flow : 215 l/h at 380 kPa under 12 V.
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© Delphi
DDNX384(EN) - Issue 1 of 12/2011 3-13

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/2 C
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© Delphi
3-14 DDNX384(EN) - Issue 1 of 12/2011

SPECIAL FEATURES OF THE COMMON RAIL SYSTEM
4.1 Fuel Supply/Air Supply
ENGINE LAYOUT Z20D 2.0l – Z22D 2.2l Euro V

HPS
T2 P2
Inlet air duct
Rail
Swirl valve
EGR
IMV
HP pump
Injectors Venturi
Preheating Filter +
Exchanger
EGR cooler
Heater
1 Fuel T˚
2
Oil pump 4
3 Tank
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Electric priming
pump
Cool air
6 5
Exhaust gas
Oil
01 o Bypass
Heating radiator
Coolan (pneumatic)
/2 C
t oil
Diesel Thermostat
unit
Radiator
T3
02 nce
Water pump Expansion tank
M
T1 AMF
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T5
O2 T4
VGT
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1
Air filter
CATA DPF EXHAUST GAS
OUTLET
FRESH AIR P4
INLET
SENSORS & ACTUATORS
T1 Inlet air temperature 1 Accelerometer sensor (x2) Throttle Valve

T2 Boost air temperature. 2 Camshaft sensor
AMF Air flowmeter
T3 PreVGT Temperature 3 Crankshaft sensor
DPF Particle filter
T4 Temperature upstream of catalyser 4 Oil level sensor
VGT
T5 Pre-DPF Temperature 5 Variable Geometry Turbo with :

Coolant temperature sensor
pneumatic actuator position sensor
P2 Boost air pressure
6 Oil pressure sensor
P4 Particle filter differential pressure sensor
O2 Oxygen probe
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-15

4.2 Electrical supply
4.2.1 Switch on DCU

When the ignition signal goes to terminal 19 in the 58 pin connector, the DCU controls the supply relay by earthing
terminal 45 (58 pin connector). If the relay is stuck, the following components are supplied by Pbatt (+12 V protected
by the fuse and the main relay) :
• The injection DCU.
• Inlet metering valve (IMV)
• The EGR solenoid valve.
• The VGT solenoid valve.
• The oxygen probe and its heater.
• The air flowmeter.
The DCU is supplied :

• When the ignition is switched on.
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• Before and after starting.
• When the engine is running.
• During and just after engine stop in order to carry out key-off tests, memory write, programming and engine
fan cooling.
01 o
/2 C
02 nce
Main supply relay T87

F1
Pbatt
201
F4 Pbatt
203
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Pbatt
205
T15
F2 245
Ignition key 219
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Starter relay
DCU
211
IGN_2
Accessory
F3 Vehicle
012 wake
electrical 212
Key switch system
+
Battery 12V
-
Earth
202
Earth
204
Earth
206
1xx = Engine connector 96 way

2xx = Vehicle connector 58 way
© Delphi
4-16 DDNX384(EN) - Issue 1 of 12/2011

CAUTION
Before disconnecting the DCU or any other electronic component of the common rail system (valves, sensors,
injectors), wait for the end of the power latch phase (approximately 10 seconds).
4.2.2 Sensor supply

The DCU generates three independent 5 Volt supplies (Vreft 1, Vref 2 and Vref 3) for all the system sensors.
These 3 supplies are protected against short circuits to earth and Vbatt as well as overloads.
Sensor supply allocation
• Vref1 :
- Engine speed sensor (maximum consumption: 15 mA).
- Cam sensor (maximum consumption : 15 mA).
- Rail pressure sensor (maximum consumption: 10 mA).
- N°1 pedal position sensor (maximum consumption : 5 mA).
• Vref2 :
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- Inlet pressure sensor (maximum consumption: 12.5 mA).
- Brake circuit pressure sensor (maximum consumption 15 mA).
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- Swirl position sensor (maximum consumption 15 mA).
- Coolant pressure sensor (maximum consumption: 7 mA).
/2 C
- Particle filter differential pressure sensor (maximum consumption 10 mA).
- N°2 pedal position sensor (maximum consumption : 5mA).
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- Vehicle speed sensor/TOSS (Transmission Output Shaft Speed) (maximum consumption : 15 mA).
• Vref3 :
- VGT position sensor (maximum consumption 15 mA).
- Air flap valve position sensor (maximum consumption 15 mA).
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- EGR position sensor (maximum consumption: 15 mA).

- Clutch and brake pedal position sensor (maximum consumption : 5 mA).
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- AT neutral position sensor (maximum consumption: 15 mA).

- ECO Mode control (maximum consumption : 15mA).
- Oil pressure sensor (maximum consumption: 12 mA).
4.3 The Immobiliser
4.3.1 Function
The engine immobiliser increases vehicle protection in the event of an attempted theft. It prevents fuel injection
control using the DCU.
4.3.2 Communication between the immobiliser and the DCU

The system uses a master-slave relationship. The DCU is the master control and always initiates any
communication.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-17


4.3.3 Functional description
Injection authorisation/prevention immobilisation has several steps :
• Step n°1 : The DCU generates a random code and sends it to the immobiliser.
• Step n°2 : The DCU and the immobiliser calculate the unlocking code from the random code.
• Step n°3 : The immobiliser sends the unlocking code to the DCU.
• Step n°4 : The DCU compares the unlocking code which it has calculated with the code received from the
immobiliser. If the two codes match, the engine may be started.
If the two codes are different, steps 1, 2 and 3 are repeated. If the two codes do not correspond after several
attempts, the immobiliser stays locked and will prevent the engine from starting.
Note:
- If the immobiliser does not respond to the DCU and the vehicle configuration is "without immobiliser", the
engine may be started.
- If the immobiliser does not respond to the DCU and the vehicle configuration is "with immobiliser", the
engine may not be started.
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- The engine cannot be started if the coded key is not identified correctly or if the key transponder does not
communicate with the immobiliser.
01 o
/2 C
4.3.4 Replacing the DCU
The DCU may only be replaced by the vehicle manufacturer's network so that the new DCU may be matched,
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coded and programmed.
Note:
Access to these services is restricted by a coded program protected by the vehicle manufacturer and
which is therefore not available.
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These services can therefore only be executed by the manufacturer's diagnostic tool.
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4.3.5 Synchronising the DCU and the immobiliser.

Synchronising consists of matching the injection DCU and the immobiliser. It must be performed when replacing
a DCU or the immobiliser to activate the engine immobiliser.
Note:
Synchronisation is a service linked to the immobiliser. This service is secure and can only be
accessed via the vehicle manufacturer's diagnostic tool.
4.3.6 Reading immobiliser faults

The injection DCU can store faults linked to the immobiliser:
List of possible faults:
• No response.
• Incorrect response.
• Functions not activated.
• NVM fault.
• General fault.
© Delphi
4-18 DDNX384(EN) - Issue 1 of 12/2011

4.4 Diagnostics
4.4.1 Diagnostic communication

Diagnosis of the injection system is performed via the CAN link in the DCU. This link connects terminals 47
and 48 of the 58 pin DCU connector to terminals 14 and 6 of the vehicle OBD socket.
Diagnostics are performed by the UDS communication protocol.
4.4.2 Diagnostic socket.

These vehicles are fitted with a 16 pin OBD socket. Communication between DIAMAND and the DCU is via the
"standard" YDT452 cable.
Diagnostic socket pin allocation

Diagnostic socket type Pin no. Description
1 positive IGN
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4 and 5 Earth
01 o 6 CAN H
14 CAN L
/2 C
16 positive batt
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For this application, it is located :

• Under the dashboard on the driver side (LHD or RHD).
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CAPTIVA diagnostic socket location.

© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-19

ORLANDO diagnostic socket location.
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01 o
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02 nce
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CRUZE diagnostic socket location.
4.5 Dashboard warning LEDs
4.5.1 Description
The following instrument panel warning LEDs are managed by the DCU via the CAN :
• Fault light.
• Preheating light.
• Immobiliser light.
• The fuel filter LED (water present in the fuel).
• Cruise control light.
• DPF clogged LED.
4.5.2 The fault LED

This indicates a fault in the injection system which requires immediate attention in the Aftermarket network.
© Delphi
4-20 DDNX384(EN) - Issue 1 of 12/2011

Engine status Light status(Normal system operation) Light status(Permanent serious fault at
key on)
Pre-start Permanently on(illumination time limited to 2 Permanently on
s.)
Starting and engine running Off Permanently on when limp home mode is
active
4.5.3 Preheating LED

It indicates the preheater plug activation to aid combustion during the starting phase. When the preheating LED
is on continuously, it indicates the preheating phase.
When the LED goes out, the preheating phase has finished and the driver may start the engine.
Engine status Light status(Normal system operation) LED status(fault detected by the pre-post
heating unit)
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Pre-start Permanently on (time on is a function of the Off
01 o coolant temperature, the battery voltage and
the atmospheric pressure and is limited to 60
s)
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Starting and engine running Off Off
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4.5.4 Immobiliser light

This indicates the operating status of the engine immobiliser system.
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LED status Possible indications

Light permanently on Communication running between the DCU and the immobiliser unit.
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DCU and immobiliser unit not synchronised.

Light off Communication established. Engine authorised to start.
Immobiliser unit not connected.
Engine stopped.
Immobiliser not installed.
Light flashing (2Hz) Fault detected on the engine immobiliser system.
Communication error between the DCU and the immobiliser unit.
Pairing invalid.
Key recognition or programming problem.
4.5.5 Presence of water in the diesel filter LED

This informs the driver that there is water in the diesel fuel filter.
Engine status Light status(Normal system operation) Light status(if water is detected in diesel
fuel filter)
Pre-start Permanently on(illumination time limited to 15 Permanently on
s.)
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-21

Engine status Light status(Normal system operation) Light status(if water is detected in diesel
fuel filter)
Starting and engine running Off Permanently on
Synchronised Permanently on Permanently on
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© Delphi
4-22 DDNX384(EN) - Issue 1 of 12/2011

4.6 DCU Inputs/Outputs
5 6 46
73 96 58
33
49 72 45
3 4
20
25 48 32
1 2 7
1 24 19
96 pin connector (identified 1xx on the wiring diagram)
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Pins Role Pins Role
1 Not used 01 o 2 Not used
3 Injector control cylinder - 4 - HSD 4 Air Temperature sensor (analogue)
/2 C
5 Pre-DPF temperature sensor signal 6 Pre - VGT temperature sensor signal
7 Exhaust gas temperature signal before the catalytic 8 Particle filter differential pressure sensor signal
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converter
9 Coolant temperature signal 10 Fuel temperature signal
11 VGT position signal 12 Boost pressure sensor signal
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13 Brake circuit pressure signal 14 Swirl position signal

15 Flap valve position analogue signal (Throttle) 16 EGR valve position signal
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17 Clutch or brake pedal position signal 18 Not used

19 Rail pressure sensor earth 20 Gearbox neutral position sensor earth
21 Brake circuit pressure sensor earth 22 Pre-DPF temperature sensor earth
23 Pre - VGT temperature sensor earth 24 Temperature sensor pre-catalyser earth.
25 Injector control cylinder 4 - LSD 26 Injector control cylinder 1 - LSD
27 Injector control cylinder - 1 - HSD 28 Accelerometer n°1 sensor shield
29 Accelerometer n°2 sensor shield 30 Accelerometer n°1 Sensor Earth
31 Accelerometer n°1 Sensor Signal 32 Accelerometer n°2 sensor signal
33 Accelerometer n°2 sensor Earth 34 Boost air temperature signal
35 Rail pressure sensor signal 36 Not used
37 Oil pressure sensor supply 38 Rail pressure sensor supply (Vref1)
39 Crank sensor supply (Vref1) 40 Camshaft sensor supply (Vref1)
41 Boost pressure sensor supply (Vref2) 42 Brake circuit pressure sensor supply
43 Swirl valve supply (Vref2) 44 DPF differential pressure sensor earth
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-23

Pins Role Pins Role

45 Coolant temperature sensor earth 46 Fuel temperature sensor earth
47 Camshaft sensor earth 48 VGT position sensor earth
49 Not used 50 Injector control cylinder - 2 - HSD
51 Injector control cylinder - 3 - HSD 52 Gearbox neutral position switch (AutoTrans)
53 Gearbox position sensor signal 54 Oxygen probe compensation resistance
55 Oxygen probe pump current 56 Oxygen probe nernst voltage
57 Oxygen probe virtual earth 58 Air flowmeter signal (frequency)
59 Camshaft sensor signal 60 Crank sensor signal
61 VGT supply (Vref3) 62 Gearbox position sensor supply (Vref3)
63 Flap valve position sensor (Throttle - Vref3) 64 EGR valve position supply (Vref3)
65 ECO Mode supply 66 DPF differential pressure sensor supply (Vref2)
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67 Turbo pressure sensor earth 01 o 68 Temperature sensor earth
69 Swirl valve position sensor earth 70 Flap valve position sensor earth (Throttle)
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71 Air temperature sensor earth (Air flow sensor) 72 EGR valve position sensor earth
73 Not used 74 Injector control cylinder 2 - LSD
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75 Injector control cylinder 3 - LSD 76 Air flowmeter supply (if not supplied by Pbatt)
77 Inlet metering valve control (PWM) 78 Brake pedal signal (Normally open)
79 Alternator control signal 80 Alternator load signal
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81 Not used 82 Oxygen probe heater control

83 Flap valve negative control (Throttle) 84 Flap valve positive control (Throttle)
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85 Fan n°1 control / Fan controller 86 EGR valve cooler bypass control
87 Crank sensor earth 88 VGT control (PWM)
89 Swirl valve control 90 EGR valve positive control
91 EGR valve negative control 92 Not used
93 Not used 94 ECO mode
95 Water in the fuel detector 96 Oil pressure sensor
58 pin connector pin allocation (identified 2xx on the wiring diagram)

Pins Role Pins Role
1 Protected DCU supply Pbatt 2 DCU earth
7 Priming pump control HSD 8 Coolant pressure sensor signal
9 Fuel level sensor n°1 signal 10 Vehicle Speed Sensor / TOSS (transmission drive shaft
speed) sensor
© Delphi
4-24 DDNX384(EN) - Issue 1 of 12/2011

Pins Role Pins Role

11 Starter relay control HSD 12 Ancillary control data
13 Signal from (Track 2) accelerator pedal sensor 14 Earth (Track 2) accelerator pedal sensor
15 Temperature sensor signal 16 Reverse gear switch signal
17 Pre-post heating unit diagnostic 18 Clutch pedal sensor signal - disengaged position
(Normally open)
19 Ignition key signal 20 Coolant pressure sensor earth
21 Vehicle speed sensor earth 22 AC refrigerant pressure sensor supply (Vref2)
23 Clutch / brake pedal position sensor supply (Vref3) 24 Accelerator pedal sensor track 1 supply (Vref1)
25 Signal from (Track 1) accelerator pedal sensor 26 Earth (Track 1) accelerator pedal sensor
27 Vehicle speed / TOSS sensor signal 28 Oil level sensor (frequency)
29 Accelerator pedal sensor track 2 supply (Vref1) 30 Brake pedal switch + brake LED signal(Normally closed)
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31 Not used 32 Clutch pedal switch signal (Normally open)
33 Fuel level sensor n°1 earth 34 Clutch / brake pedal position sensor earth
01 o
35 Fuel level sensor n°2 signal 36 Fan n°2 control
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37 Auxiliary heater relay control 38 Water heater control n°1
39 Fuel level sensor n°2 earth 40 Water heater sensor control
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41 Air conditioning relay control 42 Fan n°3 control

43 Oil vapour heater relay control 44 Not used
45 Main DUC supply 46 Pre-heater unit control
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47 CAN Low 48 CAN High

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49 Oil pump control 50 Fuel heater relay control

51 Water pump control Version 2012 52 Oil pressure sensor earth Version 2012
53 Not used 54 Not used
55 MIL LED 56 Water heater n°2 and n°3 control
57 Flowmeter switch LSD 58 Not used
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-25

4.7 Pre-post heating
4.7.1 Function
The preheater plugs are located next to each

injector to heat the air around the injector nozzle.
They are controlled by the pre-post heating unit
next to the battery.
This heating is necessary to ensure that the diesel
fuel ignites when the temperature is low.
Preheating is used in the engine starting phase
(minimum time to reach idle) and may continue if
the external temperature is very low (post heating).
Preheating time is therefore a function of the
external temperature and the engine coolant
temperature.
The unit is located either in front of the battery
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(Z20D) or behind it (Z22D).
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4.7.2 Control circuit
/2 C
The supply to the plugs is controlled by the injection DCU via the pre-post heating unit. The command is only
authorised when the supply voltage is less than 18 V to avoid damaging the preheating plugs with excess voltage.
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Specifications :
• Nominal plug supply voltage 4.4 V ±0.1 V.
• Operating temperature range: -40°C to 105°C (ambient temperature).
• Time taken to reach 1000°C : 3 s.
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• Temperature after 60 s (nominal voltage) : Between 950 and 1050 .

• Nominal current after 60 s : minimum 5.2 A and maximum 8.2 A.
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• Voltage profile : 11 V ± 0.1 V for 1.9 s then 4.4V ± 0.1 V for 58.1s.
4.7.3 Preheating
The preheating phase begins as soon as the ignition is switched on. It involves:
• Illumination of the preheating LED.
• Supplying the preheating plugs.
The duration of preheating is determined according to the engine coolant temperature:
Engine coolant temperature (°C)

–35 –25 –20 –10 0 10 20 30
Preheating duration (s)
31 22 19 17 14 0 0 0
4.7.4 Postheating
Postheating is when the heater plugs are supplied after starting the engine when the outside temperature is too
low. The preheating light is not on during postheating. The duration of preheating is determined according to the
engine coolant temperature:
© Delphi
4-26 DDNX384(EN) - Issue 1 of 12/2011

Engine coolant temperature (°C)

–30 –20 –10 0 20 30 40 60
Postheating duration (s)
115 80 30 19 11 11 0 0
However, the supply to the plugs may be interrupted momentarily, depending on the torque demand.
• If the request exceeds an upper threshold, the plugs are not supplied.
• If it falls below a lower threshold, they are supplied.
4.7.5 Diagnostics
The pre-postheating unit (PPH unit) has a diagnostic function which can detect :
• Short circuits and open circuits on the plug supply.
• Pre-post heating unit supply faults
• Communication faults with DCU.
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• Internal faults (PPH unit).
• Faults linked to pre-post heater unit temperature.
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After key on, the DCU asks the unit for diagnostic information. The DCU generates a fault code specific to each
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type of fault.
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4.8 Engine cooling
4.8.1 Function
The DCU controls the engine cooling fan units during and after engine operation. To do this, the system takes
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into account the coolant temperature and aircon cooling requirements.

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The Z20D and Z22D engines are fitted with 3 fan units. They are controlled by the DCU as follows :
• Fan n°1 : PWM signal or control relay (depending on vehicle specification).
• Fan n°2 : Control relay.
• Fan n°3 : Control relay.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-27


4.8.3 Control strategy
The fan strategy and speed control depend on :
• The engine status (running, stopped).
• Coolant temperature.
• Engine oil temperature.
• Gearbox oil temperature.
• Refrigerant pressure measurement (AC).
• Particle filter regeneration.
4.9 Particle filter
4.9.1 Particle filter
A) Principle
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The particle filter is able to satisfy current anti-pollution standards. It is located downstream of the catalytic
converter, but upstream of the exhaust silencer. This system enables - under certain conditions - the burning of
any soot particles in the exhaust gases that have been stopped by the filter. This combustion takes place at very
01 o
high temperature (approximately 650°C) and destroys most of the particles that passed through the catalytic
converter.
/2 C
B) Activation
The strategy is able to activate regeneration under three different sets of conditions:
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• When the pressure difference between particle filter entry and exit shows that the filter is heavily loaded
• When the previous regeneration cycle took place 1000 km ago
• When the agent launches the routine with the diagnostic tool
• When several regeneration attempts have failed.
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Other conditions must also be satisfied to ensure satisfactory regeneration:

• Catalytic converter temperature greater than 315°C.
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• Filter temperature greater than 650 .

C) Strategy
In order to generate the high temperature needed for particle filter regeneration, the strategy can :
• Increase the amount of fuel injected
• Add two post-injections
• Under-set the main injection
• Reduce turbo pressure (in relation to the required normal operating pressure)
• Close the flap valve for mow torque settings (town/traffic jam running).
© Delphi
4-28 DDNX384(EN) - Issue 1 of 12/2011


4.9.2 Particle filter differential pressure sensor
The sensor measures the difference in exhaust gas

pressure throughout the assembly (Catalyser /
Particle Filter). This data is required to manage the
DPF regeneration schedule to avoid clogging.
Specifications :
• Power supply : +5 V ±0.25 V.
• Maximum current : 10 mA.
• Accuracy : ± 3 kPa.
• Measurable vacuum level : -20 kPa to 120 kPa.
• Operating temperature : -40 to +140 .
It is located. Diagnostics can be carried out with the
kit YDT559B.
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4.10 EGR management
01 o
/2 C
4.10.1 Principle
The exhaust gas recirculation system (EGR) is used

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to divert part of the exhaust gases to the engine's

air inlet in order to reduce the excess air and the
temperature in the combustion chamber. This
device therefore provides a significant reduction in
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nitrogen oxide emissions from the exhaust.

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4.10.2 Function
The EGR valve is directly controlled by the DCU. The EGR valve control signal is determined depending on the
EGR setting and the air flow measured by the flowmeter. The position is copied to the DCU.
EGR regulation is activated if the following conditions are met:
• Engine running.
• Sufficient torque requested.
• Idle duration less than 1 seconds.
• Engine speed between 0 and 2600 rpm.
• Coolant temperature between 0 and 100 °C.
• Atmospheric pressure greater than 920 mbar.
• Vehicle speed less than 100 km/h.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-29


4.10.3 EGR setting
The EGR setting is calculated from a main "engine speed / indicated torque" map. It is adjusted as a function of:
• Coolant temperature
• Inlet air temperature.
• Atmospheric pressure.
• Turbo pressure loop difference.
The EGR setting directly indicates the fresh air flow which should be allowed and is measured by the flowmeter.
It increases with engine speed and torque and is therefore inversely proportional to the volume of exhaust gas.
4.10.4 EGR valve
It is located in the exhaust gas return to the inlet

circuit. The valve allows the quantity of exhaust gas
sent to the inlet to be regulated.
• Power supply : + Vbatt.
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• Response time (position 10% to 90% / position
90% to 10%) : 120 ms (opening) / 90 ms
01 o
(closing).
• Maximum operating temperature : +550°C
/2 C
(Exhaust gas)..
• Electric stops : 0.9 V ± 0.1 to +3 V.
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• Mechanical stops : 0 mm (closed position) to

8 mm (open position).
• Maximum current : 8.7 A.
• Motor coil resistance : 1.45 to 3.45 Ω
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(depending on the position).

It is located next to the flowmeter in front of the air
hose. Diagnostics can be carried out with the kit
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YDT529D.
Note:
The EGR flap remains completely open in the full load and high engine speed zones.
© Delphi
4-30 DDNX384(EN) - Issue 1 of 12/2011


4.10.5 Throttle Valve
It is located in the inlet air circuit. Closing this flap

decreases the amount of fresh air entering the
engine and consequently increases the EGR rate
when recycling is operational.
Diagnostics can be carried out with the kit
YDT710C.
• Supply voltage: 12 V.
• Normal operating voltage : 9 V to 17 V.
• Operating temperature : ±40 to +125
• Response times : 70 ms maximum (position
10% to 90%).
• Motor resistance : 1.9 Ω ± 10%.
The flap stops are as follows :
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• Electrical : 4.5 V ± 0.147 to 0.790 V ± 0.152.
• Mechanical : 4 deg ± 0.25 to 93 deg ± 1.
4.10.6 Swirl valve

01 o
/2 C
It is located in the inlet air circuit. This creates a
vortex effect in the air entering each cylinder. The
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fuel/air mix is therefore more regular improving

combustion.
It is managed by a PWM signal to the pneumatic
swirl control solenoid.
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The swirl control (2 way solenoid valve) diagnostics

can be carried out using the kit YDT246B and the
copy signal (3 way) with the kit YDT559B.
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• Supply (position sensor) 5 V ± 0.25.

• Operating range: 0 to 100%
• Operating temperature : -40 to 140 .
• Frequency range (PWM) : 150 to 350 Hz
• Solenoid vacuum : -900 mbar ±10.
• Motor coil resistance : 15.5 Ω ± 10%.
• Position sensor resistance 20 Ω
• Position sensor resolution 5 mV.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-31


4.10.7 EGR Cooler Bypass
It cools the exhaust gases sent to the EGR valve.

The flap is controlled pneumatically. The exhaust
gases are cooled when the valve is open;
conversely, when the valve is closed, the gases are
sent directly to the inlet. The valve operation period
is limited to the vehicle starting phase.
It is controlled by a PWM signal sent to a pneumatic
solenoid valve.
• EGR gas temperature - inlet : 480 .
• Gas temperature - outlet : 155 .

YDT521B.
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4.10.8 Air flowmeter
01 o
The flowmeter informs the DCU of the mass of cool
inlet air to allow the EGR flow and rate to be
/2 C
calculated in real time.
The flowmeter is a frequency type, it uses a hot-wire
02 nce
cell. The electronics measure the frequency at

which the detection cell cools in contact with the air.
The greater the cell cooling, the higher the air flow.
The frequency sent to the DCU is representative of
the quantity of air flowing in.
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It is located after the air filter. Electrical diagnostics

can be carried out using the kit YDT574C for the
Z20D.
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4.11 Air conditioning (AC) checks
4.11.1 Function
The air conditioning cools the passenger compartment by circulating a refrigerant through a heat exchanger
located in the passenger compartment ventilation circuit. A switch on the dashboard activates the air conditioning.
The air conditioning request information is transmitted directly to the injection DCU.
4.11.2 Components
The air conditioning circuit consists of:
• A compressor
This is designed to circulate the vaporised refrigerant in the circuit and thus increase its pressure.
• A condenser
This is a heat exchanger which cools the refrigerant and therefore converts it from the gaseous state at high
pressure to the liquid state at high pressure. To improve heat removal, the exchanger is located at the front
of the vehicle.
© Delphi
4-32 DDNX384(EN) - Issue 1 of 12/2011


• A dryer tank
This component is located in the high pressure part of the circuit and is designed to absorb moisture to
prevent component corrosion. It is also used to filter out impurities in the refrigerant.
• A pressostat
This is a safety device which is designed to prevent the compressor clutch operating when the pressure in
the circuit is not correct. Excessively low pressure will damage the compressor due to lack of lubrication.
Excessively high pressure will damage the thermal exchangers and the tubes.
• A pressure reducing valve
This is designed to decrease the pressure of the refrigerant suddenly to reduce its temperature greatly and
start evaporation. When the refrigerant leaves the pressure reduction valve it is in the form of a very cold
liquid and gas.
• An evaporator
This is a heat exchanger which is designed to cool the air passing through it which is then directed into the
passenger compartment. Most of the time this component is covered with condensed water. If the air
temperature drops too low, the water may freeze and block the air flow. To avoid this problem, the evaporator
is often fitted with a safety device called a thermostat, which prevents the air conditioning compressor from
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operating.
A refrigerant pressure sensor may also be fitted. This replaces the pressostat.
01 o
4.11.3 Compressor control circuit
/2 C
The compressor electromagnetic clutch is earthed by a relay controlled by the DCU, the ignition key provides the
+ 12V battery supply.
02 nce
Air conditioning control is managed by a button on the centre console. The DCU then manages the AC compressor
relay.
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© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-33


4.11.4 Compressor activation
The DCU controls the compressor supply if the following conditions are met:
• Air conditioning request detected.
• Engine running for at least 4 seconds.
• Coolant temperature greater than - 20 .
• Coolant temperature less than 115 .
• Engine speed less than 4500 rpm
• Min and Max pressostat contacts in closed position.
In transient operating conditions (heavy acceleration, moving off…),the DCU inhibits the operation of the air
conditioning compressor.
Control is managed by the DCU (A/C request) which manages the AC compressor. The DCU takes the AC request
into account when managing the engine (injections, engine load...).
4.11.5 Air conditioning request
2 py
This is detected by the DCU under the following conditions:
• A/C button pressed by the driver.
•
01 o
Min and Max pressostat contacts in closed position.
/2 C
The "air conditioning request" information is used in the following strategies:
• Management of the air conditioning compressor operation.
02 nce
• Engine cooling management (fan operation).

• Injection parameter management (accelerated idle…).
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4.12 The water heaters.
4.12.1 Function
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The direct injection engine is characterised by greater thermodynamic efficiency than an indirect injection engine,
due to the reduction in heat loss through the walls. The coolant temperature therefore increases more slowly in
a direct injection engine than it does in an indirect injection engine. However, the coolant is used by the passenger
compartment heating system. In very cold conditions, it is therefore difficult to reach a comfortable temperature
in the passenger compartment quickly.
To reduce the time taken to warm up the passenger compartment, heating resistors known as water heaters, are
located in the cooling circuit or in the passenger compartment air circuit. There are 3 fitted in this application.
Note:
The water heaters are located in the heater unit.

Each water heater is supplied by a relay controlled by the DCU. The ignition key provides the + 12V battery supply.
The water heater control strategy is linked to the battery voltage and the temperature requested.
Activation can be prevented under certain conditions :
• Battery voltage outside range.
• Engine speed outside range.
• Coolant temperature outside range.
• Engine stop status too long.
© Delphi
4-34 DDNX384(EN) - Issue 1 of 12/2011


• No air, coolant or heater temperature fault must be flagged.
• Heater(s) active for excessive time.

As WH1 has a different electrical power to WH2, three different heating powers can be obtained:
• 300 W => WH n°1 on & WH n°2 off.
• 600 W => WH n°1 off & WH n°2 on.
• 900 W => WH n°1 and WH n°2 on.
The water heaters are activated depending on the following parameters:

• Passenger compartment ventilation.
• Battery voltage.
• Engine temperature.
• Air temperature.
• Electrical consumer status : Fan, AC, pre-post heater unit.
2 py
Activation conditions : 01 o
=> Passenger compartment fan operating.
Operation of the water heaters is authorised by the injection DCU if and only if the passenger compartment
/2 C
fan is operating.
=> Coolant temperature & air temperature below a threshold

02 nce
Coolant temperature (°C) Air temperature (°C)

- 10 0 18 20
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10 Activated Activated Activated -

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85 - - - -
Shut-down conditions:
=> Engine speed less than 720 rpm
=> Battery voltage less than 11.5 V.
=> Fault detection.
4.13 The CAN
4.13.1 Function
The CAN (Controller Area Network) is a bus-based communication network which enables several signals to travel
between various electrical components with the least possible number of wires.
This allows great flexibility of use and protects signals from any interference (in the form of high frequency waves,
radiation, electrostatic discharges etc.).
4.13.2 Description
CAN communication requires an earth and two wire connections:
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-35


• C.A.N Low (CAN L).
• C.A.N High (CAN H).
All ECUs connected to the network send predefined messages (frames with ECU specific IDs) allowing them to
communicate with each other. CAN frames are chains of binary data. They are sent by an ECU to a single specific
destination ECU.
On the Z20D and Z22D engines, the injection DCU is connected to the CAN and can communicate with the
following units :
• The TCU (Transmission Control Unit)
• The TCCU (Transfer Case Control Unit)
• ABS (Anti Skid Brake System).
• Immobiliser (Key and remote opening management).
DCU
2 py
48 47
01 o
/2 C
CAN High
02 nce
CAN Low
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TCU TCCU ABS

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(Optional)
4.13.3 Fault type

The CAN may have three types of fault:
• Silence : the DCU is not communicating.
• Absent : no DCU in the network.
• Bus off : network problem.
© Delphi
4-36 DDNX384(EN) - Issue 1 of 12/2011

4.14 Camshaft sensor
This sensor is a Hall effect type. It detects the target

located on the camshaft. It therefore send a
corresponding square wave signal.
The DCU correlates the signal with the crankshaft sensor
signal to inject at the appropriate instant of the engine
cycle. Its loss prevents the engine from starting.
• Operating range: 10 to 4000 rpm.
• Power supply : +5 V (Vref1).
• Detection precision : ± 1,5°.
• Detection distance from the target : Between 0.5
mm and 1.5 mm.
It is located on the end of the camshaft on the timing side.
2 py
Diagnostics can be carried out with the kit YDT574A.
4.15 Crankshaft sensor

01 o
/2 C
This sensor is a Hall effect type. It measures the 58 teeth
and the 2-tooth gap of the target fixed on the flywheel. it
supplies a square wave signal corresponding to the
02 nce
detection of each tooth.

It is located on the gearbox housing near the engine
compartment bulkhead.
• Power supply : +5 V (Vref1).
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• Signal frequency depending on engine speed.
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• Speed detected : 20 to 8000 rpm.

• Detection distance from the target : Between 0.5
mm and 1.5 mm.
• Detection precision : ± 1,0°.
It is located on the engine housing near the cooling

radiator. Diagnostics can be carried out with the kit
YDT574A.
4.16 Accelerometer sensor
The accelerometers measure the combustion noise coming from each cylinder. There is one accelerometer for
each pair of cylinders. The strategy manages the following operations :
• Detecting injector leaks (if the injector is stuck open).
• Resetting the MDPs.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-37


This application uses two identical accelerometer
sensors located on the engine block. The harness is
shielded due to the risk of interference as the
sensors measure the combustion noise from each
cylinder.
They have an integrated piezo element that
converts the noise measured into an electrical
signal.
• Operating temperature : - 40 to +150 .
• Output voltage : 26 ± 8 mV/g (for a frequency
between 4 kHz and 8 kHz).
They are located on the engine block. Diagnostics

can be carried out with the kit YDT246A.
Detecting injector leaks (if the injector is stuck open).
2 py
Excess noise indicates that combustion is too strong, caused by too much fuel being injected into a cylinder. In
this case, the DCU reduces the pilot pulse and shifts the main injection to ensure that the increase in the
accelerometer signal effectively comes from a leak and not from an excessive pilot injection or an advanced main
injection.
01 o
/2 C
Resetting the MDPs.
Here we are considering the minimum drive pulse (MDP), the minimum pulse from which combustion can be
produced. Any pulse that is less than the MDP causes no combustion, as the coil energisation time is too short
02 nce
to lift the needle. To find this MDP, the strategy is to incrementally increase the pilot injection pulse bit by bit (in
steps of a few μs) from 0μs until the pulse provokes combustion from the pilot injection. Once this pulse value
has been found, it is deducted from the C3I physical value and saved in the DCU. This strategy is called the reset.
Six reset values in all are saved per injector. They are applied depending on rail pressure. These correction values
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are then added to the pulse request so as to compensate for system drift.
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© Delphi
4-38 DDNX384(EN) - Issue 1 of 12/2011

4.17 Pedal sensor Double track
4.17.1 Function
On electronic injection systems there is no load

lever to mechanically control the metering valve,
the position of which determines the injected flow
depending on how much the accelerator pedal is
pressed. The flow is calculated by the DCU as a
function of a large number of parameters, including
pedal position, which is measured using a
potentiometer.
The absence of a mechanical link between the
accelerator pedal and the injection system means
that there is a risk of losing control of the engine in
the event of a fault in the component responsible
for supplying the "driver request" information to the
2 py
injection system.
The pedal sensor therefore consists of two
potentiometers, whose sliders are mechanically
01 o
joined. The two potentiometers are supplied by
/2 C
distinct and separate voltage sources so two
redundant signals are supplied, which are
compared to provide reliable "driver request"
02 nce
information.
4.17.2 Measuring circuit

The two tracks are supplied by two sources with different voltages (see section Sensor supplies). Correlation
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between the two tracks is carried out to ensure the pedal position is reliable.
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• Response times : less than 100 ms.
• Track 1 supply : 5 V (Vref1).

• Track 2 supply : 5 V Vref2.
The two signals are sent to the injection DCU :

• Signal track 1 between 0 and 5 V.
• Signal track 2 between 0 and 5 V.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-39


4.17.3 Pedal position calculation
Before validating a pedal position, the DCU performs the following tests:
• It checks that there is no fault in the analogue-digital converter or in the supply to track 1.
• It checks that there is no fault in the analogue-digital converter or in the supply to track 2.
• It checks that the measurement made on track 1 is coherent.
• It checks that the measurement made on track 2 is coherent.
• It checks that there is no correlation fault between the measurement made on track 1 and that made on track
2.
• It checks the consistency between the positions of the brake pedal and the accelerator pedal.
When all these tests have been passed, the DCU validates the pedal position.
4.18 Vehicle Cruise Control / Speed Limiter
4.18.1 Function
2 py
Regulation : its role is to maintain a preset cruising
speed without the need to control the accelerator
01 o
pedal. Cruise control can be used on the motorway
/2 C
or other main roads where traffic is free flowing.
Limitation : its role is to limit vehicle speed to a
target preset by the driver. Vehicle speed is
02 nce
controlled by the accelerator pedal but may not

exceed the target. Cruise control can be used on the
motorway or other main roads where traffic is free
flowing.
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Steering wheel mounted Cruise Control button
Note:
It is possible to exceed the target speed in an emergency. The user can depress the accelerator pedal fully which
will deactivate the speed limit via a switch at the end of the pedal travel. It is of the "resistive" type.

The Cruise Control is managed via several buttons (mounted on the steering wheel controls).
• ON : activates or deactivates the function.
• RES / + : resumes the preset speed (used after deactivation)/increases the speed setting.
• SET / - : records the speed setting/reduces the speed setting.
• CANCEL : cancels the function .
Each button has a resistance value and hence a voltage read by the DCU. The DCU determines the request and
adapts the engine strategy accordingly (example : pressing the SET + button several times in succession requests
an increase in engine speed to reach the new target speed).

The strategy permanently monitors the following:
© Delphi
4-40 DDNX384(EN) - Issue 1 of 12/2011


• Vehicle speed:
The cruise control function requires a minimum vehicle speed of 40 km/h to operate. The cruise control cuts
out above 160 km/h.
• The accelerator pedal :
The driver may accelerate while in cruise control mode, as soon as he releases the accelerator, the cruise
control system returns to the last cruising speed.
• Brake pedal:
Any action at the brake pedal overrides the cruise control strategy. The driver must reset the cruising speed
to restore the strategy.
• The clutch pedal:
Cruise control is deactivated while the clutch pedal is being pressed in order to adapt the engine parameters
to this transition zone.
• Control:
The cruising speed setting can be increased or decreased whilst the cruise control is active (acceleration
and deceleration buttons).
2 py
The driver can temporarily suspend the cruise control function using the off switch.
01 o
/2 C
02 nce
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© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-41

4.19 Clutch switches
4.19.1 Function
The "declutching" information is used in the cruise

control strategy.
The clutch pedal is fitted with :
• A clutch-in or end of travel switch.
• A clutch-out or start of travel switch.
The variable changes when pedal travel starts.

Clutch pedal operation can therefore be detected.
2 py
01 o
4.20 Brake pedal switch(es)
/2 C
4.20.1 Function
02 nce
The braking information is used on the cruise control strategy to check the correlation between the positions of
the brake pedal and the accelerator pedal. A correlation fault is detected if the position of the accelerator pedal is
not zero when the brake pedal is being pressed (driver pressing both pedals).
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4.20.2 Description
The system comprises a main switch (stop switch)

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and a second redundant switch(safety switch).

When the vehicle decelerates suddenly, a
comparison is made between the two signals from
the stop switch and the safety switch to ascertain if
the braking information is correct.
The switches (main and safety) allow brake pedal
operation to be detected.
These consists of two types:
• "Normally closed" for the position "pressed".
• "Normally open" for the position "released".
© Delphi
4-42 DDNX384(EN) - Issue 1 of 12/2011

4.21 Turbocharging Pressure Control.
4.21.1 VGT boost pressure control

A) Function
The aim is to limit the turbine speed when the required maximum pressure is reached.
B) Description
The variable geometry turbo (VGT) is managed by the DCU. Its role is directly to modulate the turbo blade
positions.
The following sensors are present :
=> A turbocharging pressure sensor :
Its role is to provide the DCU with the inlet pressure value at the turbo outlet after the exchanger.
C) Variable geometry turbo actuator
Description
2 py
The variable geometry turbocharger is controlled
via a linked actuator.
01 o
/2 C
02 nce
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Diagnostics
The control circuit is diagnosed using conventional methods (detection of short circuit to earth, to +Vbatt or open
circuit) by the injection DCU.
The actuator also includes a self-diagnostic function that can detect the following three fault types:
• Supply voltage too high (>16 V) or too low (<8 V).
• Incorrect control signal.
• Internal fault.
The "internal fault" type covers the following faults:
• Actuator temperature too high.
• Unable to reach the setting (usually a mechanical fault)
• Stepping motor fault.
• Position sensor fault.
• Memory fault.
Any fault detected by the actuator is sent to the DCU by regular earthing of the control line if there is a fault on
the control line, the supply or an actuator internal fault. The earthing time depends on the fault type detected 1 s,
1.5 s, 2 s).
It is located between the cooling radiator and the engine. Position sensor diagnostics can be carried out with the
kit YDT538B. VGT solenoid valve diagnostics can be carried out with the kit YDT246A.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-43


Turbocharging pressure setting
When the inlet air flap is used during particle filter regeneration, the VGT actuator is control in open loop. The
VGT is also controlled in open loop in one part of the depollution zone. In all other instances it is controlled in a
closed loop.
Pressure regulation is managed as follows : the boost pressure requested by the DCU is compared to the pressure
read by the sensor and converted into exhaust pressure request. This request is then compared with the pressure
read by the exhaust pressure sensor (placed upstream of the EGR valve) and translated into a turbo blade setting.
Note:
The loading on the particle filter modifies the exhaust line back-pressure and thus the force acting on the turbo
blades.
Programming values
No programming values are set by the injection DCU.
4.22 Temperature sensors
2 py
4.22.1 Coolant temperature. 01 o
The coolant temperature probe is a negative
/2 C
temperature coefficient resistor. It allows the
engine temperature to be monitored and the fans
to be activated when required.
02 nce
• Operating range: -40 to 150 .

• Equivalent resistance range : 48.153 kΩ ± 5.92
% à 53.24 Ω ± 3.60%.
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The sensor can be electrically checked with the YDT521B kit. © Delphi
4-44 DDNX384(EN) - Issue 1 of 12/2011


4.22.2 Fuel temperature
The diesel temperature sensor is a negative

temperature coefficient resistor. The diesel
temperature value is used to correct the injection
parameters and also to protect the fuel tank in the
event of a critical temperature. This sensor is
mounted on the fuel filter.
• Measurement range : -30 to 110 .
• Equivalent impedance range : 26.114 kΩ at 144
Ω.
YDT529C kit.
2 py
4.22.3 Boost air temperature
This sensor is integrated in a combined pressure/

01 o
temperature sensor with the inlet air absolute
pressure sensor.
/2 C
It supplies the temperature of the cooled air leaving
the exchanger. This data allows the EGR dose to be
02 nce
calculated. The sensor values are also used in

various maps.
• Nominal resistance : 200 Ω at 0 .
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• Equivalent resistance range (Z20D) : 39.650

Ω at 97.11 Ω.
• Equivalent resistance range (Z22D) : 100.866
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Ω at 88.32 Ω.
It is fitted before the VGT (visible under the vehicle
when the engine protection is removed). The
connector is located under the air hose above the
pump. Diagnostics can be carried out with the kit
YDT538C.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-45


4.22.4 Pre - VGT exhaust gas temperature
The pre-VGT exhaust gas temperature sensor is a

platinum resistance using thin film technology. This
data allows VGT solenoid valve control strategy
management and boost air quantity control.
• Accuracy : ± 2.5 % between -40°C and 280°C/
± 0.9 % between 280°C and 850 °C.
• Response times : 5 s at 300°C/4 s at 600°C/3 s
at 800°C.
• Equivalent resistance range : 169.7 Ω ± 2;5(°C)
at 766.8 Ω ± 7;7(°C).
It is fitted before the VGT (visible under the vehicle
when the engine protection is removed). The
2 py
connector is located under the air hose above the
pump. Diagnostics can be carried out with the kit
YDT521B.
01 o
4.22.5 Pre - catalyser exhaust gas temperature
/2 C
The pre-VGT exhaust gas temperature sensor is a
02 nce

data allows VGT solenoid valve control strategy
management and boost air quantity control.
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± 0.9 % between 280°C and 850 °C.
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at 800°C.
at 766.8 Ω ± 7;7(°C).
It is located before the catalyser. Diagnostics can be
carried out with the kit YDT521B. © Delphi
4-46 DDNX384(EN) - Issue 1 of 12/2011


4.22.6 Pre - DPF exhaust gas temperature
The pre-DPF exhaust gas temperature sensor is a

data is used to manage the DPF regeneration
strategies among others.
± 0.9 % between 280°C and 850 .
at 800°C.
at 766.8 Ω ± 7;7(°C).
It is located before the DPF under the oxygen probe.
2 py
YDT521B.
4.23 Oxygen probe

01 o
/2 C
4.23.1 Oxygen probe
The sensor informs the DCU of the proportion of

02 nce
oxygen (lambda factor) present in the exhaust gas.

• Minimum lambda factor measured : 0,7.
• Response times : < 200 ms.
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It is located between the VGT and the catalyser on

the exhaust line. Diagnostics can be carried out with
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the kit YDT574D.
4.23.2 Oxygen probe heater

A heater resistance ensures that the probe reaches its minimum operating temperature. It is controlled by a PWM
signal.
• PWM signal frequency : 100 to 600 Hz
• Resistance at 21 : 2.4 Ω ± 0.6
• Power : 8.7 W (at a voltage of 7.0 V at 21°C).
• Current : 1.2 A (at a voltage of 7.0 V at 21°C).
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 4-47

2 py
01 o
/2 C
02 nce
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© Delphi
4-48 DDNX384(EN) - Issue 1 of 12/2011

COMPONENT PLACEMENT
5.1 Component location
5.1.1 Engine compartment
1 Preheating plug 10 Pre-post heating unit

2 Injector, cylinder 11 Swirl valve
3 Air flowmeter & air temperature sensor 12 EGR valve
4 Camshaft sensor 13 EGR Cooler Bypass
5 Fan units 14 Turbo charging pressure sensor
6 HP pump (IMV & venturi) 15 Rail pressure sensor
7 Accelerometer 16 Engine temperature sensor
8 Battery 17 Crankshaft sensor
9 Throttle Valve 18 DCU
2 py
01 o
/2 C
02 nce
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Z20D / Z22D Engine

© Delphi
DDNX384(EN) - Issue 1 of 12/2011 5-49

COMPONENT PLACEMENT
5.1.2 Passenger compartment
1 Passenger compartment ventilation control 5 Brake pedal switch

2 Clutch pedal switch 6 Cruise control buttons
3 A/C button 7 Diagnostic socket
4 Accelerator pedal sensor
2 py
01 o
/2 C
02 nce
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© Delphi
5-50 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.1 Cleanliness conditions
Summary : Cleanliness conditions
Caution
Cleanliness recommendations must be applied when opening
the Common Rail system.
Cleaning / Vacuuming / Protection

• Clean component environments using a clean brush and a solvent.
• Vacuum the components.
• Plug the components as soon as the circuit has been opened.
• Use lint-free cloths to protect other components from splashes and drips.
General rules
• Use a new plug.
2 py
• The plugs must be discarded after use.
• Store the components in a clean location away from external contamination and oxidation.
•
01 o
Remove protective plugs only at the time of connecting the component into the system.
/2 C
Working on the injectors
• If the injector shows signs of combustion, do not reuse it.
02 nce
• If the injector has to be reused, clean it using a solvent.

• Do not use any metal brushes.
• If the sealing washer is of the "captive" type, it will remain on the injector.
• Replace the sealing washer every time an injector is removed.
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Working on the HP tubes

• Clean and vacuum the internal tube ducts.
• Clean and vacuum the ends of the tube.
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• Clean and vacuum the capnuts.
Cleaning requirements References

Cleaning products CARCLEAN type
Clean brush (soft bristles) N/A
Lint-free cloths N/A
Clean container N/A
Vacuum cleaner YDT205
BLOVAC Type
Long vacuum cleaner nozzle YDT255
Clean plugs and caps from the dispenser YDT480
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-51

SUMMARIES
6.2 Plugs and Caps
Allocation of plugs from the dispensers YDT480
2 py
01 o
/2 C
02 nce
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Components Allocation: On component: On vehicle:

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LP inlet type F type M

LP outlet type D type G
HP pump
Venturi type D type G
HP connector type K type D
HP connector type K type D
Injector LP return type C type B
Nozzle type L --------
Rail HP connector type K type D
HP pipe HP connector type D type K
© Delphi
6-52 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.3 Fuel Filter
Summary : Fuel filter

Important
This file is a summary of points to be remembered when removing/refitting
Delphi components. For details, refer to the complete method described in
the relevant section.
Precautions
The kit DIAMAND YDT300 is not compatible with this application.
Make arrangements to collect the fuel when disconnecting the various pipes and sensors and when opening the filter.
Check the condition of the filter.
Check the filter cover seal condition
2 py
Check the condition of the water detector.
01 o Check the condition of the water detector seal.
Special tooling Part number

/2 C
25 ml flask. YDT273
02 nce
500 ml flask. YDT377

Injector return adaptor. YDT419
Additional parts and consumables Part number

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The water detector sensor connector. 9001-932

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Access to component Special features

Located next to the tank, under the vehicle. Using a workshop ramp.
Resetting Special features

Switch the ignition on to activate the electric pump in the tank. N/A
Schedule Time (h) Preliminary operations

Fuel filter. 0.2 Without
Component to tighten Torque

Fuel filter cover (SUV). 20 Nm ± 2
Fuel filter cover (Saloon/PCV). 20 Nm ± 2
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-53

SUMMARIES
6.4 Rail/Injector high pressure pipe
Summary : Rail/Injector high pressure pipe

Important
Precautions
Be prepared to collect the fuel when disconnecting various pipes and sensors.
Before starting component removal, carry out all preliminary operations. See section PRELIMINARY OPERATIONS
2 py
Sockets for HP pipe. YDT339 / YDT512
Vacuum cleaner. YDT205
01 o
Long vacuum cleaner nozzle. YDT255 YDT250 (kit)
/2 C
02 nce
Direct. N/A

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Start the leak detection test using the diagnostic tool. N/A

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1 Injector / rail pipe. 0.2 With.

0.5 (Z22D)
4 Injector / rail pipes. With.
0.6 (Z20D)

HP pipe on rail. 30 N.m ± 5
HP pipes on injectors. 30 N.m ± 5
© Delphi
6-54 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.5 Injector
Summary : Injector
Important
Precautions
Check the condition of the injector before refitting (traces of combustion, damage, ...)
Make sure that the flameproof washers are not stuck in the injector wells
2 py
Before starting component removal, carry out all preliminary operations. See section PRELIMINARY OPERATIONS.
01 o
/2 C
Diamand. YDT450 / YDT460
Additional kit for electrical diagnostics. YDT479
02 nce
Additional kits for hydraulic diagnostics. YDT278

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Flameproof washer extraction tool. YDT256

Injector chuck. YDT522
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Clean the bottom of the wells. YDT530

Injector connector (DELPHI PACKARD).. 9001-886
Injector connector seal (DELPHI PACKARD). 9001-851
Sealing washer. 9001-850K (Z22D) & 9001-850L (Z20D)

Removing the HP pipe. N/A
Remove the low pressure circuit. N/A

Configure the new C3I in the DCU. Ensure the correct cylinder allocation is observed.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-55

SUMMARIES

1 injector. 0.4 With
4 injectors. 1.2 With

Injector clamp bolt. 10 N.m ± 1 + 60°
2 py
01 o
/2 C
02 nce
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© Delphi
6-56 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.6 Rail
Summary : Rail
Important
Precautions
2 py
01 o
/2 C
02 nce

Rail pressure sensor connector. 9001-935
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Removing the injector/rail pipes. Refer to the relevant reference file.

Removing the pump/rail HP pipe. Refer to the relevant reference file.


0.7 (Z22D)
Rail. With.
0.9 (Z20D)

Rail mounting bolt on the cylinder head. 20 Nm
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-57

SUMMARIES
6.7 Pump/Rail high pressure pipe
Summary : Pump/Rail high pressure pipe

Important
Precautions
Before starting component removal, carry out all preliminary operations. See section PRELIMINARY OPERATIONS.
Apply a counter torque with a flat spanner on the pump HP connector when loosening and tightening the HP pipe.
2 py
01 o
/2 C
02 nce

Direct. N/A
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Pump/Rail pipe 0.2 With.

HP pipes on rail 30 N.m ± 5
HP pipes on pump 30 N.m ± 5
© Delphi
6-58 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.8 High pressure pump
Summary : Common Rail Pump

Important
Precautions
Replace the O ring on the pump nozzle.
Be prepared to collect the fuel when disconnecting various pipes and sensors
2 py
Special tooling 01 o Part number
/2 C
Additional kits for hydraulic diagnostics YDT377 / YDT465
02 nce
Sockets to disconnect the LP flexible pipes (Z22D). YDT597

va

Ad
Pump nozzle O ring 7190-065KK

Oldham Coupling. 7190-299

Removing the DCU (SUV). Refer to the relevant reference file.
Removing the DCU bracket (SUV). N/A
Removing the battery (SUV). N/A
Removing the Pump/Rail HP pipe Refer to the relevant reference file.
Disconnecting the low pressure circuit. N/A


High Pressure Pump (SUV). 1 (Z22D) With.
High Pressure Pump (Saloon/PCV). 0.6 (Z20D) With.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-59

SUMMARIES

HP pump fixing bolt on the cylinder head. 25 N.m ± 2.5
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
6-60 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.9 Venturi
Summary : Venturi
Important
CAUTION
The venturi is not currently removable as it is integral with the HP pump body. It must therefore be replaced if the venturi
is faulty. See section Removing/refitting the High Pressure Pump.
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-61

SUMMARIES
6.10 Inlet metering valve (IMV)
Summary : IMV
Important
Precautions
Never leave the IMV orifice open.
2 py
Never re-use an IMV once it has been removed.
Replace the IMV mounting bolts with those provided in the kit.
01 o Lubricate the IMV seals before refitting.
/2 C
02 nce

Additional kits for hydraulic diagnostics. YDT410
va

Ad

IMV kit 9109-942
Inlet metering valve connector (IMV) 9001-925

Partial removal of engine harness N/A


Inlet metering valve (IMV) 0.3 With.
© Delphi
6-62 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES

3 Nm
Slacken ½ turn
Inlet metering valve (IMV)
1.5 Nm ± 0.2 / 3 Nm ± 0.3 / 5.5 Nm
± 0.6
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-63

SUMMARIES
6.11 Fuel temperature sensor
Summary : Fuel temperature sensor

Important
Precautions
Never leave the fuel temperature sensor orifice open.
2 py
01 o
/2 C
02 nce

Under the vehicle Located on the fuel filter block
va

Ad

Temperature sensor 0.3 Without

N/A N/A
© Delphi
6-64 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.12 DCU
Summary : DCU
Important
Note:
Refitting the DCU requires the (programming, C3I...) diagnostic tool for the data transfer.
Precautions
Follow the DCU connector locking/unlocking procedure.
2 py
Special tooling 01 o Part number
/2 C

02 nce
Direct. N/A

va
Initialise the DCU (only when installing a new DCU) N/A

Ad

DCU 0.3 With.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-65

SUMMARIES
6.13 Torque settings

Fuel filter bracket on the chassis 9 N.m ± 1
Fuel filter cover 5.5 N.m ± 0.5
HP pipes on rail 29 N.m ± 2
HP pipes on injectors 29 N.m ± 2
HP pipes on pump 29 N.m ± 2
Injector clamp bolt 6 N.m ± 1 + 90°
Rail mounting bolt on the cylinder head 9 N.m ± 1
Air box bolt 14 N.m ± 2
Battery support bolt 20 Nm ± 2
2 py
HP pump fixing bolt on the cylinder head. 25 N.m ± 2.5
01 o 3 Nm
Inlet metering valve (IMV) Slacken ½ turn
/2 C
1.5 Nm ± 0.2 / 3 Nm ± 0.3 / 5.5 Nm ± 0.6
Accelerometer fixing bolt on the engine block 9 N.m ± 1
02 nce
va
Ad
© Delphi
6-66 DDNX384(EN) - Issue 1 of 12/2011

SUMMARIES
6.14 Schedule
REMOVAL/REFITTING Time (h) Preliminary operations

Preliminary operations 0,1 N/A
DCU 0.3 With
Fuel filter 0.2 Without
1 Injector / rail tube 0.2 With
4 Injector / rail pipes (Z20D) 0.5 With
4 Injector / rail pipes (Z22D) 0.6 With
1 injector 0.4 With
4 injectors 1,2 With
Rail (Z20D) 0.9 With
2 py
Rail (Z22D) 0.7 With
Pump/Rail pipe 01 o 0.2 With
Inlet metering valve (IMV) 0.3 With
/2 C
Temperature sensor 0.3 With
HP pump (Z20D) 0.6 With
02 nce
HP pump (Z22D) 1 With

Complete system Z20D 2.6 N/A
Complete system Z22D 2.7 N/A
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 6-67

SUMMARIES
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
6-68 DDNX384(EN) - Issue 1 of 12/2011

PRELIMINARY OPERATIONS
CAUTION
Check that the pressure in the system is zero.
• Switch off the ignition and wait for 30 seconds.

• Open the bonnet.
2 py
• Remove the oil filler plug.
01 o
/2 C
• Remove the engine cover.
• Refit the oil filler plug.
02 nce
va
Ad
SUV
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 7-69

PRELIMINARY OPERATIONS
Saloon/PCV
2 py
• Disconnect the battery.
01 o
/2 C
02 nce
va
Ad
CYLINDER AND INJECTOR NUMBERING

• Cylinder 1 accessory drive belt side
• Cylinder 4 transmission side (box side)
Injector No 1 is considered to be that fitted to cylinder No

1. It is important to observe this convention so as to avoid
any C3I addressing errors.
© Delphi
7-70 DDNX384(EN) - Issue 1 of 12/2011

REMOVING/REFITTING THE FUEL FILTER

For this section, please refer to the following paragraphs when the situation warrants it :
• Cleanliness conditions
• Plugs and Caps
• Torque settings
• Schedule

25 ml flask YDT273
500 ml flask YDT377
Injector return adaptor YDT419
Note:
The filter is supplied by GENERAL MOTORS for all applications, these are not DELPHI components.
2 py
8.1 Removing the filter 01 o
/2 C
Refer to the vehicle service document for the replacement periods.
Note:
02 nce
The fuel filter for all applications is located under the vehicle and not in the engine compartment.
The operation is easier if the vehicle is lifted on a workshop ramp.
va
8.1.1 SUV
Removing the filter elements

Ad
• Connect a container (type YDT273) to the

drain screw using a flexible tube.
• Loosen the screw by one turn to drain the filter
block.
• Tighten the screw and remove the container.
• Using a socket or a 32 flat spanner,
unscrew the two filter block covers.
CAUTION
Some residual fuel may flow out despite
draining the filter.
• Remove the filter block covers.

• Remove the filter elements.
• Recycle the filter elements.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 8-71

REMOVING/REFITTING THE FUEL FILTER

8.1.2 Saloon/PCV
Removing the filter element :

• Connect a container with a flexible tube (ex:
container YDT377 + adaptor YDT419) on
the filter block drain screw.
• Loosen the central part of the nut on the filter
block cover by one turn using a large flat
screwdriver.
• Drain the filter block.
• Tighten the central part of the nut and remove
the container.
• Using a socket or a 36 flat spanner,
unscrew the filter block cover.
2 py
CAUTION
Some residual fuel may flow out despite draining the filter.
01 o
/2 C
• Remove the filter block cover.
• Remove the filter element.
• Recycle the filter element.
02 nce
8.2 Preparing the filter

va
• Check the general condition of the filter (dents ; conformity…).

• Check the condition of the filter head seal and change it if necessary.
Ad
8.3 Refitting the filter
Refitting the filter element (SUV)

• Place the new filter elements in the filter block.
• Refit the covers.
• Tighten the covers to a torque of 20 Nm ± 2.
Refitting the filter element (Saloon/PCV)
• Place the new element in the filter block.
• Refit the cover.
• Tighten the cover to a torque of 25 Nm ± 2.
Resetting
• Reconnect battery.
• Switch on the ignition to activate the electric pump
and fill the filter block.
• Start the engine and let the engine speed stabilise.
• Check the sealing of the filter.
• Erase the fault codes caused by the operations.
© Delphi
8-72 DDNX384(EN) - Issue 1 of 12/2011

REMOVING/REFITTING THE RAIL/INJECTOR HIGH PRESSURE PIPES

• Plugs and Caps
• Torque settings
• Schedule

Sockets for HP pipe YDT339 / YDT512
Long vacuum cleaner nozzle YDT255 YDT250 (kit)
9.1 Removing the rail/Injector high pressure pipe
2 py
Removing a rail/injector HP pipe
•
01 o
Clean and vacuum out all the HP unions.
/2 C
• Slacken the HP unions.
• Remove the HP pipe.
02 nce
Note:
The pipes are all different and are specific to each
cylinder.
• Clean and vacuum out each HP end before fitting a
va
protective plug.
Ad
Plug the openings

• Of the injector.
• On the rail.
• Of the HP pipe.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 9-73

REMOVING/REFITTING THE RAIL/INJECTOR HIGH PRESSURE PIPES
9.2 Preparing the rail/Injector high pressure pipe
The HP pipes provide a link between all of the components of the common rail system.
CAUTION
For the rest of the operations (HP pipes, HP pump, rail...), follow the cleanliness and safety instructions and use the
correct tightening torques.
9.3 Refitting the rail/Injector high pressure pipe
Refitting a Rail/Injector HP pipe

• Remove and discard the plugs from the HP pipe
concerned.
• Fit the pipe olive into the injector cone and hand
tighten the nut.
• Fit the pipe olive into the rail cone and hand tighten
2 py
the nut.
• Check the position of the HP pipe. 01 o
• Tighten the HP pipe to a torque of 30 Nm ± 5.
• Apply the same method for all the injector HP
/2 C
pipes.
02 nce
Resetting
• Start the engine and let the engine speed stabilize.
va
• Check the HP connector seals using the leak detection cycle (Cycle activated using the diagnostic tool).
Ad
© Delphi
9-74 DDNX384(EN) - Issue 1 of 12/2011

REMOVING / REFITTING AN INJECTOR

• Plugs and Caps
• Torque settings
• Schedule

Diamand YDT450 / YDT460
Additional kit for electrical diagnostics YDT479
Additional kit for hydraulic diagnostics. YDT278
Flameproof washer extraction tool YDT256
2 py
Injector chuck YDT522
Clean the bottom of the wells 01 o YDT530

/2 C
Injector connector (DELPHI PACKARD) 9001-886
02 nce
Injector connector seal (DELPHI PACKARD). 9001-851

Sealing washers. 9001-850K (Z22D) & 9001-850L (Z20D)

va
10.1 Removing the injector

Ad
• Remove the corresponding HP pipe. See section
REMOVING/REFITTING A RAIL/INJECTOR HIGH
PRESSURE PIPE
• Disconnect the injector connector.
• Move the electrical harness away from the area of
operation.
• Disconnect the injector backleak hose.
• Plug all the openings.
CAUTION
Be prepared to collect diesel from the return circuit when
disconnecting on the injector.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 10-75


• Loosen the injector clamp fixing bolt.
• Remove the clamp.
• Remove the injector.
2 py
Note:
If the injector is difficult to remove by hand, use the
injector chuck YDT522.
01 o
• Check that the flame-proof washer is still on the
/2 C
injector nozzle. Use the special extractor YDT256
if the washer is stuck at the bottom of the well.
• Cap the injector nozzle with the correct cap.
02 nce
va
Store the injectors and HP pipe in a clean location away from external contamination and oxidation.
Ad
10.2 Preparing an injector
• Check that the new injector is fitted with all its protective plugs.
• Check the general condition of the injector.
• Check and read the C3I.
• Check there is a new sealing washer.
• Check the condition of the injector connector.
• Check the condition of the vehicle wiring.
• Check there is no sealing washer in the injector well (old washer).
• Clean the injector well using tool YDT530.
CAUTION
The YDT252 tool MUST NOT be used on applications using the DFI1.5 injectors as the injector wells have been modified
compared to the previous generations. Refer to the Intec DT469 in Direct Evolution for more information.
© Delphi
10-76 DDNX384(EN) - Issue 1 of 12/2011

10.3 Refitting the injector
Note:
If the injector is not replaced by a new one, fit a new sealing washer.
• Refit the injector.

• Refit the clamp.
• Hand tighten the clamp bolt, without applying the torque, to make refitting the HP pipe easier.
• Refit the HP pipe. See section Refitting the rail/Injector high pressure pipe.
• Tighten the clamp bolt to a torque of 10 Nm ± 1
then 60° ± 5.
• Reconnect the injector connector.
• Fit the backleak tube.
2 py
01 o
/2 C
02 nce
Resetting
• Connect the battery.
• Load the new C3I into the DCU (only if a new injector has been fitted).
va
CAUTION
Ensure the correct cylinder allocation is observed. See section PRELIMINARY OPERATIONS
Ad

© Delphi
DDNX384(EN) - Issue 1 of 12/2011 10-77

2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
10-78 DDNX384(EN) - Issue 1 of 12/2011

REMOVING / REFITTING RAIL

• Plugs and Caps
• Torque settings
• Schedule

2 py
Rail pressure sensor connector 9001-935
01 o
/2 C
11.1 Removing the rail
02 nce
Remove the components to obtain access to the rail
• Remove the Rail/Injector HP pipes. See section Removing the Rail/Injector high pressure pipe.
• Remove Pump/Rail HP pipe. See section Removing the HP pump/rail high pressure pipe.
va
Removing the rail

• Disconnect the rail pressure sensor.
Ad
• Remove the 2 rail mounting bolts.

© Delphi
DDNX384(EN) - Issue 1 of 12/2011 11-79

REMOVING / REFITTING RAIL

• Remove rail.
2 py
11.2 Preparing the Rail
• Check that the new rail is fitted with all its protective plugs.
01 o
• Check the general condition of the new rail.
/2 C
• Check the condition of the rail pressure sensor connector.
02 nce
11.3 Refitting the Rail
Refitting the rail

va
• Position the rail against the cylinder head.

• Torque tighten the 2 rail fixing bolts to 20 Nm.
Ad
• Reconnect the rail pressure sensor.
Refit the HP pipes

• Refit the HP RAIL/INJECTOR pipes. See section Refitting the rail/Injector high pressure pipe.
• Refit the PUMP/RAIL HP pipe. See section Refitting the HP pump/rail high pressure pipe.
Resetting
© Delphi
11-80 DDNX384(EN) - Issue 1 of 12/2011

REMOVING/REFITTING THE HIGH PRESSURE PUMP AND ASSOCIATED COMPONENTS

This section describes the REMOVAL/REFITTING of the following components :
• HP Pipe Rail/Pump.
• IMV
• Fuel temperature sensor.
• HP pump.
• Plugs and Caps
• Torque settings
• Schedule
12.1 Removing/Refitting the HP pump/Rail HP pipe
2 py
01 o
/2 C
02 nce
12.1.1 Removing the pump/rail HP pipe

Removing the HP pipe
va
• Clean and vacuum the rail and pump HP pipe

nuts.
• Loosen the rail side pipe nut.
Ad
• Loosen the pump side pipe nut.
CAUTION
Apply a counter torque to the pump HP connector using a 15 spanner when slackening the nut to avoid rotation.
• Remove the pipe.

© Delphi
DDNX384(EN) - Issue 1 of 12/2011 12-81


12.1.2 Preparing the pump/rail HP pipe
The HP pipes provide a link between all of the components of the Common Rail system.
CAUTION
For the rest of the operations (HP pipes, HP pump, rail...), follow the cleanliness and safety instructions and use
the correct tightening torques.
12.1.3 Refitting the pump/rail HP pipe
Refitting the Pump/Rail pipe

• Refit the HP pipe.
• Hand tighten the nuts.
• Torque the HP pipe to 30 Nm +/- 5 while
applying a counter torque with a 15
spanner.
2 py
01 o
/2 C
02 nce
Resetting
va

Ad
12.2 Removing/Refitting the Venturi
CAUTION
The venturi is not currently removable as it is integral with the HP pump body. It must therefore be replaced if the venturi
is faulty. See section Removing/refitting the High Pressure Pump.
12.3 Removing/Refitting the IMV

Additional kit for hydraulic diagnostics. YDT410
© Delphi
12-82 DDNX384(EN) - Issue 1 of 12/2011


IMV kit 9109-942
IMV connector 9001-925
12.3.1 Removing the IMV

Removing the IMV
• Disconnect the IMV.
• Remove the 2 IMV mounting bolts.
• Use a CARCLEAN-type solvent and a vacuum
cleaner on the surrounding area to make sure
that no dirt or particles contaminate the
pump.
2 py
01 o
/2 C
02 nce
• Slacken the two bolts completely and remove them.

• Use a CARCLEAN-type solvent to clean the surrounding area.
• Use a vacuum cleaner to suck out the particles.
• Remove the IMV using small gentle oscillating movements.
va
• Store the IMV in a clean location away from external contamination.

Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 12-83


12.3.2 Preparing the IMV
CAUTION
Never leave an IMV opening unplugged .
Never reuse an IMV once it has been removed;
General condition
• Check the condition of the sensor connector
(2 pin; brown).
• Replace the mounting bolts with those
provided in the kit.
• Lubricate the IMV seals.
2 py
01 o
/2 C
12.3.3 Refitting the IMV
02 nce
CAUTION
Only remove new unit from its packaging just before fitting it in the place of the faulty component.
va
Refitting the IMV

• Position the IMV on the pump.
• Do not use connector as a lever.
Ad
• Do not turn the IMV using the rear location.
CAUTION
Make sure that the IMV O rings are not damaged when fitting the unit to the pump.
• Push the IMV until it contacts the pump housing.

• Turn the IMV to line up the mounting holes.
• Fit and gently tighten the two IMV/pump mounting bolts (Torx male 25).
• Torque the bolts to 3 Nm to ensure full contact.
• Then loosen the bolts half a turn.
• Apply the torque in steps : 1.5 Nm then 3 Nm and finally 5.5 Nm.
• Connect the IMV.
Resetting
• Check the sealing of the LP connectors.
© Delphi
12-84 DDNX384(EN) - Issue 1 of 12/2011

12.4 Removing/Refitting the fuel temperature sensor


Connector repair harness. 9001-933
Note:
The temperature sensor is supplied by GENERAL MOTORS for all applications, these are not DELPHI components.
12.4.1 Removing the fuel temperature sensor
2 py
The fuel temperature sensor is located on the filter block.
01 o
Access to component
/2 C
• Place the vehicle on a workshop ramp.
Removing the temperature sensor
02 nce
• Disconnect the fuel temperature sensor.

• Move the electrical harness away from the
area of operation.
• Unclip the fuel temperature sensor from its
va
mounting and clean the area with a

CARECLEAN type lubricant.
• Check that no dirt or other matter can get
Ad
between sensor and filter block.

• Take out sensor.
• Store the diesel temperature sensor in a clean
location away from external contamination.
12.4.2 Preparing the fuel temperature sensor
CAUTION
Never leave the sensor orifice open.
Never re-use a sensor once it has been removed.
General condition
• Lubricate the sensor seal.
12.4.3 Refitting the fuel temperature sensor
Refitting the fuel temperature sensor

• Before fitting the sensor, use a CARECLEAN type lubricant to clean surrounding area. Check that no dirt or
other matter can get between sensor and housing.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 12-85


• Clip the sensor in its mounting in the filter block by hand.
• Connect the fuel temperature sensor.
Resetting
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
12-86 DDNX384(EN) - Issue 1 of 12/2011

12.5 Removing/refitting the High Pressure Pump.

Additional kits for hydraulic diagnostics YDT377 / YDT465
Sockets to disconnect the LP flexible pipes (Z22D). YDT597
2 py
Pump nozzle O ring 7190-065KK
Oldham Coupling.
01 o 7190-299
12.5.1 Removing the HP pump

/2 C
Preliminary dismantling to access the HP pump (SUV)
02 nce
• Remove the DCU. See section REMOVING/REFITTING THE DCU

• Disconnect the battery earth terminal.
• Slacken the 2 battery clamp nuts.
va
• Remove the battery clamp.

• Remove the battery.
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 12-87


• Loosen and then remove the 5 upper DCU
support bolts.
• Remove the support.
• Loosen and remove the AC hose clamp bolt.
2 py
• Remove the lower DCU support.
01 o
/2 C
02 nce
va
Remove the components to access the HP

Ad
pump (All applications)

• Separate the engine harness from its
support (vacuum pump side).
• Separate the engine harness from its
support (HP pump side). © Delphi
12-88 DDNX384(EN) - Issue 1 of 12/2011


• Remove Pump/Rail HP pipe. See section
Removing the HP pump/rail high pressure
pipe.
• Disconnect the IMV.
• Move the electrical wiring from the area of
operation.
• Disconnect the LP pipes from the HP pump.
CAUTION
On the SUV, the pipes have a special lock which require the tool YDT597.
2 py
• Disconnect the IMV. 01 o
• Move the electrical wiring from the area of
operation.
/2 C
• Disconnect the venturi pipe on the HP pump.
02 nce
va
Ad
Removing the HP pump

• Loosen the HP pump mounting bolts on the
cylinder head (3 bolts).
• Remove the engine harness support (SUV).
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 12-89


• Waggle the HP pump gently to remove it from
the cylinder head.
• Remove the HP pump (SUV on the left /
CHEVROLET Orlando & Cruze on the right).
CAUTION
The Oldham coupling can slide on the pump drive
shaft once the latter is free from the cylinder head.
12.5.2 Preparing the HP pump
2 py
CAUTION
Remove the protective plugs only when connecting the HP or fuel supply pipes.
01 o
/2 C
General condition
• Check the condition of the LP diesel inlet/
outlet.
02 nce
• Check the IMV connector condition (2 pin ;

brown).
• Check that the pump shaft turns freely.
• Check the condition of the oil lip seal on the
va
pump shaft.
• Replace the pump nozzle O ring if necessary.
Ad
• Check the condition of the Oldham coupling.
12.5.3 Refitting the HP pump
Refitting the HP pump

• Lubricate the pump nozzle to aid interlocking
and to prevent cutting the O ring.
• Position the HP pump in front of its mounting.
• Fit the pump and place the flange in contact
with the cylinder head.
• Refit the engine harness support (SUV).
• Refit the mounting bolts.
• Torque the fixing bolts to 25 Nm ± 2.5.
© Delphi
12-90 DDNX384(EN) - Issue 1 of 12/2011


Resetting (All applications)
• Clip the engine harness in its support (vacuum pump side).
• Reconnect the LP fuel inlet and outlet hoses.
• Connect the IMV.
• Refit the HP pipe. See section Refitting the HP pump/rail high pressure pipe.
Resetting (SUV)
• Refit the lower DCU support.
• Refit the AC hose clamp bolt.
• Refit the upper DCU support with its 5 bolts.
• Refit the battery and its clamp.
Resetting (All applications)
• Reconnect the battery.
• Start the engine and let the engine speed stabilise.
• Check the sealing of the LP connectors.
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 12-91

2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
12-92 DDNX384(EN) - Issue 1 of 12/2011

REMOVING/REFITTING THE DCU

• Plugs and Caps
• Torque settings
• Schedule

Additional kits for electrical diagnostics YDT374
13.1 Removing the DCU
Removing the DCU
2 py
• The DCU is located to the left of the battery.
• Unlock and disconnect the two DCU connectors.
01 o
/2 C
02 nce
va
Ad
• Unclip the DCU from its mounting.

• Remove the DCU.
13.2 Preparing the DCU
• Check the general condition of the DCU.

• Check the condition of the two DCU connectors (96 and 58 pins).
• Check the condition of the DCU connector locking lugs.
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 13-93

REMOVING/REFITTING THE DCU

• Check the condition and position of the vehicle harness connector seals.
13.3 REFITTING THE DCU
REFITTING THE DCU

• Offer the DCU up to its support.
• Push the DCU to lock it into its support.
• Connect the 2 DCU connectors (96 and 58 pins).
CAUTION
Position the connector guided by the 3 plastic lugs, then push the lock lever until the "click" of the clips is heard.
• If reusing the old DCU there is no reinitialisation to perform.

If using a new DCU:
• If the old DCU was not communicating, take note of the data to initialise the DCU (refer to the diagnostic
manual).
2 py
• If the old DCU was communicating, transfer the data stored in the diagnostic tool (refer to the diagnostic
manual).
CAUTION
01 o
Refer to the instructions in the diagnostic manual for the next two operations.
/2 C
• The C3I for each injector must be entered before starting the engine. If this operation is not carried out, a recovery
mode sets the engine speed to 1300 rpm with no pedal control possible.
02 nce
• It is also necessary to copy the programming values into the new DCU memory.
• Check the configuration is correct according to the vehicle configuration.
Resetting
va

• Start the engine to check operation.
Ad
© Delphi
13-94 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
REFERENCE VALUES
14.1 Reference values
CAUTION
It is impossible to measure resistances less than 1Ω using a conventional multimeter. Use the KELVIN method (4
wires) to measure injector resistance.
DCU pin connections :

• 96 way connector: numbering 1xx
• 58 way connector: numbering 2xx
Components Terminals Resistance values

Sensor DCU
Fuel heater (integrated in Pin 1 250 (relay)
the fuel filter and combined YDT538C
with the fuel temperature
2 py
sensor)
Fuel temperature sensor Pin 1 195(signal) Depends on temperature See specific table.
(integrated in the filter and Pin 2
01 o earth
/2 C
combined with the heater
YDT538C
control)
02 nce
Water in fuel sensor Pin 1 209(signal)

Pin 2 234(earth)
YDT529C
Inlet metering valve (IMV) Non-polarised 177 (PWM control) 5.44 Ω ± 10% at 20°C
va
YDT330B
Pin A 135 (measurement)
Ad
Pin B 119 (earth)

Rail pressure sensor Voltage depends on the pressure
Pin C 138 (+5 V supply)
YDT330C
HSD LSD Cyl 180 mΩ
127 126 1
Non-polarised
Injectors 150 174 2
YDT479
151 175 3
103 125 4
Airflowmeter sensor Pin 5 158(signal)
Pin 2 171(earth)
YDT574C
(Z22D)
Inlet Air Temperature Pin 3 104(signal) Depends on temperature See specific table.
sensor (analogue) Pin 1 171(earth)
YDT574C
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 14-95

III APPENDICES
REFERENCE VALUES

Sensor DCU
Throttle Valve Pin 4 184 (+ signal)
Pin 5 183 (- signal)
YDT710C
Flap valve position sensor Pin 1 163 (signal)
(Throttle) Pin 2 115 (earth)
Pin 3 170 (analogue copy)
YDT710C
Boost inlet air temperature Pin 1 134 Depends on temperature See specific table.
sensor Pin 2 112 (measurement)
(Sensor combined with Pin 3 141 (+ 5V supply)
absolute inlet air pressure
2 py
Pin 4 167 (earth)
sensor)
YDT538C
Inlet air absolute pressure
sensor
01 o
Integrated circuit (resistance cannot be
/2 C
(Sensor combined with
measured)
boost inlet air temperature
sensor)
02 nce
Swirl valve solenoid YDT246B

Swirl valve position sensor Pin 1 169 (earth) 3.9 Ω ± 12 %
Pin 2 114 (signal)
va
Pin 3 143 (VREF2 supply)

YDT559B
Ad
EGR valve YDT529D

EGR position sensor Pin 1 164 (VREF3 supply)
Pin 3 172 (earth)
Pin 5 116 (signal)
YDT529D
EGR valve cooler bypass Pin 1 186 (signal)
solenoid YDT521B
VGT solenoid valve Pin 1 188 (signal)
YDT246A
VGT position sensor Pin 1 161(VREF3 supply)
Pin 2 111(signal)
Pin 3 148(earth)
YDT538B
© Delphi
14-96 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
REFERENCE VALUES

Sensor DCU
Oxygen probe YDT574D 154(signal)
155(signal)
156(signal)
157(signal)
182(supply)
Temperature sensor pre- Pin 1 106(signal) Depends on temperature See specific table.
VGT. Pin 2 123(supply)
YDT521B
Temperature sensor pre- Pin 1 107(signal) Function of temperature.See specific table.
catalyser. Pin 2 124(supply)
2 py
YDT521B
Pre-DPF temperature Pin 1 105(signal) Function of temperature.See specific table.
sensor Pin 2
01 o
122(supply)
YDT521B
/2 C
Particle filter differential Pin 1 108(signal) Depends on the pressure See specific table.
pressure sensor
02 nce
Pin 2 144(earth)
Pin 3 166(VREF2 supply)
YDT559B
Crankshaft sensor Pin 1 160 (measurement) Hall effect sensor
va
Pin 2 187 (earth)

Pin 3 139 (supply)
Ad
YDT574A
Camshaft sensor Pin 1 147 (earth) Hall effect sensor
Pin 2 159 (signal)
Pin 3 140 (supply)
YDT574A
Accelerometer n°1 Pin 1 131 (signal) Piezoelectric sensor
Pin 2 130 (earth)
YDT246A
Accelerometer n°2 Pin 1 132 (signal) Piezoelectric sensor
Pin 2 133 (earth)
YDT246A
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 14-97

III APPENDICES
REFERENCE VALUES

Sensor DCU
Pin 1 229 (+5V supply track 2)
1.2 kΩ ± 0.4 between terminals 1 and 5 of the
Pin 2 224 (+5V supply track 1)
sensor
"Double track" pedal Pin 3 226 (earth track 1)
1.7 kΩ ± 0.8 / -0,2% between terminals 2 and
sensor Pin 4 225 (signal track 1)
3 of the sensor
Pin 5 214 (earth track 2)
Voltage depends on the position
Pin 6 213 (signal track 2)
Coolant temperature Pin 1 109 (signal) Depends on temperature See specific table.
sensor Pin 2 145 (earth)
YDT521B
Oil level sensor Pin 1 228 (signal)
2 py
Preheating unit
Preheating plugs 01 o
Aircon pressure sensor Pin 1 222 (VREF2 supply) Depends on the pressure See specific table.
/2 C
Pin 2 208 (signal)
Pin 3 220 (earth)
02 nce
Vehicle speed / TOSS Pin 1 227 (signal) Hall effect sensor

sensor Pin 2 221 (earth)
Pin 1 227 (signal) Hall effect sensor
va
Pin 2 221 (earth)

Pin 3 210 (supply)
Ad
Coolant temperature sensor

Temperature (°C) Nominal resistance between sensor Resistance tolerance between sensor
terminals (Ω) terminals (Ω)
20 2449,9 ± 159,1
50 826,3 ± 41,5
80 321,4 ± 15,0
120 112,9 ± 7,2
Inlet air temperature sensor (integral in air flowmeter)

Temperature (°C) Minimum resistance between Nominal resistance between Maximum resistance between
sensor terminals (Ω) sensor terminals (Ω) sensor terminals (Ω)
–40 35140 39260 43762
–20 12660 13850 15120
–10 7943 8609 9307
0 5119 5499 5892
20 2290 2420 2551
40 1096 1166 1238
© Delphi
14-98 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
REFERENCE VALUES
Inlet air temperature sensor (integral in air flowmeter)

Temperature (°C) Minimum resistance between Nominal resistance between Maximum resistance between
sensor terminals (Ω) sensor terminals (Ω) sensor terminals (Ω)
50 0,779 0,835 0,892
70 0,416 0,452 0,488
90 0,238 0,261 0,285
110 0,144 0,159 0,176
120 0,114 0,127 0,141
Diesel temperature sensor

Temperature (°C) Nominal resistance between sensor Resistance tolerance between sensor
terminals (Ω) terminals (Ω)
–40 75780 68780 to 82780
2 py
–20 21873 19713 to 24033
–10 12462 11334 to 13590
0 7355 6742 to 7968
01 o
20 2812 2645 to 2979
/2 C
40 1199 1137 to 1260
50 811,2 772.3 to 850
02 nce
70 394,8 383.2 to 406.4

90 206,6 201.2 to 211.9
110 115,1 112.45 to 117.7
va
120 87,7 85.8 to 89.6

Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 14-99

III APPENDICES
REFERENCE VALUES
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
14-100 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
WIRING DIAGRAM
15.1 Wiring diagram
15.1.1 Wiring diagram - 96 pin connector
Accelerometer 1 Inlet metering valve (IMV) 2

T87
1 Signal (+) 177
131
2 Earth and shielding EGR Cooler Bypass 2
130 186
Accelerometer 2
1 Signal (+)
132 Signal (PWM)
2 Earth and shielding 188
133 Vref3 Copy B VGT
T87 161
Copy signal C
4 Flowmeter supply 111
176 Earth copy
148
5 Air flow signal
Air 158
flowmeter 2 Flowmeter earth
QL 257
2 py
Vref1 3
3 Earth 140
171 Signal 2
CAM Camshaft
Inlet Air T°C T° 159
1 Signal Earth sensor
Sensor 104 1
HALL
147
01 o Vref1 3
139 CPS Crankshaft
/2 C
Signal 2
2 Signal (+) 160 sensor
190 Earth 1 HALL
M 1 Signal (-) 187
191
EGR valve 5 Vref3 Copy
02 nce
164
3 Copy signal
116 Vref1 C Vs Rail
4 Earth copy 138 Signal V
172 135 Earth Sig pressure
119 B
Rtn
P sensor
Signal (PWM) Vref2 2 Vs Turbocharging

va
4 141 V
189 Signal 1 Sig
112 pressure
Vref2 Copy Earth
DCU
Swirl valve 3 4 Rtn

sensor
143 167 P
2 Copy signal
114 Signal T° Air T°C Sensor
134 3
Ad
1 Earth copy
169
Vref2 3 Vs
166 Particle filter
1 Signal (+) 108
Signal 2 Sig V differential
184 P pressure sensor
M 2 Signal (-)
144
Earth 1
Rtn
Throttle 183
5 Vref3 Copy
163
3 Copy signal
115
4 Earth copy
170
Injector HSD-A
127 Injector
1 Signal 126 Cyl1
109 Injector LSD-1A
Coolant T° 2 Earth
sensor 145 Injector HSD-B
T° 151 Injector
175 Cyl3
1 Signal Injector LSD-1B
Pre-DPF exhaust 105
2 Earth Injector HSD-A
gas T°C sensor T° 122 103 Injector
1 Signal 125 Cyl4
110 Injector LSD-2A
Fuel T°C sensor 2 Earth
T° 146 Injector HSD-B
150 Injector
1 Signal
PreVGT 106 174 Cyl2
exhaust gas 2 Earth Injector LSD-2B
T° 123
sensor
1xx = Engine connector 96 way

© Delphi
DDNX384(EN) - Issue 1 of 12/2011 15-101

III APPENDICES
WIRING DIAGRAM
15.1.2 Wiring diagram - 58 pin connector
Main supply relay T87

F1 Vbatt
Pbatt
201
Water heater n°1 T87
F4 Pbatt 238
203
Pbatt
205 Water heaters n°2 and n°3
T15 256
F2 245
Ignition key 219 Vbatt
Starter relay
Fan 1 (On/Off or PWM)

211 185
IGN_2
Fan 2 (On/Off)
Accessory 236
F3 Vehicle
012 wake
electrical 212 Fan 3 (On/Off)
system 242
Key switch
2 py
Nernst voltage 6
156
Earth (virtual) 2
157
+
-
Battery 12V
01 o 154
Compensation resistance 5 02 probe
/2 C
IGN Clutch sensor clutch Pump current 1
155
DCU
engaged position
232
182 Heater control
3 4
Heater
02 nce
2 1 Main brake switch

230 Vehicle speed
4 3 Redundant brake switch 227
178 Earth (option) Speed
221 sensor
Brake light Vref2 supply
va
210
Vref2 supply
Clutch sensor clutch 222
disengaged position Signal
V Refrigerant
218 208 Pressure
Ad
Reversing switch Earth P Sensor

216 220
Water in
Signal H2O
195 fuel
Temperature 1 Signal
107 sensor
sensor pre- 2 Earth
catalyser. T° 124
CAN High Vehicle
248
Sensor n°1 247
2 Vref1 supply CAN Low Vehicle
224
4 Signal
225
3 Earth
Accelerator 226
Earth
pedal sensors 1 Vref2 supply 202
229 Earth
6 Signal 204
213 Earth
5 Earth 206
214 1xx = Engine connector 96 way
Sensor n°2
© Delphi
15-102 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
TOOLING
16.1 Tooling required
16.1.1 Special tooling

Injector holder locking spanner YDT232
Long vacuum cleaner nozzle YDT255
Long nose sealing washer extractor YDT256
17 mm adjustable wrench YDT339
Injector chuck YDT522
Well bottom cleaning tool YDT530
Pump hose extractor YDT597
2 py
Hydraulic diagnostic Part number
H3PI - Hydraulic diagnostics kit
01 o YDT278
500 ml Quick fit container YDT377
/2 C
Dummy actuator kit YDT410
02 nce
Injector return adaptor YDT419

Kit HP-T - Hydraulic diagnostics YDT465
DCU diagnostic Part number
va
DIAMAND diagnostic tool YDT450 / YDT460

Electrical diagnostic Part number
Ad
Burst unit YDT175

Sensor and actuator mini-harness kit YDT246
154-way DCU harness terminal box kit YDT374 = YDT375 + YDT376
Injector diagnostic harness YDT479
16.1.2 Standard tooling
Standard tooling Part number

Adaptor 1/4 to 3/8 Facom R0.232 type
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 16-103

III APPENDICES
TOOLING
Standard tooling Part number

1/2 to 3/8 adapter Facom S.230 type
Reducer 3/8 to 1/4 Facom J.230 type
1/2 square drive Facom S.373 type
1/4 square drive Facom R0.373 type
Square drive Facom J.373 type
8 - 19 mm pipe wrench Facom 76.8 to 76.19 type
Torque wrench, 0-5 Nm Facom R.304DA type
Torque wrench, 5-25 Nm Facom R.305DA type
Torque wrench, 10-50 Nm Facom J.305DA type
Torque wrench, 20-100 Nm Facom S.305DA type
8 - 19 mm combination wrench Facom 40.8 to 40.19 type
2 py
Angular tightening spanner Facom DM360 or D360 type
1/4 ratchet
01 o Facom R0.161 type
1/2 ratchet Facom S.161 type
/2 C
Hexagonal socket Facom R.8 to R13 type
02 nce
1/2 screwdriver socket Facom SHP.6L type

3/8 OGV socket Facom J.10 type
3/8 OGV socket Facom J.22LA type
va
3/8 OGV socket Facom J.13LA type

3/8 OGV socket Facom SJ.27 type
Ad
12 sided long socket Facom J.19LA type

Torx socket Facom R0.373 type
Adaptor socket Facom S.236 type
Adaptor socket Facom R0.235 type
Polygonal adapter Facom 12.19 type
Torx adapter Facom EX.125 type
Torx adapter Facom EX.230 type
Flat nose pliers Facom 187.14CPY type
1/4 extension Facom R0.209 type
1/4 extension Facom R0.210 type
1/2 extension Facom S.210 type
1/2 extension Facom S.208 type
3 claw extractor Type Facom U.302
© Delphi
16-104 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
TOOLING
16.1.3 Consumables summary
Required cleanliness Part number

Plug dispenser YDT480
(9001-870 to 9001-881 from dispenser)
Clean brush
Cleaning solution Careclean brand
Lint-free cloths
Clean container
16.1.4 Repair harness range
Parts for repair: Part number
2 py
Injector connector repair harness. 9001-886
• Injectors (Contacts gold)
01 o
• Inlet metering valve(IMV) (Contacts silver)
/2 C
• Temperature sensor pre-VGT. (Contacts tinned)
02 nce
• Temperature sensor pre-catalyser.

• Pre-DPF temperature sensor
va
• Coolant temperature sensor (Contacts gold)

Ad
• Fuel temperature sensor (integrated in the filter). (Contacts gold)

• Rail pressure sensor. (Contacts silver)
• VGT solenoid valve (Contacts tinned)
• Swirl valve solenoid
• EGR cooler bypass solenoid valve.
• Particle filter differential pressure sensor (Contacts gold)
• Swirl valve copy sensor.
(Other repair harness variants are available and are listed in the technical bulletin DT458 in DIRECT EVOLUTION)
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 16-105

III APPENDICES
TOOLING
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
16-106 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
ABBREVIATIONS
17.1 Abbreviations/Descriptions
+IGN + Ignition on (battery voltage when ignition is on)
+Bat or VBat Battery voltage
ABS Anti Lock Brake System
AC Air Conditioning
Immob Immobiliser
ADIN Alternator-starter
AIH Air Heater (preheating resistor)
Supp. Power supply
AMF Air Mass Flow
AOS Anti-Oscillation Strategy
ASR Anti-skid
LP Low pressure
PPH unit Pre-post heating unit
ACCR Air conditioning cooling requirement
2 py
BSI Built-In Systems Interface
ERU Engine Relay Unit
01 o
LP Low pressure
Automatic Automatic transmission
/2 C
Transmission
Manual Manual gearbox
02 nce
Transmission
Sequential Sequential gearbox
C3I Individual Injector Correction
C.A.N Controller Area Network (communication network)
va
3D Mapping Three dimensional map

SC Short circuit.
Ad
SC - Short circuit to earth

SC+ Short circuit to a positive potential
Control Control
PCC Passenger Compartment Connector
A/C Air conditioning
EMC External Motor Connector
EMC Effective Average Torque
IMC Internal Motor Connector
PCC Passenger Compartment Connector
CR Common Rail
RHD Right-Hand Drive
LHD Left-Hand Drive
DCU Diesel Control Unit (injection DCU)
DTC Diagnostic Trouble Code (fault code)
EEPROM Electronically Erasable Programmable ROM
EGR Exhaust Gas Recirculation
EOBD European On Board Diagnostic
ESP Electronic Stability Programme
SV Solenoid valve
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 17-107

III APPENDICES
ABBREVIATIONS
DPF Particle filter
Gap Gap representing two teeth missing from flywheel
Fan Fan unit
Fan 1 Fan low speed
Fan 2 Fan high speed
Heater Water heaters
Hexadecimal 16-character digital base from 0 to F
HP High pressure
HPS High Pressure Sensor
US Unserviceable, off
HSD Controlled by positive side of injector control circuit (High Side Drive)
IDE Identification
IMV Inlet Metering Valve
Info. Information
Key off Ignition off
2 py
Key on Ignition on
Limp home Recovery strategy which sets the engine speed to 1300 rpm regardless of pedal position. Used
to drive the vehicle to nearest parking place.
01 o
LIN Controller Area Network (communication network)
/2 C
Linearised A linearised value is the conversion of the signal sent to the DCU input into a physical value
LSD Controlled by earth (negative) side of injector control circuit (Low Side Drive).
02 nce
VSL Vehicle speed limiter

Max Maximum
MDP Minimum Drive Pulse (minimum pulse required for injection).
Min Minimum
va
NVM Non Volatile Memory

OBD On Board Diagnostic (diagnostics linked to emissions)
Pedal 1 Data from track 1 of accelerator pedal sensor
Ad
Pedal 2 Data from track 2 of accelerator pedal sensor

Power latch Phase when DCU is on standby after ignition is switched off
PPH Pre-Post Heating
Prail Rail pressure
Preheating 1 Resistor control for preheating 1
Preheating 2 Resistor control for preheating 2
PWM Pulse With Modulation (%) See PWM
RAA Inlet air heater
TAR Turbo Air Reheat (TAR)
RAM Random Access Memory
RCW Remote Control Wake
PWM Open Cycle Ratio (%)
PI regulator Proportional Integral Regulator
RN Random Number
CTR Coolant Temperature Reheat
VCC Cruise control
S2RE Electronic heating regulation system
A-S After Sales
© Delphi
17-108 DDNX384(EN) - Issue 1 of 12/2011

APPENDICES III
ABBREVIATIONS
Swirl Inlet throttle
T° Temperature
Temp. Temperature
TCU Transmission Control Unit (automatic transmission control unit - TCU)
VGT Variable Geometry Turbo.
Thermo. 1, 2 or 3 Water heater 1, 2 or 3
Digital value It is the output value from the analogue / digital converter
VAN Vehicle Area Network
Vext Sensor supply voltage (approx 5 V)
VSD Vehicle Specific Data (vehicle information used to program the codes)
WH Water Heater
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 17-109

APPENDICES III
NOTES
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 18-110

APPENDICES III
NOTES
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
DDNX384(EN) - Issue 1 of 12/2011 18-111

III APPENDICES
NOTES
2 py
01 o
/2 C
02 nce
va
Ad
© Delphi
18-112 DDNX384(EN) - Issue 1 of 12/2011

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TABLE OF CONTENTS

SPECIAL FEATURES OF THE SYSTEM I

REMOVING / REFITTING SYSTEM COMPONENTS II

Produced and published by:

DDNX384(EN) - Issue 1 of 12/2011 i

1. CHEVROLET Z20D Z22D ENGINE SPECIFICATIONS

3.2.3 Water detector............................................................................................................................................3-12

4.1 Fuel Supply/Air Supply...............................................................................................................................................4-15

4.2.2 Sensor supply.............................................................................................................................................4-17

ii DDNX384(EN) - Issue 1 of 12/2011

4.11 Air conditioning (AC) checks......................................................................................................................................4-32

4.11.4 Compressor activation...............................................................................................................................4-34

4.12 The water heaters........................................................................................................................................................4-34

DDNX384(EN) - Issue 1 of 12/2011 iii

iv DDNX384(EN) - Issue 1 of 12/2011

8.2 Preparing the filter......................................................................................................................................................8-72

9.2 Preparing the rail/Injector high pressure pipe .........................................................................................................9-74

10. REMOVING / REFITTING AN INJECTOR

DDNX384(EN) - Issue 1 of 12/2011 v

vi DDNX384(EN) - Issue 1 of 12/2011

14. REFERENCE VALUES

DDNX384(EN) - Issue 1 of 12/2011 vii

viii DDNX384(EN) - Issue 1 of 12/2011

CHEVROLET Z20D Z22D ENGINE SPECIFICATIONS

1.1 Z20D/Z22D Engine Specifications

CAPTIVA Z22D Euro V

DDNX384(EN) - Issue 1 of 12/2011 1-1

CHEVROLET Z20D Z22D ENGINE SPECIFICATIONS

1-2 DDNX384(EN) - Issue 1 of 12/2011

PARTS SUPPLIED BY DELPHI

2.1 High pressure pump

The pump has the following inlets/outlets :

• Pumping chamber : 0.97 cm3/pump

DDNX384(EN) - Issue 1 of 12/2011 2-3

PARTS SUPPLIED BY DELPHI

The IMV regulates the quantity of fuel delivered to

It is located on the pump. Diagnostics can be carried

HP outlet diameter : M14 x 1.5 mm.

This part should only be manipulated in accordance

A counter torque is required for all tightening/

This part does not require any network intervention.

2-4 DDNX384(EN) - Issue 1 of 12/2011

PARTS SUPPLIED BY DELPHI

This unit mechanically limits the pressure to 2150

• The inlet diameter is 9.89 mm. It is straight

These are quickfit type connectors with flexible

DDNX384(EN) - Issue 1 of 12/2011 2-5

PARTS SUPPLIED BY DELPHI

These parts do not require any network

These are quickfit type connectors with metal

It is integral with the pump body.

2-6 DDNX384(EN) - Issue 1 of 12/2011

PARTS SUPPLIED BY DELPHI

2.2.1 Tubular rail

DDNX384(EN) - Issue 1 of 12/2011 2-7

PARTS SUPPLIED BY DELPHI

The HP sensor transmits the rail pressure value to

The injector is a DFI1.5 type and conforms to Euro V standards.

2-8 DDNX384(EN) - Issue 1 of 12/2011

PARTS SUPPLIED BY DELPHI

- Z20D : thickness 3 mm.

supplied with fuel by the HP pipes.

Diagnostics can be carried out using the YDT479 kit.

DDNX384(EN) - Issue 1 of 12/2011 2-9