Rexton1 PDF

TABLE OF CONTENTS
DIAGNOSTIC I
TECHNICAL INFORMATION II
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Produced and published by:

Delphi France SAS
Diesel Aftermarket
12 - 14 Boulevard de l’industrie
41042 Blois Cedex Tel: (+33) (0) 2 54 55 39 39
France Fax: (+33) (0) 2 54 55 39 12
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 i

I DIAGNOSTIC
TABLE OF CONTENTS
1. DIAGNOSTIC TOOL FUNCTIONS

1.1 DIAGNOSTIC TOOL CONNECTION..............................................................................................................................1-1
1.2 READING THE DEFECT CODES....................................................................................................................................1-5
1.2.1 Principle........................................................................................................................................................1-6
1.2.2 The environment data..................................................................................................................................1-6
1.3 READING OF DYNAMIC PARAMETERS......................................................................................................................1-8
1.3.1 List of parameters........................................................................................................................................1-9
1.4 DCU identification.......................................................................................................................................................1-14
1.5 ACTUATORS CONTROL.............................................................................................................................................1-15
1.6 MANAGEMENT OF C3I AND AFTER-SALES TRAINING..........................................................................................1-16
1.6.1 Definition of C3I and programming..........................................................................................................1-16
1.6.2 Replacement of an injector........................................................................................................................1-16
1.6.3 Replacement of a DCU...............................................................................................................................1-18
1.6.4 System replacement..................................................................................................................................1-19
1.7 TEST ROUTINES..........................................................................................................................................................1-20
1.7.1 Leak detection cycle...................................................................................................................................1-20
1.8 READING / WRITING THE VIN....................................................................................................................................1-21
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1.8.1 Principle......................................................................................................................................................1-21
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1.8.2 Procedure....................................................................................................................................................1-21
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1.9 Vehicle CONFIGURATION OPTIONS.........................................................................................................................1-22
1.9.1 Reading the configuration.........................................................................................................................1-22
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1.9.2 Writing the configuration..........................................................................................................................1-22
2. DEFECT CODES AND CHECKS
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2.1 DIAGNOSTIC CHARTS / DEFECT CODES..................................................................................................................2-23
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3. NON DETECTABLE FAULTS
3.1 LIST OF FAULTS / SYMPTOMS................................................................................................................................3-149
3.1.1 Irregular acceleration - deceleration.......................................................................................................3-149
3.1.2 Engine hesitation......................................................................................................................................3-150
3.1.3 Engine stop - stalling...............................................................................................................................3-151
3.1.4 Rushing noise...........................................................................................................................................3-152
3.1.5 Noise interference....................................................................................................................................3-153
3.1.6 Engine noise.............................................................................................................................................3-154
3.1.7 Excessive consumption...........................................................................................................................3-155
3.1.8 Engine difficult to start when hot............................................................................................................3-156
3.1.9 Engine starts then stalls...........................................................................................................................3-158
3.1.10 Smoke on acceleration............................................................................................................................3-160
3.1.11 Blue & white smoke.................................................................................................................................3-162
3.1.12 Black smoke..............................................................................................................................................3-163
3.1.13 Lack of power...........................................................................................................................................3-164
3.1.14 Engine does not start...............................................................................................................................3-166
3.1.15 Engine does not stop...............................................................................................................................3-168
3.1.16 Engine dies when moving off.................................................................................................................3-169
3.1.17 Smell of fuel..............................................................................................................................................3-170
3.1.18 Exhaust smells..........................................................................................................................................3-171
3.1.19 Idle speed stuck (too high/too low) No engine brake............................................................................3-172
3.1.20 Idle unstable - hunting.............................................................................................................................3-173
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DIAGNOSTIC I
TABLE OF CONTENTS
3.1.21 Engine overheat.......................................................................................................................................3-175
3.1.22 Excess engine speed on releasing accelerator pedal............................................................................3-176
3.1.23 Too much power......................................................................................................................................3-177
3.1.24 Flat spot on acceleration..........................................................................................................................3-178
4. CHECKS
4.1 DESCRIPTION OF THE CHECKS...............................................................................................................................4-179
4.1.1 Electrical supply circuit check.................................................................................................................4-179
4.1.2 Checking the air inlet circuit....................................................................................................................4-179
4.1.3 Checking the LP circuit.............................................................................................................................4-179
4.1.4 Looking for HP leaks................................................................................................................................4-180
4.1.5 Checking engine parameters...................................................................................................................4-180
4.1.6 Check C3I conformity...............................................................................................................................4-182
4.1.7 Checking the injectors and the HP pump...............................................................................................4-182
4.1.8 Checking the DCU....................................................................................................................................4-182
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 iii

II TECHNICAL INFORMATION
TABLE OF CONTENTS
5. TECHNICAL INFORMATION
5.1 TIGHTENING TORQUES...........................................................................................................................................5-183
5.2 RESISTANCE VALUES..............................................................................................................................................5-184
5.3 WIRING DIAGRAM....................................................................................................................................................5-187
5.4 TOOLING REQUIRED................................................................................................................................................5-189
6. FAULT CODE INDEX
6.1 Fault code index........................................................................................................................................................6-191
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DIAGNOSTIC I
DIAGNOSTIC TOOL FUNCTIONS
1.1 DIAGNOSTIC TOOL CONNECTION

Equipment required
Diagnostic communication is sent by the vehicle's CAN. Adapter YDT321 and diagnostic lead YDT182, or the auxiliary
harness YDT233 if applicable, must be used with the DIAMAND YDT300 diagnostic tool.
YDT300 DIAMAND diagnostic tool
YDT182 Diagnostic lead OBD16

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YDT321 "Diag On CAN" diagnostic interface
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I DIAGNOSTIC

The diagnostic tool is connected using auxiliary harness YDT233 and the terminal box kit for DCU DCM3.2.
YDT233 Auxiliary harness
YDT175 Terminal box
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DIAGNOSTIC I
YDT374 Terminal box interface for DCU DCM3.2 -

YDT375
Terminal box covers for DCU DCM3.2 -

YDT376
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Pins No. of pins available

VBATT 2-01, 2-03, 2-05
Earth 2-02, 2-04, 2-06
CAN+ 2-53
CAN- 2-54
Note: Connector 1: 96 way Connector 2: 58 way

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I DIAGNOSTIC

Diagnostic socket description
The diagnostic socket is of 16 way EOBD type.
Diagnostic socket type: Pin no. Description

4 Earth
5 Earth
6 CAN H
8 + IGN
14 CAN L
16 + batt
Diagnostic socket location
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REXTON/RODIUS/KYRON left side (driver's side) under
the dashboard.
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DIAGNOSTIC I
1.2 READING THE DEFECT CODES
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I DIAGNOSTIC

1.2.1 Principle
This function allows reading data relating to defects stored in the DCU memory. This data is:
• The number of defects stored in the DCU memory.
• The defect code (DTC).
• The (permanent or temporary) status.
• The environment data.
Erasing of the information relating to a defect is done automatically if the defect is not detected again during 40
operating cycles. The DCU memory can only contain ten separate faults.
1.2.2 The environment data.

Environment data allows knowing the system's operating conditions when a defect appears (defect context).
CAUTION
Care must be taken when interpreting environment data for the information is recorded in memory at the same
time as the defect. This means that the environment data does not describe the engine's operating conditions
when the defect is first detected, but when it is detected for the Nth time (N being the number of detections needed
to register the defect in the memory). Furthermore, the defect having been present when it was saved in memory,
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it could be that some of the environment data has been corrupted. In this case, linearized data obtained through
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the conversion of the raw signal is sometimes used, this provides the first data available in the DCU.
Variable Definition
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Air inlet temperature Measurement of the air inlet temperature after the air filter. °C
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Sensor integrated in the airflow meter.
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Atmospheric pressure Atmospheric pressure measurement. mbar
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- Sensor integrated in the DCU.
Turbocharging pressure Turbocharging pressure measurement. mbar
- Sensor located on the inlet manifold after the turbo.
Battery voltage Battery voltage measurement. V
Raw battery voltage. Raw battery voltage measurement. V
Coolant temperature Engine coolant temperature measurement. °C
Engine speed Engine speed measured over a complete cycle (720 degrees). rpm
Engine status Shows the engine's status: No units
- Stopped.
- Starting.
- Engine running.
- Engine stalled.
EGR solenoid valve OCR Value indicating the EGR solenoid valve opening cycle ratio. %
Turbo solenoid valve OCR Value indicating the turbo pressure regulation solenoid valve opening cycle %
ratio.
EGR solenoid valve flap Value indicating the EGR solenoid valve flap control opening cycle ratio. %
OCR
Measured airflow Airflow measurement after the air filter. mg/rev
Diesel temperature Fuel temperature measurement between the transfer pump and the high °C
pressure pump.
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DIAGNOSTIC I
Variable Definition Units

Gearbox ratio Value indicating the gear engaged in the gearbox. No units
- 0 : Neutral.
- 1 to 6: gear engaged.
- 7 : Reverse.
- 8 : Invalid.
Ignition on Value indicating the ignition key status: No units
- Ignition off.
- Ignition on.
Sensor supply 5V (Vext1) Voltage measurement applied at the terminals of the sensors supplied by V
Vext1.
Sensor supply 5V (Vext2) Voltage measurement applied at the terminals of the sensors supplied by V
Vext2.
IMV control OCR Value indicating the IMV control opening cycle ratio. %
- 0% = Fully open (the IMV is not supplied).
- 100% = Closed (Maximum current to the IMV).
Measured rail pressure Rail pressure measurement.
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Secondary supply 2.5V supply for track 2 of the pedal sensor. V
Pre-post heating relay Preheater sparkplugs control status: No units
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control - Deactivated.
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- Activated.
Air conditioning request
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Driver's request: No units
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- Yes = A/C button activated and air conditioning circuit pressure
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correct.
- No = no air conditioning request.
Torque request Accelerator pedal position measurement - correlation with the engine torque. Nm
Vehicle's speed Vehicle's speed measurement. km/h
Vehicle's mileage Distance covered by the vehicle. km
DPF differential pressure Pressure variation measurement between DPF inlet and outlet kPa
Raw catalyst upstream Catalyst inlet temperature measurement °C
temperature
Raw downstream catalyst Catalyst outlet temperature measurement °C
temperature
DPF load Soot quantity measurement in the DPF %
Regeneration assisting Indicates the DPF regeneration progress No units
status
Engine charging Indicates the torque developed by the engine nM
Exhaust temperature Indicates the exhaust temperature °C
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I DIAGNOSTIC
1.3 READING OF DYNAMIC PARAMETERS
The dynamic parameters allow checking the system status in real time.
Note: Some variables may be represented in three different ways:

• Raw value
• Linearized value
• Physical value
The diagram below shows the processing sequence of an analogue signal with different representations of the variable
associated with it.
Linearised Physical
Sensor Measurement Raw Conversion Filtering
value value
signal and conversion value
SENSOR
V x 0.1 - 50 degC, rpm... Deg C, rpm...
V
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0...1023
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Analogue - digital
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converter
Software
DCU
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The raw value
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(Example: Raw atmospheric pressure, raw air flow, raw
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diesel temperature etc...) V
The raw value is the image, supplied by the analogue - Vext
digital converter, of the voltage transmitted by the DCU
inlet sensor. This value is difficult to interpret, but may
allow detecting a sensor or DCU defect (analogue-digital
converter) or a defect on the harness.
This value is typically found between 0 and 1023. In some
cases it can also be converted into a physical value by
the diagnostic tool (°C, bar etc...).
0
0 1023
Raw value
The linearised value

(Example: Linearized atmospheric pressure, linearized air flow, linearized diesel temperature etc...)
The linearized value of a variable is the raw value transmitted by the sensor, to which a conversion function is applied
to obtain a physical value representative of the value measured. We thus for example obtain values in Celcius degrees,
rpm etc.
The physical value
(Example: Atmospheric pressure, requested air flow, diesel temperature, etc...)
This is the "default" value of a variable used in various system strategies. Under normal conditions, the linearized value
and the physical value are practically the same.
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DIAGNOSTIC I

If a sensor defect appears (OC or SC+ for example), the physical variable associated with the sensor then takes a recovery
value, while the linearized variable displayed has a corrupted value.
1.3.1 List of parameters

Defect LED status Indicates the status of the defect LED control: No units
- Deactivated (LED off).
- Activated (LED on).
Engine status Shows what the engine's status is: No units
- Stopped.
- Starting.
- Engine running.
- Engine stalled.
Air conditioning relay Indicates the status of the air conditioning relay control: No units
control - DCU prevention (the air conditioning compressor is not controlled).
- DCU authorisation (the air conditioning compressor is controlled).
Fan switch Indicates the fan switch status:
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- Open.
- Closed (the fan condensers are operating).
Fan setting 1
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Indicates the fan rotation proportion compared to the maximum speed %
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possible.
Fan setting 2 -
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Yes (Fan 2 rotation request). %
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- No (no rotation reqeust).
Stop switch (brake pedal) Indicates the position of the stop switch: No units
- Open (brake pedal released)
- Closed (brake pedal depressed)
Safety switch (brake pedal) Indicates the position of the safety switch: No units
- Open (brake pedal depressed)
- Closed (brake pedal released)
The position of the safety switch should be the opposite of the stop switch
position.
Brake pedal Indicates the position of the brake pedal: No units
- Depressed.
- Released.
Clutch switch Indicates the position of the clutch switch: No units
- Open (clutch pedal released)
- Partially open.
- Closed (clutch pedal depressed).
Fuel filter LED status This is the status of the fuel filter control LED: No units
The LED is lit when water is detected in the diesel fuel filter.
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I DIAGNOSTIC

PPH LED status This is the status of the preheating control LED: No units
Air conditioning request Informs you on the detection of the air conditioning requests: No units
• Yes (indicates that the DCU has detected an air conditioning request.
The request is detected if and only if the following conditions are met
(A/C button activated, passenger compartment ventilation operating
and refrigerant fluid pressure correct).
• No (indicates that at least one of the above conditions has not been
met).
Passenger compartment Indicates if the ventilation control in the passenger compartment is activated No units
ventilation status or not:
- Activated (if terminal 107 of the DCU is earthed).
- Deactivated (if terminal 107 of the DCU is not earthed).
Water heater 1 status This is the status of the water heater 1 control: No units
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- Activated (if the DCU has earthed terminal 61).
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- Deactivated (if the DCU has connected terminal 61 to +bat).
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Water heater 2 status This is the status of the water heater 2 control: No units
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- Activated (if the DCU has earthed terminal 62).
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- Deactivated (if the DCU has connected terminal 62 to +bat).
Gearbox ratio
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Value indicating the gear engaged in the gearbox. With a manual gearbox: No units
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- 0 : Neutral.
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- 1 to 6: gear engaged.
- 7 : Reverse.
- 8 : Invalid.
Pre-post heating control Preheater plugs control status: No units
- Activated (preheater plugs supplied).
- Deactivated (preheater plugs not supplied).
EGR solenoid valve setting This indicates the fresh air flow which should be let in and measured by the mg/rev
flowmeter. It increases with engine speed and torque and is therefore
inversely proportional to the volume of exhaust gas.
Measured airflow Measurement of the airflow after the air filter. mg/rev
Raw air flow Measurement of the air flow after the air filter. The raw value corresponds No units
to the conversion of the analogue signal transmitted to the DCU input to a
digital signal. Correspondance between the digital value displayed and the
voltage issued by the air flowmeter: [300 => 1.5V], [400 => 2V], [640 => 3V],
[850 => 4V], [1000 => 4.8V].
Coolant temperature Measurement of the engine coolant temperature. °C
Linearized coolant Measurement of the engine coolant temperature. The linearized value °C
temperature corresponds to the conversion in a physical value of the signal transmitted
to the DCU inlet.
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DIAGNOSTIC I

Air temperature. Measurement of the inlet air temperature after the air filter (sensor integrated °C
in air flowmeter). The measured value corresponds to the temperature of the
outside air.
Linearized air temperature. Inlet air temperature measurement after the air filter. The linearized value °C
corresponds to the conversion of the signal transmitted to the DCU input to
a physical value.
Diesel temperature Fuel temperature measurement between the transfer pump and the high °C
pressure pump.
Linearized diesel Fuel temperature measurement between the transfer pump and the high °C
temperature pressure pump. The linearized value corresponds to the conversion of the
signal transmitted to the DCU input to a physical value.
Atmospheric pressure Atmospheric pressure measurement (the sensor is integrated in the DCU). bar
Linearized atmospheric Atmospheric pressure measurement (the sensor is integrated into the bar
pressure DCU). The linearized value corresponds to the conversion of the signal
transmitted to the DCU input to a physical value.
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Measured rail pressure Rail pressure measurement. bar
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Linearized rail pressure Rail pressure measurement. The linearized value corresponds to the bar
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conversion of the signal transmitted to the DCU input to a physical value.
Requested rail pressure Pressure request determined by the DCU as a function of the engine operating bar
conditions.
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Manifold pressure Measurement of the turbocharging pressure. bar
Linearized manifold
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Turbocharging pressure measurement. The linearized value corresponds to bar
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pressure the conversion of the signal transmitted to the DCU input to a physical value.
Requested manifold Turbocharging pressure request determined by the DCU as a function of the bar
pressure engine operating conditions.
Battery voltage Battery voltage measurement. V
Pedal position Measurement of the accelerator pedal position measurement. %
Pedal position track 1 Position of the accelerator pedal measured by track 1. %
Pedal position track 2 Position of the accelerator pedal measured by track 2. %
Idle speed setting Idle speed request determined by the DCU as a function of: rpm
- The engine temperature and the gear engaged (the idle setting
reduces as the engine temperature increases).
- Activation of the water heaters.
- Activation of the air conditioning.
- The battery voltage.
Engine speed Engine speed measured over a complete cycle (720 degrees). rpm
Indicated engine torque This represents the torque which the engine should produce. Obtained by N.m
adding together the "driver's request" (calculated from the pedal position)
and the resistant torque.
Vehicle speed Measurement of the vehicle speed. km/h
Requested fuel Represents the total fuel requested (pilot + main). mg/rev
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I DIAGNOSTIC

Main fuel requested Injected fuel request (for the main injection) determined by the DCU as a mg/rev
function of the engine operating conditions.
Pilot fuel requested Injected fuel request (for the separate pilot injection) determined by the DCU mg/rev
as a function of the engine operating conditions.
Note: The separate pilot injection is only used in the starting phase. When
the engine is running, the close pilot injection is used.
Main advance requested Main injection advance request determined by the DCU as a function of the engine degrees
engine operating conditions.
Pilot advance requested Advance request (for the separate pilot injection) determined by the DCU as engine degrees
a function of the engine operating conditions.
EGR solenoid valve control Value indicating the EGR solenoid valve control opening cycle ratio. %
OCR
EGR throttle solenoid valve Value indicating the EGR throttle solenoid valve control opening cycle ratio. %
control OCR
IMV control OCR Value indicating the IMV control opening cycle ratio. %
- 0% = Fully open (the IMV is not supplied).
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- 100% = Closed (Maximum current to the IMV).
Turbo solenoid valve OCR Value indicating the turbo pressure regulation solenoid valve control opening %
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cycle ratio.
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Linearised sensor supply Measurement of the voltage applied at the terminals of the sensors supplied V
(Vext1)
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by Vext1. The linearised value corresponds to the conversion of the signal
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Linearized sensors supply Measurement of the voltage applied at the terminals of the sensors supplied V
(Vext2) by Vext2. The linearized value corresponds to the conversion of the signal
Secondary supply 2.5V supply for track 2 of the pedal sensor. V
Linearised sensor supply Measurement of the voltage applied at the terminals of the sensors supplied V
(Vext1) by Vext1.
Linearized sensor supply Measurement of the voltage applied at the terminals of the sensors supplied V
(Vext2) by Vext2.
HSD 1 voltage Measurement of the voltage at the terminals of HSD 1 (injector control V
circuit).
HSD 2 voltage Measurement of the voltage at the terminals of HSD 2 (injector control V
circuit).
Accelerometer 1 noise level Level of noise measured by accelerometer 1 (corresponds to the measurement No units
of background noise).
Accelerometer 2 noise level Level of noise measured by accelerometer 2 (corresponds to the measurement No units
of background noise).
Cruise control (ON/OFF Indicates the status of the ON/OFF button for the cruise control system: No units
button) - Activated.
- Deactivated.
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DIAGNOSTIC I

Cruise control (safety Indicates the status of the safety button for the cruise control system: No units
- Deactivated.
Cruise control (acceleration Indicates the status of the acceleration button for the cruise control system: No units
- Deactivated.
Cruise control (deceleration Indicates the status of the deceleration button for the cruise control system: No units
- Deactivated.
Cruise control (recall Indicates the status of the recall button for the cruise control system: No units
- Deactivated.
Engine immobiliser status - Deactivated = immobiliser deactivated (the engine may be started). No units
- Activated = immobiliser activated (the engine may not be started).
Ignition key Ignition switch status No units
DCU relay status
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Indicates the status of the injection DCU supply relay control: No units
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- Activated (DCU supplied).
- Deactivated (DCU not supplied).
Cyl. by cyl. balancing offset
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Offset determined by the fuel balancing strategy in each cylinder (cylinder μs
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– cyl. 1 balancing strategy). This offset is applied to the injector control pulse for
cylinder 1.
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Cyl. by cyl. balancing offset Offset determined by the fuel balancing strategy in each cylinder (cylinder μs
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cylinder 2.
cylinder 3.
cylinder 4.
cylinder 5.
MDP – cylinder 1 Indicates the minimum pulse value for cylinder 1. μs
MDP update – cylinder 1 Minimum pulse update number for cylinder 1. No units
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I DIAGNOSTIC

Vehicle mileage Distance covered by the vehicle. km
VLC(0) Correction The calculated correction at low engine speed by the VLC strategy. This Nm
correction helps reduce the flow request so that the pressure can still be
controlled when the system is under-capacity.
VLC(1) Correction The calculated correction at high engine speed by the VLC strategy. This Nm
correction helps reduce the flow request so that the pressure can still be
controlled when the system is under-capacity.
1.4 DCU identification
This service allows identifying:

- The software version and calibration of the injection DCU.
DCU identification Meaning
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N Indicates the type of DCU:
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N => Common Rail 32 bits DCM3.2 DCU
SOFTWARE VERSION c Identifies the vehicle manufacturer:
(5 characters) C => SsangYong
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D
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Indicates the type of software (takes into account the vehicle or engine application).
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08 Indicates the modification level applied to the software.
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CALIBRATION A This letter is assigned according to the vehicle configuration (number of cylinders, type of gearbox, engine
VERSION power...).
(3 characters) A3 This figure indicates the type of calibration contained in the injection DCU.
Note: The above identification is given as an indication. To display the identification, select "DCU IDENTIFICATION" in
the diagnostic menu of the tool.
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DIAGNOSTIC I
1.5 ACTUATORS CONTROL
The diagnostic tool allows controlling the state of some DCU outputs.
Output Verification conditions Normal consequences on the system

EGR solenoid valve Ignition on, pre-starting The solenoid valve oscillates between two states
Solenoid valve flap Ignition on, pre-starting The solenoid valve oscillates between two states
Turbo solenoid valve Ignition on, pre-starting The solenoid valve oscillates between two states
Defect LED Ignition on, pre-starting The defect LED flashes.
High speed fan Ignition on, pre-starting Fan activation (high speed)
Low speed fan Ignition on, pre-starting Fan activation (low speed)
Preheating LED Ignition on, pre-starting The preheating LED flashes
Fuel filter LED Ignition on, pre-starting The fuel filter LED flashes
Supply relay Ignition on, pre-starting The relay oscillates between two states
Pre-post heating relay Ignition on, pre-starting The relay oscillates between two states
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Engine immobiliser LED Ignition on, pre-starting The immobiliser LED flashes
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Air conditioning relay Ignition on, pre-starting The relay oscillates between two states
Water heater relay 1 Ignition on, pre-starting The relay oscillates between two states
Water heater relay 2
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Ignition on, pre-starting The relay oscillates between two states
Inlet metering valve (IMV)
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Ignition on, pre-starting The IMV piston vibrates (no audible noise)
Injector – cylinder 1
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Ignition on, pre-starting Injector of cylinder 1 valve vibrates
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Injector – cylinder 2 Ignition on, pre-starting Injector of cylinder 2 valve vibrates
To select an actuator, observe the following procedure:

• Select menu 1: "DIAGNOSTIC MENU"
• Select menu 3: "ACTUATOR CONTROLS"
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I DIAGNOSTIC
1.6 MANAGEMENT OF C3I AND AFTER-SALES TRAINING
1.6.1 Definition of C3I and programming

C3I is a calibration which is proper to each injector. It describes the initial specifications of the injector in question.
C3I is determined when the injector is tested at the end of assembling. It is represented by a 20 character
alphanumerical code, which is clearly shown on a label applied on the injector-holder body.
Trainings are corrective terms that allow characterizing the ageing of injectors. Determined by the accelerometer
strategy which allows a closed loop correction of the injector MDP.
The DCU determines the pulse applied to the injector as a function of:
• The target which represents the initial average characteristics of a representative set of injectors.
• The C3I which represents the initial characteristics of each individual injector.
• Programmings which represent the current state of each injector (taking into account wear and ageing of
components).
The DCU must therefore know the C3I to determine with precision the pulse to be applied to each injector. This
condition is necessary to ensure optimum operation of the injection system. If the C3I of an injector is not entered
into the DCU, the DCU applies an uncorrected pulse to the injector as a function of the injector's own
characteristics, which may lead to serious degradation in the engines performance.
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In the same way, the DCU must also learn the MDP trims relative to each injector. If these trims are lost, the pulse
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which should be applied to each injector will not take into account the ageing of components, which results in a
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temporary degradation in engine performance.
For further information, refer to the manual
In after-sales:
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1. If an injector is replaced, the C3I of that injector must be entered into the DCU. The DCU automatically
n
reinitialises the programming values for this injector when the C3I is entered.
2.
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When replacing the DCU, the following should be done:
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• Enter the C3I values into the new DCU.
• Enter the vehicle VIN.
• Synchronise the immobiliser and the DCU (function not available in DIAMAND).
Note: It is not possible to copy the learnt MDP trim values from the faulty DCU into the new DCU. The new
DCU therefore uses default values to define the pulse to be applied to each injector. It is therefore possible
that the vehicle performance may be degraded during the first few hundred kilometres following the repair.
This degraded performance is rapidly corrected by the accelerometer strategy which learns the actual
characteristics of the injectors as recycling progresses.
3. In case of system replacement, it will be necessary to do the following:
• Enter the C3I for all the injectors in the DCU. Make sure of the cylinder number.
Note: When replacing the system, the programming does not need to be reinitialised for this application.
Special functions are available in the diagnostic tool to carry out these operations easily in the after sales network.
1.6.2 Replacement of an injector

If an injector has to be replaced, the C3I for the new injector must be entered into the DCU. To do this, perform
the following procedure:
• In the diagnostic menu, click on the "SPECIAL FUNCTIONS" button.
• Click on the "C3I" button.
• On the ''C3I menu'' screen, click on the ''WRITE A C3I button''.
• On the ''C3I entry'' screen, enter the C3I in the special field. The C3I is shown on the label on the new injector.
© Delphi
1-16 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

• Click on the button corresponding to the cylinder to calibrate. A photo of the engine shows the cylinder
layout.
N.B. All the C3I are shown in relation to the cylinder number and not the injector number.
Note: The C3I includes a checksum which allows detecting entry errors. The checksum is the result of a calculation
performed on all the values contained in the C3I. When the DCU receives a new C3I it carries out the same
calculation. If the result is identical to the checksum contained in the C3I, it means that the values entered by the
operator are correct. In this case, the DCU saves the C3I in its memory and returns a positive response: "The
injector calibration is successful". If the result is different, it indicates a code entering error. In this case, the DCU
returns a negative response: "Write error". The operator must restart the procedure from the beginning.
To check that the C3I entered are correctly saved, the DCU memory can be consulted. To do this follow the
procedure below:
• Click the "C3I" button.
On the ''C3I menu'' screen, click on the button ''READ C3I''. The C3I READ screen appears with, in the lower
part a photo of the engine to quickly locate the cylinders and in the upper part, the C3I for each injector.
Check the conformity of the C3I saved in the DCU memory with the labels on the injectors. If they do not
match, correct the data saved in the DCU memory using the "C3I MENU".
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 1-17

I DIAGNOSTIC

1.6.3 Replacement of a DCU
If the DCU fails, before replacing it, try to recover the injection system data saved in it (C3I for each injector) so
as to copy it in the new DCU. If it is not possible to communicate with the faulty DCU, the data should be entered
manually in the new DCU.
A. Copying the C3I
In some cases, despite the failure in the DCU, it is still possible to recover the data so that it can be copied
to the new DCU. To do so, proceed as follows:
• Click on the "DCU" button.
• Click on the “CHANGE DCU” button, the “change DCU” screen appears.
• Follow the instructions given by DIAMAND:
Click on the “READ C3I” button to check that the data is not corrupt. If the C2I are corrupt, abort the
procedure and copy the C3I manually into the new DCU, otherwise continue.
• Click on “START PROCEDURE” to transfer the C3I from the faulty DCU to the computer memory. If the
transfer fails, check the connections, the ignition key and start the procedure again, otherwise continue.
- Switch off the ignition for at least 30 seconds.
- Remove the faulty DCU.
- Put the new injection DCU in position.
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- Switch on the ignition.
• Once the ignition is on, click on "CONTINUE PROCEDURE" to transfer the C3I from the faulty DCU to
d
the new DCU. If the transfer fails, follow the instructions given by DIAMAND. If the problem persists,
c e
click on "RESTART THE WHOLE PROCEDURE FROM THE START". If the transfer is successful, continue.
n
a
- Check the C3I by clicking on "READ C3I". Check the conformity of the C3I saved in the DCU
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memory with the labels on the injectors.
- Erase the diagnostic trouble codes by clicking on "DEFECT CODES".
B. Manual entry of the vehicle configuration
In some cases it is impossible to communicate with the faulty DCU. The C3I for each injector must then be
entered manually (See § 1.5.2).
Note: If no C3I are saved, the DCU uses default values. The degradation of the vehicle's performance will
be significant and permanent. Activation of the limp home strategy (engine speed set to 1300 rpm regardless
of pedal position).
C. Writing of the VIN
After copying or manually entering the C3I in the new DCU, enter the vehicle VIN (refer to § 1.7).
D. Synchronisation of the immobiliser and the DCU
Function not available in DIAMAND.
The immobiliser must be reset by Ssangyong.
© Delphi
1-18 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

1.6.4 System replacement
a. If it is necessary to replace the injection system (pump, injectors, HP pipes…) apart from the DCU, the C3I
for the four injectors must be entered manually (See § 1.5.2).
b. Zero reset of VLC.
Problem
The combination of parameters such as fuel temperature, internal part wear, filter condition ... etc means that the
injection system may reach its limits while operating. In this case, the pressure demand in the rail cannot be
maintained due to a lack of capacity in the system and the DCU will generate a fault. The diagnosis of such a
system then becomes very difficult and may lead to unjustified replacement of components.
Description of the VLC principle

The change of most of the parameters mentioned above is not known or difficult to evaluate by the DCU. So as
to avoid the generating of a failure, the DCU will reduce the fuel requested to a value that allows it to maintain
and check the pressure in the rail, ie it will adjust – within certain limits - in a dynamic manner the injection system's
operation according to the operating peak (fuel temperature, engine speed…).
This strategy is known as VLC (Variable Limit Capacity).
In practice, this strategy manifests itself by the calculation of 2 offsets.
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The VLC offsets can be read using the diagnostic tool.
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Diagnosis of an under-capacity system
In the event of a complaint for an under-capacity system, 2 cases may arise:
d
1. Appearance of defect code P1170 (correction of high fuel flow - VLC strategy).
c e
If a defect code is raised by the DCU on a vehicle with VLC strategy, it indicates that the system is
n
overshooting the operating zone for that strategy (ie more fuel than the maximum authorised is taken).
a
In this case, there is a real defect of one or more components.
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2. No defect is raised by the DCU.
In this case the defect is of "lack of performance" type. This symptom may have 2 causes:
=> Change to VLC mode.
=> Defect of one or more components which may affect engine performance.
Follow the diagnostic procedure below:

a. Conditions under which symptom appear:
=> Intermittent defect
=> Fuel level near minimum
=> Heat conditions
b. Diagnosis of the following elements:
=> Turbo
=> Counter pressure at exhaust
c. Reading the VLC offsets using the diagnostic tool:
If the offsets are null, the VLC strategy has not been activated. In this case, follow the conventional
diagnostic procedure for the high pressure circuit.
If the offsets are not null, the strategy has been activated. In this case, there are no defective
components and the under-capacity of the system is "normal".
Using the zero reset service

Follow the procedure below:
=> Read the defect codes.
=> If there is P1170, carry out a system diagnosis.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 1-19

I DIAGNOSTIC

=> Replace the faulty component (Pump, injector...).
=> Do a zero reset using the service.
Note: This service should be used if the high pressure pump is to be replaced.
1.7 TEST ROUTINES
Test routines are pre-defined services that can be launched using an external tool (diagnostic tool or end of line calibration
tool). DIAMAND proposes a test routine:
• Leak detection cycle.
1.7.1 Leak detection cycle

A) Principle
After intervening on the high pressure circuit, it is necessary to check the absence of high pressure leaks. To avoid
having to carry out a road test, the DCU has a leak detection cycle that puts the injection system under high
pressure.
The leak detection cycle consists in performing four no load accelerations, during which the pressure request is
forced up to a value close the maximum pressure authorised by the system (1600 bar) for approximately five
seconds. This cycle can only be activated when the following conditions are met:
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• Engine running.
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• The coolant temperature is higher than 60°C.
• The vehicle speed is zero.
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• The gearbox is in neutral (manual gearbox) or the P/N position (automatic transmission).
• The system has not detected any failures.
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This cycle can be launched using the diagnostic tool.
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CAUTION
In order to avoid any risk of injury from a jet of high pressure diesel, it is recommended that this test be carried
out with the bonnet closed. DELPHI DIESEL SYSTEMS does not accept any liability for injuries sustained during
a leak detection cycle.
© Delphi
1-20 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

B) Procedure
• Apply leak detector solution to the connectors removed during the procedure.
• Start the engine.
• Let the engine idle until the coolant temperature exceeds 60°C.
• Close the bonnet.
• In the diagnostic menu, select "ROUTINES".
• Click on the "LAUNCH" button to activate the leak detection cycle.
• If the conditions required to start the cycle are met, the engine will perform four no load accelerations.
• Wait a few seconds then switch off the ignition.
• Open the bonnet and visually check for diesel leaks revealed by the leak detector solution previously applied
to the connectors removed during the operation.
• Remove the leak detection solution using a solvent of "CARECLEAN" type.
CAUTION
In case of leaks, it is essential to carefully remove all traces of leak detection solution before opening the high
pressure circuit, for particles of the leak detection solution may pollute the injection system.
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1.8 READING / WRITING THE VIN
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1.8.1 Principle
d
The V.I.N. (Vehicle Identification Number) is the vehicle chassis number. By law, when a DCU is replaced, agents
e
are asked to enter the chassis number into the new DCU. This procedure can be carried out with the diagnostic
c
tool.
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1.8.2 Procedure
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To access the READ/WRITE VIN screen:
• Select the "DCU" button.
• Click on the "READ/WRITE VIN" button.
If no VIN is saved in the DCU, a "WRITE VIN" button is available.
Enter the VIN and click on the "WRITE VIN" button.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 1-21

I DIAGNOSTIC
1.9 Vehicle CONFIGURATION OPTIONS
This service allows reading the vehicle configuration options.
1.9.1 Reading the configuration

• In the special functions menu, click on the "VEHICLE CONFIGURATION OPTIONS" button to display the
current configuration contained in the injection DCU.
Possible configurations according to options:
Options Possible configurations

DCU configuration Yes / No
Water heaters Absent / Present
Cruise control Absent / Present
Immobiliser Absent / Present
Gearbox Manual / Automatic
Automatic starting
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Absent / Present
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Vehicle speed information Multiplexed / Wire
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Emissions cycle ECE / FTP
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ESP Absent / Present
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TCCU Absent / Present
Fan control (PWM)
v a Yes / No
1.9.2 Writing the configuration

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This service is not available for this application.
© Delphi
1-22 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
DEFECT CODES AND CHECKS
2.1 DIAGNOSTIC CHARTS / DEFECT CODES

AIR FLOWMETER SIGNAL
Diagnostic Diagnostic tool title Detection
trouble code
P0100 Flowmeter supply - Vext 5V supply defect or analogue / digital converter defect
P0101 Air flowmeter signal Non plausible airflow information
P0102 Flowmeter signal - low Airflow information at permanent low level
P0103 Flowmeter signal - high Airflow information at permanent high level
Fault LED Recovery mode
On => EGR control deactivated
=> Cruise control deactivated
=> Acceleration control deactivated
Symptoms
=> Unstable engine speed
=> Smoke
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=> Lack of performance
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Electrical faults Diagnostic tool title
OC Flowmeter signal - low
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SC- Flowmeter supply - Vext
SC+
c eFlowmeter supply - Vext
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OC Flowmeter signal - high
SC-
v a Flowmeter signal - low
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SC+ Flowmeter signal - high
OC Flowmeter signal - high
SC- on 108 (5V supply to turbocharging pressure sensor) Flowmeter supply - Vext
SC+ (5V power supply to turbocharging pressure sensor) Flowmeter supply - Vext
SC-(5V power supply to turbocharging pressure sensor) Flowmeter supply - Vext
SC+(5V power supply to turbocharging pressure sensor) Flowmeter supply - Vext
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-23

I DIAGNOSTIC
Swirl valve signal 5

1 93 EGR
Swirl actuator
differential
51 pressure
sensor
Air temperature signal 53
2 54
Earth sensor
3 61 EGR
Flow meter 29 1
Power supply 5V - Vext2 temperature
4 60 2 sensor 1
78
DCU
5 Flow meter signal
70
30 1 EGR
Earth EGR feedback 9 temperature
4 2 sensor 2
6
VREF EGR feedback 33
EGR solenoid 2
valve 44
82 1 EGR
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6 temperature
p
EGR feedback 23 2 sensor 3
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Solenoid valve control 48
5
ed
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Fault chart (Code P0100 - P0101 - P0102 - P0103)
Stage Operation / Decision
an Result
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1 Check the supply to the sensor terminals Carry out the repairs required.
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Is there a supply problem?
2 Check the sensor connection Carry out the repairs required.
Is there a connection problem?
3 Check the electrical features (See Reference values Chapter) and Replace the sensor
correlative value read with the expected value
Wrong features?
4 Check the connection of the DCU Carry out the repairs required.
5 With the terminal box check the continuity and electrical insulation Carry out the repairs required.
of lines
Is there a wire problem?
6 Replacing the sensor Replace the DCU
Does the problem persist?
© Delphi
2-24 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
TURBOCHARGING PRESSURE SIGNAL

trouble code
P0105 Turbo pressure sensor supply - Vext 5V supply fault or analogue / digital converter fault
P0106 Turbo pressure signal - high - ignition on Inlet pressure greater than 2490 mbar when switching on
P0107 Turbo pressure signal - low Inlet pressure less than 500 mbar
P0108 Turbo pressure signal - high Inlet pressure greater than 2490 mbar
P0109 Turbo pressure signal - low - ignition on Inlet pressure less than 500 mbar when ignition switched on
Off Turbo pressure control in open loop
Symptoms
Lack of performance
SC-(5V supply to flowmeter) Turbo pressure sensor supply - Vext
SC+ (5V supply to flowmeter) Turbo pressure sensor supply - Vext
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OC Turbo pressure signal - low
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SC- Turbo pressure sensor supply - Vext
SC+ Turbo pressure sensor supply - Vext
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OC Turbo pressure signal - high
SC-
c eTurbo pressure signal - low
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SC+ Turbo pressure signal - high
Drift
v a Turbo pressure signal - low - when ignition switched on
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Turbo pressure signal - low - when ignition switched on
OC Turbo pressure signal - high
SC-(5V power supply to turbocharging pressure sensor) Turbo pressure sensor supply - Vext
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-25

I DIAGNOSTIC
DCU power supply

Power supply relay 3
F1 DCU power supply
KL30 KL87
1 58 channel
F2 DCU power supply connector
KL30
5
Power supply control
44
Battery Turbo
12V solenoid valve
1 Solenoid valve control DCU
2 71
Earth sensor
Earth A 83
96 channel
Supercharging connector
B NC.
pressure
sensor Power supply 5V - Vext2
C 60
Sensor signal
D 63
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Fault chart (Code P0105 - P0106 - P0107 - P0108 - P0109)
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Stage Operation / Decision Result
c
1 Is trouble code P0105 present? Disconnect the sensors supplied by Vext one by one and check if
an the fault disappears. If the defect is no longer present, the sensor
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that was disconnected was faulty. If the defect is still present after
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replacing the sensor, then check the continuity and electrical
insulation of the disconnected line.
2 Check the air inlet circuit's conformity (tightness of clips, fouling, Carry out the repairs required.
incorrect assembly...)
Air line problem?
3 Check the sensor connection Carry out the repairs required.
Connection problem?
4 Visually inspect the sensor Replace the sensor
Is there a sensor problem?
6 Check the continuity and the electrical insulation of wires Carry out the repairs required.
7 Replace the sensor Change the DCU
8 The problem is resolved
© Delphi
2-26 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
AIR TEMPERATURE SIGNAL

trouble code
P0110 Air temperature sensor supply - Vext 5V supply defect or analogue / digital converter defect
P0112 Air temperature signal - low Inlet air temperature less than -40°C.
P0113 Air temperature signal - high Inlet air temperature greater than 120°C.
On Water heaters deactivated
Symptoms
None
OC Air temperature signal - high
OC Air temperature signal - high
SC- Air temperature signal - low
SC+ Air temperature signal - high
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1 93 EGR
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Swirl actuator
differential
e
51 pressure
c
sensor
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Air temperature signal
a
54 53
2
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Earth sensor
3 61 EGR
Flow meter 29 1
4 60 2 sensor 1
78
DCU
5 Flow meter signal
70
30 1 EGR
4 2 sensor 2
6
EGR solenoid 2
valve 44
82 1 EGR
6 EGR feedback temperature
23 2 sensor 3
5
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-27

I DIAGNOSTIC
Fault chart (Code P0110 - P0112 - P0113)

1 Is defect code P0110 present? Disconnect the sensors supplied by Vext one by one and check if
the defect disappears. If the defect is no longer present, the sensor
2 Check the sensor's connection Carry out the repairs required.
Connection problem?
3 Measure the characteristics (voltage or resistance) at the sensor Replace the sensor
terminals
Is there a characteristic problem?
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6 Change the DCU
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© Delphi
2-28 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
COOLANT TEMPERATURE SIGNAL

trouble code
P0115 Coolant temperature sensor supply - Vext 5V supply defect or analogue / digital converter defect
P0117 Coolant temperature signal - low If the coolant temperature is less than -40°C
P0118 Coolant temperature signal - high If the coolant temperature is greater than 140°C
Off Reconstitution of the coolant temperature (fuel temperature for 1 minute then temperature limited to 80°C)
Symptoms
None
OC Coolant temperature signal - high
SC- Coolant temperature signal - low
SC+ Coolant temperature signal - high
OC Coolant temperature signal - high
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Temperature 1
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Temperature signal
156
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sensor DCU
Earth sensor
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Water
4 157
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1 Is defect code P0115 present? Disconnect the sensors supplied by Vext one by one and check if
terminals
6 Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-29

I DIAGNOSTIC
PEDAL SENSOR SIGNAL TRACK 1

trouble code
P0120 Pedal sensor track 1 supply – Vext 5V supply defect or analogue / digital converter defect
P0122 Pedal sensor track 1 signal – low Information for track 1 less than 4%
P0123 Pedal sensor track 1 signal – high Information for track 1 greater than 95%
On => Cruise control deactivated
=> Reduction in indicated torque
Symptoms
OC Pedal sensor track 1 signal – low
SC- 5V supply defect or analogue / digital converter defect
SC+ 5V supply defect or analogue / digital converter defect
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OC Pedal sensor track 1 signal – high
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SC- Pedal sensor track 1 signal – low
SC+ Pedal sensor track 1 signal – high
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OC Pedal sensor track 1 signal – high
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Pedal sensor
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Power supply track 1 (5V) 58 channel
24 72
connector
Signal track 1
Track 1 25 71
1
Earth Track 1
3 26 53
Power supply track 2 (5V) DCU
5 10 57
4 Signal track 2
Track 2 13 32
6
Earth Track 2
14 14
2

© Delphi
2-30 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-31

I DIAGNOSTIC
MDP UPDATES
trouble code
P0147 Number of MDP updates (Low Pressure) This defect is lifted when the accelerometer is not running in pressure area #1
P0148 Number of MDP updates (Low Pressure) This defect is lifted when the accelerometer is not running in pressure area #1
Off • Torque reduction requested
Symptoms
Lack of performance
Fault chart (Code P0147 - P0148)

1 Write the C3I for the injector concerned with the diagnostic tool, The problem is resolved
erase the defects then switch the ignition off and on again
Is the fault resolved?
2 Replace the injector and enter the new C3I in the DCU Change the DCU
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© Delphi
2-32 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
INJECTOR - MDP DRIFT

trouble code
P0171 Injector-holder cylinder 1 - MDP drift This defect is lifted when the MDP calculated is below the predefined threshold
value.(injector-holder drift)
value.(injector-holder drift)
value. (injector-holder drift)
On => Accelerometer decoding deactivated
=> Pilot and post injection deactivated
y
=> Rail discharge by cylinder injector 1,2,3,4 or 5 deactivated
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=> Pressure control defect detection (loop difference and trim) deactivated
=> Torque limitation
ed
=> Reduced fuel mode activated
c
=> EGR control deactivated
Symptoms
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=> Rushing noise when reaccelerating after a no load position
=> Engine noisy
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-33

I DIAGNOSTIC
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
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Is the defect resolved?
2 Replace the injector and enter the new C3I in the DCU Change the DCU
© Delphi
2-34 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
FUEL TEMPERATURE SIGNAL

trouble code
P0180 Fuel temperature sensor supply - Vext 5V supply defect or analogue / digital converter defect
P0182 Fuel temperature signal - low If the fuel temperature is less than -40°C
P0183 Fuel temperature signal - high If the fuel temperature is greater than 140°C
Off Pressure control defect detection (trim) deactivated
Symptoms
None
OC Fuel temperature signal - high
SC- Fuel temperature signal - low
SC+ Fuel temperature signal - high
OC Fuel temperature signal - high
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Temperature signal
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Temperature 1 108
n
sensor DCU
a
Gas oil Earth sensor
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2 132
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terminals
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-35

I DIAGNOSTIC

6 Change the DCU
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© Delphi
2-36 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Rail pressure signal

trouble code
P0190 Rail pressure sensor supply - Vext 5V supply defect or analogue / digital converter defect
P0191 Rail pressure signal - pressure drop Pressure drop greater than 250 bar between two successive measurements
P0192 Rail pressure signal - low Rail pressure less than -112 bar
P0193 Rail pressure signal - high Rail pressure greater than 1912 bar
On => Pilot and post injections deactivated
=> Rail discharge through injectors deactivated
=> Pressure control defects detection (loop difference & trim) deactivated
=> Cylinder balancing strategy deactivated
=> Accelerometer decoding deactivated
=> Leak detection cycle prevented
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=> IMV fully open
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=> Overpressure detection deactivated
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=> Mode Limp Home activé
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Symptoms
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=> Engine noisy
=> Idle unstable
OC Rail pressure signal - high
SC- Rail pressure signal - low
SC+ Rail pressure signal - high
SC- Rail pressure sensor supply - Vext
SC+ Rail pressure sensor supply - Vext
CC- (alimentation débitmètre d’air) Rail pressure sensor supply - Vext
CC+ (alimentation débitmètre d’air) Rail pressure sensor supply - Vext
CC- (alimentation capteur pression suralimentation) Rail pressure sensor supply - Vext
CC+(alimentation capteur pression suralimentation) Rail pressure sensor supply - Vext
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-37

I DIAGNOSTIC
Sensor signal
A 159
Sensor Earth Sensor
Rail pressure B 184 DCU
Power supply
C 5V - Vext 186

1 Vérifier la présence d'alimentation aux bornes du capteur Carry out the repairs required.
Problème d'alimentation ?
2 Check the connection of the sensor Carry out the repairs required.
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3 Vérifier les caractéristiques électriques (Voir Chapitre Valeurs de Remplacer l'ensemble capteur / rail
référence) et corréler la valeur lue avec la valeur attendue
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Caractéristiques incorrectes ?
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5 A l'aide de la boîte à bornes, vérifier la continuité et l'isolement Carry out the repairs required.
électrique des lignes
6 Check the high pressure system (absence of leaks) Carry out the repairs required.
Are any leaks detected?
7 Remplacer l'ensemble capteur / rail Replace the DCU
© Delphi
2-38 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
PORTE INJECTEUR – CIRCUIT OUVERT

trouble code
P0201 Injector cylinder no. 1 - open circuit La temps de montée en courant dans l’injecteur est trop élevé
On => Pressure control fault detection (trim) deactivated
Symptoms
=> Engine noisy
y
=> Engine running on 4 cylinders
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=> Engine stalling
d
OC Injector cylinder no. 1 - open circuit
OC
c e Injector cylinder no. 4 - open circuit
n
OC
v a Injector cylinder no. 1 - open circuit
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Injector cylinder no. 4 - open circuit
Injector cylinder no. 3 - open circuit
OC on 118 • Injector cylinder no. 2 - open circuit
• Injector cylinder no. 5 - open circuit
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-39

I DIAGNOSTIC
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
Co
Note:
d
- Limiting as far as possible the number of injector disconnections.
c e
- When replacing an injector, the C3I for the new injector should be entered in the DCU.
an
v
Ad
1 Check the IMV connection Carry out the repairs required.
2 Check the electrical insulation of the coil's terminals and the Replace the injector.
injector's body with a multimeter
short circuit
of lines
5 Replace the injector. Replace the DCU
© Delphi
2-40 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
DCU SUPPLY - RELAY STUCK

trouble code
P0215 DCU supply control - relay stuck The DCU is still supplied but the time lapsed since the open request to the supply
relay is greater than 3000 ms. It is assumed that the relay is stuck in the closed
position
On None
Symptoms
Impossible to cut the supply to the DCU. There is a risk of rapid battery discharge.
SC- on 9 DCU supply control - relay stuck
SC+ on 3, 4 or 5 DCU supply control - relay stuck
y
Power supply relay DCU power supply
p
3 58 channel
Co
connector
F1 KL30 KL87 DCU power supply
1
d
F2
KL30 DCU power supply
e
5
c
n
44
a
F3 +AC
v
KL30 Ignition key
Ad
KL15 19 DCU
Earth
2
Earth
4
Earth
Battery12V 6
Earth Earth
Fault chart (Code P0215)

1 Check the connection of the supply relay Carry out the repairs required.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-41

I DIAGNOSTIC

4 Replace the relay Change the DCU
5 Does the problem persist?
py
d Co
c e
an
v
Ad
© Delphi
2-42 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
ENGINE SPEED SIGNAL

trouble code
P0219 Engine speed signal - too early Engine event too early
On None
Symptoms
Engine stalling
- +
1 187
Speed sensor
DCU
Engine
2 - 188
+
py
d Co
c e
n
1 Check the connection of the sensor
v a Carry out the repairs required.
Ad
3 Check the continuity and the electrical insulation Carry out the repairs required.
4 Change the sensor The problem is resolved
Is the problem resolved?
5 Check the target Replace the target
Is there a target problem?
6 Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-43

I DIAGNOSTIC
PEDAL SENSOR SIGNAL TRACK 2

trouble code
P0220 Pedal sensor track 2 supply – Vext 5V supply fault or analogue / digital converter fault
P0222 Pedal sensor track 2 signal – low Information for track 2 less than 4%
P0223 Pedal sensor track 2 signal – high Information for track 2 greater than 50%
Symptoms
OC Pedal sensor track 2 supply – Vext
SC- Pedal sensor track 2 supply – Vext
SC+ Pedal sensor track 2 supply – Vext
y
OC Pedal sensor track 2 signal – low
p
Co
SC- Pedal sensor track 2 signal – low
SC+ Pedal sensor track 2 signal – high
d
OC Pedal sensor track 2 supply – Vext
c e
Pedal sensor
an
v
Ad
24 72
connector
Signal track 1
Track 1 25 71
1
Earth Track 1
3 26 53
5 10 57
4 Signal track 2
Track 2 13 32
6
Earth Track 2
14 14
2

the fault disappears. If the defect is no longer present, the sensor
© Delphi
2-44 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-45

I DIAGNOSTIC
TURBO SOLENOID VALVE CONTROL

trouble code
P0245 Turbo solenoid valve control - OC SC- Open circuit or short circuit to earth
P0243 Turbo solenoid valve control Consistency
P0246 Turbo solenoid valve control - SC SC+ Short circuit, short circuit to +
=> Wastegate control deactivated
Symptoms
Lack of performance
OC Turbo solenoid valve control - OC SC-
SC- Turbo solenoid valve control - OC SC-
y
SC+ Turbo solenoid valve control - SC SC+
p
Power supply relay
d Co
DCU power supply
3
c e
F1 KL87 DCU power supply
KL30
58 channel
connector
n
1
a
F2 DCU power supply
v
KL30
5
Ad
DCU
F4 Power supply control
44
Vbatt
Flap control
Solenoid valve 75
Battery
12V flap ON/OFF
Earth Vbatt

1 Check the solenoid valve connection Carry out the repairs required.
2 Measure the characteristics (voltage or resistance) at the solenoid Change the solenoid valve
valve terminals
© Delphi
2-46 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

4 Check the continuity and the electrical insulation Repair the wiring harness
5 Replace the solenoid valve Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-47

I DIAGNOSTIC
INLET METERING VALVE CONTROL (IMV)

trouble code
P0251 Inlet metering valve control - short circuit Short circuit or short circuit to +
P0253 Inlet metering valve control - short circuit to Short circuit to earth
earth
P0255 Inlet metering valve control - open circuit Open circuit?
On => Timed engine stop
=> Limp home mode activated
=> Leak detection cycle prevented
y
=> Pressure control fault detection (trim) deactivated
p
Co
d
Symptoms
=> Engine stop
c e
n
=> Engine noisy
v a
Ad
=> Idle unstable
OC Inlet metering valve control - open circuit
SC- Inlet metering valve control - short circuit to earth
SC+ Inlet metering valve control - short circuit
© Delphi
2-48 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3
F1 KL87 DCU power supply
KL30
58 channel
connector
1
F2 DCU power supply
KL30
5
DCU
F4 Power supply control
44
Vbatt
IMV control
BP actuator 176
Battery
12V
(IMV)
Earth
y
p
1 Carry out an electrical diagnosis of the IMV. Carry out the repairs required.
Co
Is there an electrical problem?
d
2 Carry out the diagnosis of the HP sensor. Carry out the repairs required.
c e
HP sensor problem?
n
3 Check the LP circuit Carry out the repairs required.
Is there a LP system problem?
v a
Ad
4 Check the HP circuit Carry out the repairs required.
Is there a HP system problem?
5 Check the injectors Carry out the repairs required.
Is there an injector problem?
6 Remove the high pressure pump. Carry out the repairs required.
High pressure pump problem?
7 Replace the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-49

I DIAGNOSTIC
INJECTOR-HOLDER - COMBUSTION TOO LOW

trouble code
P0263 Injector for cylinder no.1 - acyclism - Large drift in injector for cylinder 1 (it is providing less fuel, with the extreme case
combustion too low being that the injector is blocked in the closed position). This fault is raised by the
cylinder "balancing strategy".
"cylinder balancing" strategy.
py
Co
ed
n c
a
=> Torque reduction requested
v
Ad
=> IMV drift deactivated
Symptoms
=> Engine noisy
=> Engine running on 4 cylinders
© Delphi
2-50 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
Co
First check there is no trouble code present relating to the electrical diagnosis of the injectors.
ed
c
an Drain, clean and put in conformity (filter...).
v
Ad
Non compliant fuel
2 Check cylinder tightness (internal leak and external leak). Carry out the repairs required.
Is there a cylinder sealing problem?
3 Condition of the air inlet system Clean the inlet manifold
Inlet circuit
4 Check how the supply operates. If necessary temporarily neutralize Carry out the repairs required.
the supply for the test.
5 Carry out an injector hydraulic test (external test means, bench...) Replace the injector.
Is the injector faulty?
6 Replace the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-51

I DIAGNOSTIC
ACCELEROMETER SIGNAL
trouble code
P0325 Accelerometer 1 – (no signal at idle speed) Detecting the fault relies on detecting combustion. At idle speed the detection
window is shifted to the combustion caused by the main injection. If the ratio
increases this indicates that the accelerometer is operating correctly. If not a fault
is raised to indicate a faulty sensor.
P0330 Accelerometer 2 – (no signal at idle speed) Detecting the fault relies on detecting combustion. At idle speed the detection
window is shifted to the combustion caused by the main injection. If the ratio
increases this indicates that the accelerometer is operating correctly. If not a fault
is raised to indicate a faulty sensor.
On => Torque reduction requested
Symptoms
=> Engine noisy
y
p
Co
OC Accelerometer 1 – (no signal at idle speed)
SC- Accelerometer 1 – (no signal at idle speed)
d
OC Accelerometer 2 – (no signal at idle speed)
SC-
c e
Accelerometer 2 – (no signal at idle speed)
an
v
Accelerometer 1
1
2
Ad Signal sensor
Earth Sensor
146
DCU
147
Signal sensor
1 116
Accelerometer 2 DCU
Earth Sensor
2 141

1 Check the accelerometer connection Carry out the repairs required.
Connection problem
2 Check the wiring on the accelerometers and the screening Carry out the repairs required.
Is there a wiring problem?
© Delphi
2-52 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3 Check the accelerometer mounting; are the correct tightening Carry out the repairs required.
torques used?
Accelerometer or attachment problem
4 Check the computer connection (signal, earth and shielding) Carry out the repairs required.
of lines
6 Does the problem persist? Replace the accelerometer
7 Does the problem persist? Replace the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-53

I DIAGNOSTIC
ENGINE SPEED SIGNAL

trouble code
P0335 Engine speed signal - loss of signal Loss of engine speed signal
P0336 Engine speed signal - loss of gap No detection of the flywheel gap, but no additional or missing teeth detected.
P0337 Engine speed signal - engine stalls Engine stalling
Illuminated (if None
P0335 / P0336)
Symptoms
Engine stalling
Engine speed signal - loss of signal
py
Co
- +
1 187
Speed sensor
DCU
d
Engine
e
2 - 188
c
+
an
v
Stage
Ad
Operation / Decision Result
6 Change the DCU
© Delphi
2-54 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
CAMSHAFT SIGNAL
trouble code
P0341 Camshaft signal - synchronisation The camshaft signal does not arrive when expected (incorrect synchronisation with
the flywheel).
P0344 Camshaft signal - loss of signal The camshaft sensor does not give a signal.
On None
Symptoms
Engine stalling
OC Camshaft signal - loss of signal
SC- Camshaft signal - loss of signal
SC+ Camshaft signal - loss of signal
py
3
d Co
Earth Sensor
114
c e
n
Sensor Camshaft signal
2 138 DCU
a
Camshaft
v
Power supply 5V - Vext
Ad
1 137

2 Visually inspect the sensor Change the sensor
6 Check the timing / pump setting Set the timing / pump setting
Is there a setting problem?
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-55

I DIAGNOSTIC

7 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
2-56 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
ENGINE SPEED SIGNAL

trouble code
P0372 Engine speed signal - loss of teeth Missing teeth detected over one revolution of the flywheel.
On None
Symptoms
Engine stalling
- +
1 187
Speed sensor
DCU
Engine
2 - 188
+
py
d Co
c e
n
Ad
6 Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-57

I DIAGNOSTIC
EGR control
trouble code
P0400 EGR regulation - generic EGR loop error.
P0405 EGR regulation - negative drift - low The EGR is shut
P0406 EGR regulation - positive drift - upwards THE EGR is open
P0407 EGR flap position signal - Below minimum The control value of the EGR position is too low.
threshold
P0408 EGR flap position signal - Above maximum The control value of the EGR position is too low.
threshold
Off • Cruise control deactivated
• Flowmeter plausibility deactivated
• EGR flap not steered
Symptoms
py
Co
Lack of performance
d
Mechanical faults Diagnostic tool title
e
EGR valve blocked closed EGR regulation - generic
EGR valve blocked open
n c
EGR regulation - generic
v a
Ad
Swirl actuator 1 93 EGR
differential
51 pressure
sensor
2 54
Earth sensor
3 61 EGR
Flow meter 29 1
4 60 2 sensor 1
78
DCU
5 Flow meter signal
70
30 1 EGR
4 2 sensor 2
6
EGR solenoid 2
valve 44
82 1 EGR
23 2 sensor 3
5
© Delphi
2-58 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Fault chart (Code P0400 - P0401 - P0402 - P0405 - P0406 - P0407 - P0408)
1 Check the condition of the EGR valve Replace the EGR valve
Is there a valve problem?
2 Check the air and exhaust lines Carry out the repairs required.
3 Check the flowmeter Change the flowmeter
Is there a flowmeter problem?
4 Carry out an electrical diagnostic of the EGR valve.
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-59

I DIAGNOSTIC
FAN CONTROL
trouble code
P0480 Fan 1 control - open circuit CO on the PWM module
P0481 GMV1 control short circuit Short circuit on GMV1 relay
P0482 Fan 1 control - short circuit to earth CC- on GMV1 relay
P0483 GMV - PWM control
Off • Air conditioning deactivated
Symptoms
Air conditioning configuration
Fault chart (Code P0480 - P0481 - P0482 - P0483 - P0484 - P0485)

1 Check the connection of the relay
py
Carry out the repairs required.
Co
2 Check for on-line power on the relay coil Carry out the repairs required.
ed
3
n
Check the electrical continuity between the relay coil's two
c Replace the relay
a
terminals
v
Ad
Open circuit?
of lines
6 Check the earthing points Carry out the repairs required.
Is there an earth problem?
7 Does the problem persist? Replace the relay
© Delphi
2-60 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
VEHICLE SPEED LOSS SIGNAL

trouble code
P0503 Vehicle speed signal - excessive Vehicle speed information is not entered
Off None
Symptoms
Engine stop

1 Ignition off, measure the impedance on the CAN network, all DCUs Open circuit on one of the two lines or one of the two end-of-line
connected (directly on the DCU network, not via the diagnostic DCUs is disconnected or faulty
socket)
Impedance = ~120 Ohms
2 Impedance = ~0 Ohms The two lines are in short circuit or one of the DCUs on the CAN
y
network is faulty
p
Co
3 Impedance <> 60 Ohms See diagnostic chart Locating short circuits on the CAN network
4 Disconnect the injection DCU from the CAN network and measure Replace the DCU
d
the resistance between the CAN-H and CAN-L pins connected to
e
the CAN network.
Resistance <> ~120 Ohms
n c
5 Consult the manufacturer's agent
v a
Ad
Locating short circuits on the CAN network
1 With the ignition on, use a multimeter to measure the voltage on The CAN-H line is short circuited to +Batt, carry out the necessary
the CAN-H line, then the CAN-L line in relation to the earth (directly repairs.
on the CAN network, not via the diagnostic socket)
VCAN-H = Battery voltage
2 VCAN-H = ~0 V The CAN-H line is short circuited to earth, carry out the necessary
repairs.
3 VCAN-L = Battery voltage The CAN-L line is short circuited to +Batt, carry out the necessary
repairs.
4 VCAN-L = ~0 V The CAN-L line is short circuited to earth, carry out the necessary
repairs.
the CAN network.
6 Consult the manufacturer's network
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-61

I DIAGNOSTIC
AC pressure signal
trouble code
P0530 AC pressure signal - Low
P0532 AC pressure signal - Low
P0533 AC pressure signal - High
Off Air conditioning cut out
Symptoms
No air conditioning

2 Visually inspect the detector Carry out the repairs required.
Is there a wiring problem?
py
Co
3 Check the sensor's condition, its attachment Carry out the repairs required.
Is there a wiring or connection problem?
4 Check the connection of the DCU
ed Carry out the repairs required.

n c
a
v
Ad
of lines
6 Does the problem persist? Replace the sensor
© Delphi
2-62 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
BATTERY VOLTAGE SIGNAL

trouble code
P0560 Battery voltage signal - A/D converter Analogue / digital converter fault
P0562 Battery voltage signal - low Battery voltage less than 6 Volts
P0563 Battery voltage signal - high Battery voltage greater than 18 Volts
Off => AC function deactivated
=> Water heaters deactivated
=> Leak detection cycle deactivated
=> Pressure control fault detection (loop difference and trim) deactivated
y
=> Default value used for injector resistance
p
Co
Symptoms
d
=> Starting impossible
=> Engine noisy
c e
=>
an
Rushing noise when reaccelerating after a no load position
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-63

I DIAGNOSTIC

3 58 channel
connector
1
F2
5
44
F3 +AC
KL30 Ignition key
19 DCU
KL15
Earth
2
Earth
4
Earth
Battery12V 6
y
Earth Earth
p
d Co
c e
an Result
v
1 Check the battery voltage at Key On Check the battery and charge it
Ad
Is the voltage too low?
2 Check the battery terminals and the tightness of the clamps Carry out the repairs required.
Is there a terminal or clamp problem?
4 Check the charging circuit Carry out the repairs required.
Is there a charging problem?
5 Change the DCU
© Delphi
2-64 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
BRAKE PEDAL SIGNAL

trouble code
P0571 Brake switch signal - generic Incoherence between the main brake switch and the redundant switch.
On Cruise control deactivated
Symptoms
None
Brakes contact
Safety contact signal
Vbatt 39
DCU
Stop contact signal
+AC 23
Stop indicator
py
d Co
c e Result
n
1 Check the brake switch connection Carry out the repairs required.
v a
Ad
2 Check the switch supply Carry out the repairs required.
3 Check the mobility of the brake pedal Carry out the repairs required.
Is the pedal stuck?
6 Replace the brake switch Change the DCU
Does the fault persist?
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-65

I DIAGNOSTIC
CAN NETWORK ANOMALY

trouble code
P600 CAN NETWORK ANOMALY Frame cuts on the network
P602 CAN - Configuration Error at configuration
Off None
Symptoms
Engine stop

1 Ignition off, measure the impedance on the CAN network, all DCUs Open circuit on one of the two lines or one of the two end-of-line
connected (directly on the DCU network, not via the diagnostic DCUs is disconnected or faulty
socket)
Impedance = ~120 Ohms
2 Impedance = ~0 Ohms
py
The two lines are in short circuit or one of the DCUs on the CAN
Co
network is faulty
3 Impedance <> 60 Ohms See diagnostic chart Locating short circuits on the CAN network
ed
c
n
the CAN network.
v a
Ad
5 Consult the manufacturer's agent
Locating short circuits on the CAN network

1 With the ignition on, use a multimeter to measure the voltage on The CAN-H line is short circuited to +Batt, carry out the necessary
the CAN-H line, then the CAN-L line in relation to the earth (directly repairs.
on the CAN network, not via the diagnostic socket)
VCAN-H = Battery voltage
2 VCAN-H = ~0 V The CAN-H line is short circuited to earth, carry out the necessary
repairs.
3 VCAN-L = Battery voltage The CAN-L line is short circuited to +Batt, carry out the necessary
repairs.
4 VCAN-L = ~0 V The CAN-L line is short circuited to earth, carry out the necessary
repairs.
the CAN network.
6 Consult the manufacturer's network
© Delphi
2-66 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
DCU WATCHDOG
trouble code
P0606 Watchdog – Reset CPU The watchdog cannot carry out a main microprocessor reset.
On None
Symptoms
Engine stop

1 Check the DCU earth Carry out the repairs required.
2 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-67

I DIAGNOSTIC
ABS ESP calculator anomaly

trouble code
P0608 CAN - ABS/ESP
Off None
Symptoms
Engine stop

1 Check the DCU earth Carry out the necessary operations
2 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
2-68 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
C31 defect
trouble code
P0611 C2I/C3I fault
P0612 C2I/C3I fault
On for P0661 Fast idle
Symptoms
• Write failure for C3I
• Impossible to read the C3I

1 Reading the C3I Rewrite the C3I
Reading impossible
2 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-69

I DIAGNOSTIC
TCU and TCCU defect

trouble code
P0613 CAN - TCU
P0614 CAN TCCU
Off None
Symptoms

1 Check the DCU earth Carry out the necessary operations
2 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
2-70 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
INJECTOR CONTROL
trouble code
P062D Bank 1 injectors - low Short circuit to earth on the injector control for cylinders 1, 3 and 4
P162D Bank 1 injectors - high Short circuit to positive on the injector control for cylinders 1, 3 and 4
On => Use of a default value for:
- Resistance for the injector for cylinder 1
=> Rail discharge through injector for cylinder 1 deactivated
y
=> Injection on cylinder 1 prohibited
p
Co
d
c e
n
Symptoms
=> Engine stalling
v a
Ad
=> Starting difficult
=> Idle speed unstable (random check at low fuelling)
SC- Bank 1 injectors - low
SC+ Bank 1 injectors - high
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-71

I DIAGNOSTIC
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
Fault chart (Code P062D - P162D)
d Co
e
c
1 Check the connection of the injectors Carry out the repairs required.
an
v
Ad
2 Disconnect the injectors and switch on the ignition See the diagnostic chart "Checking the injector connection"
Is the problem still present?
3 Erase the faults, switch off the ignition, reconnect one injector and Switch off the ignition, reconnect another injector and switch the
switch the ignition on again ignition on again
Does the fault return?
4 Replace the corresponding injector and enter the new C2I into the Change the DCU
DCU
Checking the injector connection

Fault chart (Code P062D - P162D)
2 Check the continuity and the electrical insulation of wires Change the DCU
© Delphi
2-72 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
INJECTOR CONTROL
trouble code
P062E Bank 2 injectors - low Short circuit to earth on the injector control for cylinders 2 and 5
P162E Bank 2 injectors - high Short circuit to positive on the injector control for cylinders 2 and 5
On => Use of a default value for:
y
p
Co
d
c e
n
Symptoms
=> Engine stalling
v a
Ad
=> Starting difficult
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-73

I DIAGNOSTIC
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
Fault chart (Code P062E - P162E)
d Co
e
c
1 Check the connection of the injectors Carry out the repairs required.
an
v
Ad
2 Disconnect the injectors and switch on the ignition See the diagnostic chart "Checking the injector connection"
Is the problem still present?
3 Erase the faults, switch off the ignition, reconnect one injector and Switch off the ignition, reconnect another injector and switch the
switch the ignition on again ignition on again
Does the fault return?
4 Replace the corresponding injector and enter the new C2I into the Change the DCU
DCU
Checking the injector connection

Fault chart (Code P062E - P162E)
2 Check the continuity and the electrical insulation of wires Change the DCU
© Delphi
2-74 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
CAN - Configuration
trouble code
P0630 CAN - Configuration
P0631 Can Configuration
Off None
Symptoms

1 Consult the manufacturer network to solve this defect
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-75

I DIAGNOSTIC
IMMOBILISER - KEY MEMORY

trouble code
P0633 Immobiliser - key memory The maximum number of keys (5) which can be saved in the immobiliser memory
has been reached.
On None
Symptoms
None
DCU power supply

F1 KL30 KL87 DCU power supply 58 channel
1 connector
F2 KL30
DCU power supply
5
py
44
Co
F3 KL15 ADC indicator control
KL30
9
d
DCU
e
Ignition key
c
19
an
ISO K line
Vbatt Antenna
v
Immobilizer 52
Ad
Key and transponder
Vehicle ISO K diagnostic line
Diagnostic plug 31

Faults linked to the immobiliser require a specific tool to be processed. Because of this, only Ssangyong can effectively
solve this type of fault.
© Delphi
2-76 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
5V SENSOR SUPPLY
trouble code
P0641 5V supply (Vext1) – A/D converter Analogue / digital converter fault
P0642 5V sensor supply (Vext1) - low Sensor supply voltage (Vext1) less than 4.75V
P0643 5V sensor supply (Vext1) - high Sensor supply voltage (Vext1) less than 5.34V
P0651 5V supply (Vext2) – A/D converter Analogue / digital converter fault
P0652 5V sensor supply (Vext2) - low Sensor supply voltage (Vext2) less than 4.75V
P0653 5V sensor supply (Vext2) - high Sensor supply voltage (Vext2) greater than 5.34V
On Code P0641 to P0643:
=> Pilot and post injection prevented
y
p
Co
d
=> IMV fully open
Code P0651 to P0653:
c e
n
=> Timed engine stop
=>
v a
Accelerometer decoding deactivated
Ad
=> Rail pressure limiting mode activated
Symptoms
=> Engine stop
=> Engine noisy
=> Idle unstable
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-77

I DIAGNOSTIC
5V SENSOR SUPPLY
SC- 5V sensor supply (Vext1) - low
SC+ 5V sensor supply (Vext1) - high

1 Check the connection of the sensors supplied by Vext1 or Vext2 (air Carry out the repairs required.
flowmeter, turbo pressure sensor, temperature sensor, pedal
sensor, rail pressure sensor, cam sensor).
2 Visually inspect each sensor Replace the sensor
py
Co
4
ed
Check the continuity and the electrical insulation of the wires for Carry out the repairs required.
c
all sensors supplied by Vext1 or Vext2.
an
v
Ad
5 Follow the diagnostic charts for the sensors supplied by Vext1 or
Vext2
© Delphi
2-78 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
PPH PLUG LINE - OPEN CIRCUIT

trouble code
P0670 Heater plugs circuit Electric defect on the preheating module
P0671 PPH plug line cylinder 1 - open circuit Open circuit on the line connected to the preheating plug for cylinder 1
On None
Symptoms
=> Starting difficult or impossible
=> Smoke
y
Fuse
p
Co
Vbatt
d
96 channel
Cylinder 1 connector
e
68
c
Pre-post heating
Cylinder 2
n
case Spark plugs
a
control DCU
v
Cylinder 3
Ad
+AC 52 58 channel
PPH indicator
Cylinder 5
Spark
plugs

1 Is trouble code P1676 present? See fault chart for code P1676
2 Check the connection of the preheating plug Carry out the repairs required.
4 Check the continuity and electrical insulation of the supply line for Carry out the repairs required.
the plug
5 Replace the plug Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-79

I DIAGNOSTIC
DCU SUPPLY - RELAY OPEN

trouble code
P0685 DCU supply control - relay open The supply relay is open without an injection DCU order
Off None
Symptoms
=> Engine stalling
OC DCU supply control - relay open
SC+ DCU supply control - relay open
SC- DCU supply control - relay open
OC DCU supply control - relay open
OC on relay supply DCU supply control - relay open
py
Co
3
d
58 channel
e
connector
c
1
n
F2
a
5
v
Ad
44
F3 +AC
KL30 Ignition key
KL15 19 DCU
Earth 2
Earth
4
Earth
Battery12V 6
Earth Earth

1 Check the connection of the supply relay Carry out the repairs required.
© Delphi
2-80 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

4 Replace the relay Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-81

I DIAGNOSTIC
2.5V SUPPLY
trouble code
P0697 2.5V supply - A/D converter Analogue / digital converter fault
P0698 2.5V supply - low The supply voltage for track 2 of the pedal sensor is less than 1.79V
P0699 2.5V supply - high The supply voltage for track 2 of the pedal sensor is greater than 3V
On • Deactivation of air conditioning.
• EGR control deactivated
• EGR position diagnostic deactivated
• Turbo deactivation
Symptoms
None
OC 2.5V supply - high
y
SC- 2.5V supply - low
p
Co
SC+ 2.5V supply - high
OC 2.5V supply - high
ed
c
Pedal sensor
an
Power supply track 1 (5V)
v
24 58 channel
72
Ad
connector
Signal track 1
Track 1 25 71
1
Earth Track 1
3 26 53
5 10 57
4 Signal track 2
Track 2 13 32
6
Earth Track 2
14 14
2

1 Check the pedal sensor connection Carry out the repairs required.
© Delphi
2-82 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

4 Check the continuity and the electrical insulation of the wires Carry out the repairs required.
Is there a wires problem?
5 Follow the fault chart for the accelerator pedal sensor faults (codes
P0120 to P0123 and P0220 to P0223)
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-83

I DIAGNOSTIC
CAN - TCU
trouble code
P0700 CAN - TCU Communication problem on the CAN network between the TCU and the injection
DCU
Off Cruise control deactivated
Symptoms
Different for each function
DCU
48 47
py
CAN High
Co
CAN Low
ed
n c
a
TCU TCCU ABS
v
Ad
(Optional)

Faults linked to the CAN require a specific tool to be processed. Because of this, only Ssangyong can effectively solve
this type of fault.
© Delphi
2-84 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
CLUTCH PEDAL SIGNAL

trouble code
P0704 Clutch pedal switch signal No variation in the status of the clutch switch when the vehicle speed is greater
than 40 km/h for 5 seconds
Off None
Symptoms
None
OC Clutch pedal switch signal
SC- Clutch pedal switch signal
SC+ Clutch pedal switch signal
Clutch contact
Clutch contact signal
py DCU
Co
34
d
Earth
c e
an
v
Ad
1 Check the connection of the switch Carry out the repairs required.
2 Visually inspect the switch Change the switch
Is there a switch problem?
5 Change the switch Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-85

I DIAGNOSTIC
MANUAL GEARBOX SWITCH

trouble code
P0805 MANUAL GEARBOX SWITCH The manual switch has retained its initial position when the vehicle speed is greater
than 70 km/h.
Off None
Symptoms
Fast idle 950 rpm.
SC+ MANUAL GEARBOX SWITCH
Clutch contact
Clutch contact signal
py DCU
Co
34
d
Earth
c e
It is the 58-way connector
an
v
Ad
1 Check the DCU configuration (configuration). Correct the configuration (DCU configuration).
Is there a configuration problem?
3 Check the connection of the manual switch Carry out the repairs required.
5 Change the manual switch Change the DCU
© Delphi
2-86 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
ATMOSPHERIC PRESSURE SIGNAL

trouble code
P1101 Generic atmospheric pressure signal Diagnostic trouble code P1105, 1107, 1108
P1105 Atmospheric pressure sensor supply - Vext Analogue / digital converter fault
Off None
Symptoms
None
Internal to the DCU

1 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-87

I DIAGNOSTIC
FLOWMETER SIGNAL
trouble code
P1102 Flowmeter signal - low The flowmeter is out of range
P1103 Flowmeter signal - low The flowmeter is out of range
On None
Symptoms
Power loss
Note:
• Prioritarily process the turbo pressure plausibility defects.
• In case of intervention on the accelerometer, reinitialize the C3I of all the injectors.

y
1 Check the conformity of the air line Carry out the repairs required.
p
Co
(Tightness of clips, contamination, incorrect fitting, presence of
water,...)
d
Air line problem?
2 Check the supply to the sensor terminals
c e Carry out the repairs required.
n
3 Check the connection of the DCU
Ad
4 Check the electrical features (See Reference values Chapter) and Replace the flowmeter
correlative value read with the expected value
Wrong features?
of lines
7 Replace the flowmeter Replace the DCU
© Delphi
2-88 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Turbo pressure signal - gradient

trouble code
P1106 Turbo pressure signal - plausibility Gradient greater than 2.5 bar/s
Off Turbo pressure control in open loop
Symptoms
Lack of performance
DCU power supply

F1 DCU power supply
KL30 KL87
1 58 channel
F2 KL30 DCU power supply connector
5
44
Battery Turbo
py
Co
12V solenoid valve
2 71
d
Earth sensor
e
Earth A 83
c
96 channel
Supercharging
n
connector
B NC.
a
pressure
v
60
Ad
C
Sensor signal
D 63

Air line problem?
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-89

I DIAGNOSTIC

6 Change the sensor Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
2-90 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
ATMOSPHERIC PRESSURE SIGNAL

trouble code
P1107 Atmospheric pressure signal - low Atmospheric pressure less than 600 mbar.
P1108 Atmospheric pressure signal - high Atmospheric pressure greater than 1049 mbar
Off None
Symptoms
None
Internal to the DCU

1 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-91

I DIAGNOSTIC
TURBOCHARGING PRESSURE SIGNAL

trouble code
P1109 Turbo pressure signal - plausibility Correlation with the atmospheric pressure at idle speed
On • Turbo pressure control in open loop
• EGR flap deactivation
Symptoms
Lack of performance
DCU power supply

F1 DCU power supply
KL30 KL87
1 58 channel
F2 KL30 DCU power supply connector
y
p
44
Co
Battery Turbo
12V solenoid valve
d
2 71
c e Earth sensor
n
Earth A 83
a
96 channel
v
Supercharging connector
B NC.
Ad
pressure
C 60
Sensor signal
D 63

Air line problem?
© Delphi
2-92 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

6 Change the sensor Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-93

I DIAGNOSTIC
COOLANT TEMPERATURE SIGNAL

trouble code
P1115 Coolant temperature signal - plausibility The coolant temperature difference must be greater than 5°C after 5 minutes of
engine operation.
P1116 Coolant temperature signal - generic Diagnostic trouble code P0115, P0117, P0118 or P1115
Off If P1116 :
=> AC function deactivated
=> Engine overheat detection threshold lowered
Symptoms
y
p
=> Engine noisy
Co
=> Slow increase in temperature in passenger compartment
d
e
See diagnostic trouble code P0115, P0117 and P0118
n c
Coolant temperature signal - generic
v a
Temperature
sensor
1 Ad Temperature signal
156
DCU
Water Earth sensor
4 157

1 Is fault code P1116 present? Deal with the following fault codes as a priority: P0115, P0117,
P0118
terminals
© Delphi
2-94 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

6 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-95

I DIAGNOSTIC
PEDAL SENSOR TRACK 1&2 CORRELATION

trouble code
P1120 Pedal sensor - correlation track 1&2 (1 > 2) Difference between the information given by tracks 1 and 2 of the pedal sensor.
P1121 Pedal sensor - correlation track 1&2 (2 > 1) Difference between the information given by tracks 1 and 2 of the pedal sensor.
Symptoms
Lack of performance
See diagnostic fault codes P0120, P0122, P0123 & P0220, P0222, Pedal sensor - correlation track 1&2 (1 > 2) or Pedal sensor - correlation track 1&2
P0223 (2 > 1)
Pedal sensor
y
Power supply track 1 (5V)
p
24 58 channel
72
Co
connector
Signal track 1
Track 1 25 71
d
1
e
Earth Track 1
c
3 26 53
n
a
5 10 57
v
Ad
4 Signal track 2
Track 2 13 32
6
Earth Track 2
14 14
2

1 See diagnostic fault codes P0120, P0122, P0123 P0220, P0222,
P0223
© Delphi
2-96 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
DOWNGRADED MODE
trouble code
P1122 Limp home mode A fault with the "limp home" recovery mode is present.
P1123 Reduced fuel mode activated A fault with the "reduction in indicated torque" recovery mode is present.
On If P1122 : Limp home mode
If P1123 : Reduction in indicated torque
Symptoms
Lack of performance

1 Deal with all the faults present which have a "limp home" or
"reduction in indicated torque" recovery mode.
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-97

I DIAGNOSTIC
ACCELERATOR & BRAKE CORRELATION

trouble code
P1124 Accelerator pedal - stuck - correlation with The brake pedal is operated although the accelerator is still being pressed for a
brake pedal prolonged period.
Off => Cruise control deactivated
Symptoms
=> Fast idle
SC+ Accelerator pedal - stuck - correlation with brake pedal
Pedal sensor
y
24 72
connector
p
Co
Signal track 1
Track 1 25 71
1
Earth Track 1
d
26 53
e
3
c
n
5 10 57
v a
4 Signal track 2
Ad
Track 2 13 32
6
Earth Track 2
14 14
2
Brakes contact
Vbatt 39
DCU
Stop contact signal
+AC 23
Stop indicator

1 Check the accelerator pedal moves freely Replace the accelerator pedal
Is the pedal stuck?
© Delphi
2-98 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

2 Check the brake switch connection Carry out the repairs required.
4 Check the continuity and the electrical insulation of the line Carry out the repairs required.
connected to terminal 58 of the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-99

I DIAGNOSTIC
MDP UPDATE
trouble code
P1147 MDP UPDATE The MDP update (minimum drive pulse) determined by the accelerometer strategy
is not able to be carried out due to the presence of certain faults or the update
number is insufficient.
P1148 MDP UPDATE The MDP update (minimum drive pulse) determined by the accelerometer strategy
is not able to be carried out due to the presence of certain faults or the update
number is insufficient.
=> Reduction in maximum engine speed
Symptoms
Lack of performance
y
p
Co
1 List all fault codes Deal with the other fault codes first
Are other fault codes present?
d
2 Select dynamic parameters from the menu Carry out the repairs required.
Check the consistency of each sensor
c e
n
Is there a lack of consistency?
3 Change the DCU
v a
Ad
© Delphi
2-100 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
FUEL FILTER
trouble code
P1149 Diesel filter - presence of water Presence of water in the diesel filter
Off Reduced fuel mode activated
Symptoms
=> Water level LED illuminated (diesel filter)
Fuel filter display

+AC control
79 DCU
96 channels connector
Indicator
py
Co
1 Bleed the diesel fuel filter
ed The problem is resolved
c
2
a
Check the connection of the water detector
n Carry out the repairs required.
v
Ad
3 Visually inspect the detector Change the detector
Is there a detector problem?
6 Change the detector Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-101

I DIAGNOSTIC
VLC STRATEGY
trouble code
P1170 Fuel correction too high – VLC strategy The torque correction applied by the VLC strategy is too high.
Note: The VLC strategy (Variable Limit Capacity) consists of reducing the fuel
demand in order to be able to maintain pressure control.
On None
Symptoms
Lack of performance

1 Carry out the electrical diagnosis of the IMV (See codes P0251, Carry out the repairs required.
P0253 and P0255)
y
p
Co
2 Carry out the diagnosis of the HP sensor (See codes P0192 and Carry out the repairs required.
P0193)
d
Is there a HP sensor problem?
c e
n
4 Check the HP circuit
Ad
6 Check the HP pump Carry out the repairs required.
Is there a HP pump problem?
7 Change the DCU

1 Check the low pressure system: Fill the tank
Check there is fuel in the fuel tank
Is the tank empty?
2 Visually inspect the fuel supply and return pipes: Carry out the repairs required.
- Look for leaks,
- Check the connections,
- Check the quick release connections.
Is there a pipe problem?
3 Check there is no air in the low pressure system Place a container under the venturi. Disconnect the pump return
Is there air in the low pressure circuit? hose at the venturi and prime the circuit using the priming bulb
© Delphi
2-102 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

4 Check the diesel filter reference Replace the filter with an original part
Is the filter part number incorrect?
5 The low pressure circuit is correct

1 Check the high pressure system: Carry out the repairs required.
Start the HP leak detection cycle
2 The high pressure circuit is correct

1 Check the injectors and the HP pump:
py
Refer to the high pressure diagnostic section
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-103

I DIAGNOSTIC
INJECTOR - MDP DRIFT

trouble code
P1171 CYLINDER 1 INJECTOR - MDP DRIFT This fault is raised when the MDP correction stored in the non-volatile memory
has reached the lower threshold (injector drift).
=> Pilot and post injection deactivated
y
=> Rail discharge through injector for cylinder 1,2,3,4 or 5 deactivated
p
Co
=> Torque limitation
ed
c
Symptoms
an
v
Ad
=> Engine noisy
© Delphi
2-104 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
d Co
e
c
an
v
Ad
2 Replace the injector and enter the new C2I into the DCU Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-105

I DIAGNOSTIC

trouble code
P1190 Rail pressure signal - sensor drift Rail pressure > 90 bar for several successive key ons (sensor drifting upwards).
On => Pilot and post injection deactivated
=> Pressure control fault detection (loop difference & trim) deactivated
=> IMV fully open
y
p
Co
Symptoms
d
=> Engine noisy
c e
=> Idle unstable
an
v
Ad
Sensor signal
A 159
Sensor Earth Sensor
Power supply
C 5V - Vext 186

2 Visually inspect the sensor Change the rail + sensor assembly
© Delphi
2-106 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

5 Replace the sensor / rail assembly Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-107

I DIAGNOSTIC
INLET METERING VALVE CONTROL (IMV)

trouble code
P1191 Time for pressure to rise when starting fault The pressure rise time when starting is too slow. This fault is liable to be raised
when starting the engine for the first time following an operation on the hydraulic
circuit.
=> IMV fully open
y
p
Co
d
Symptoms
c e
n
=> Engine noisy
=> Idle unstable
v a
Ad

1 Carry out the electrical diagnosis of the IMV (See code P0251) Carry out the repairs required.
2 Carry out the diagnosis of the HP sensor. (See code P0190) Carry out the repairs required.
3 Check the LP system (see chart for checking the LP circuit) Carry out the repairs required.
4 Check the HP system (see chart for checking the HP circuit) Carry out the repairs required.
5 Check the injectors (see chart for checking the injectors) Carry out the repairs required.
7 Change the DCU
© Delphi
2-108 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

Is the tank empty?
- Look for leaks,
3 Check there is no air in the low pressure system Place a container under the venturi.
Is there air in the low pressure circuit? Disconnect the pump return hose at the venturi and prime the circuit
using the priming bulb.
y
p
Co
1 Check the high pressure system:
ed Carry out the repairs required.
n c
a
v
Ad

© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-109

I DIAGNOSTIC

trouble code
P1192 Rail pressure signal - low - when ignition Rail pressure less than –90 bar when ignition switched on (sensor drifting
switched on downwards)
P1193 Rail pressure signal - high - when ignition Rail pressure when ignition switched on is more than 90 bar higher than the rail
switched on pressure when the ignition was last switched off (sensor drifting upwards)
=> IMV fully open
y
p
Co
d
c e
Symptoms
n
=> Engine noisy
v a
Ad
=> Idle unstable
Sensor signal
A 159
Sensor Earth Sensor
Power supply
C 5V - Vext 186

© Delphi
2-110 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

2 Visually inspect the sensor Change the rail + sensor assembly
5 Replace the sensor / rail assembly Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-111

I DIAGNOSTIC
INJECTOR - SHORT CIRCUIT

trouble code
P1201 Injector cylinder no. 1 - short circuit The injector for cylinder 1 is not controlled. The other injectors are controlled
normally.
normally.
normally.
normally.
normally.
=> Default value used for resistance of injector concerned
y
p
Co
ed
Symptoms
c
=> Engine noisy
an
v
Ad
SC between LSD and HSD or SC on the coil for the injector for cylinder Injector cylinder no. 1 - short circuit
1
2
3
4
5
© Delphi
2-112 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
d Co
e
c
1 Switch off the ignition and check the injector connection Carry out the repairs required.
an
v
Ad
2 Disconnect the injector. Injector faulty, replace the injector
4 Check the electrical insulation of the wires Carry out the repairs required.
5 Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-113

I DIAGNOSTIC
TURBOCHARGING PRESSURE CONTROL

trouble code
P1234 Turbo pressure regulation - generic Turbo power pressure overpressure detected
P1235 Turbo pressure regulation - generic Lack of turbo power pressure
P1236 Turbo pressure regulation - generic Very low pressure of turbo power pressure
=> Turbo pressure control in open loop
Symptoms
=> Smoke
=> Engine speed unstable
y
Mechanical faults Diagnostic tool title
p
Co
Wastegate stuck closed Turbo pressure regulation - generic
Wastegate stuck open Turbo pressure regulation - generic
ed
n
Swirl valve signal
c 5
a
1 93 EGR
v
Swirl actuator
differential
Ad
51 pressure
sensor
2 54
Earth sensor
3 61 EGR
Flow meter 29 1
4 60 2 sensor 1
78
DCU
5 Flow meter signal
70
30 1 EGR
4 2 sensor 2
6
EGR solenoid 2
valve 44
82 1 EGR
23 2 sensor 3
5
First deal with the turbo pressure sensor electrical faults (codes P0105 to P0109) if they are present.
© Delphi
2-114 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

1 Check the operation: Carry out the repairs required.
- of the air inlet circuit (leaks, air filter...)
- of the wastegate control pneumatic circuit
Is there an operation problem?
2 Check the condition and operation of the wastegate Replace the wastegate
Is there a wastegate problem?
4 Change the DCU
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-115

I DIAGNOSTIC
Rail pressure check

trouble code
P1252 Rail pressure check - overpressure Overpressure
P1253 Rail pressure check - negative error Rail pressure loop difference (50 bar)
P1254 Rail pressure check - positive error Rail pressure loop difference (50 bar)
P1256 Rail pressure check - trim low and fuel low The rail pressure is slightly less than the demand. The checking device tries to
open the IMV by progressively reducing the current applied to the actuator. When
the current correction arrives at the minimum threshold a fault is raised to indicate
that the system is not able to reach the pressure demand.
P1257 Rail pressure check - trim low and fuel high The rail pressure is slightly less than the demand. The checking device tries to
open the IMV by progressively reducing the current applied to the actuator. When
the current correction arrives at the minimum threshold a fault is raised to indicate
P1258 Rail pressure check - trim low and fuel low The rail pressure is higher than the demand. The checking device tries to close the
IMV by progressively increasing the current applied to the actuator. When the
y
current correction arrives at the maximum threshold a fault is raised to indicate
p
Co
P1259 Rail pressure check - trim low and fuel high The rail pressure is higher than the demand. The checking device tries to close the
IMV by progressively increasing the current applied to the actuator. When the
d
current correction arrives at the maximum threshold a fault is raised to indicate
c e
an
P1260 IMV rail - trim pressure control Rail pressure is different from requested pressure. The controller is trying to close
v
the IMV. The PWM is at maximum. A defect is lifted to indicate that the system
Ad
cannot reach the requested pressure
On For diagnostic trouble codes 1253 to 1260:
Symptoms
=> Engine noisy
© Delphi
2-116 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Fault chart (Code P1252 - P1253 - P1254 - P1256 - P1257 - P1258 - P1259 - P1260)
1 Carry out the electrical diagnosis of the IMV (See codes P0251, Carry out the repairs required.
P0253 and P0255)
2 Carry out the diagnosis of the HP sensor. (See codes P0192 and Carry out the repairs required.
P0193)
4 Check the HP circuit Carry out the repairs required.
y
p
7 Change the DCU
d Co
e
c
an
v
Ad
Is the tank empty?
- Look for leaks,
1 Check the high pressure system: Carry out the repairs required.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-117

I DIAGNOSTIC
py
d Co
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Ad
© Delphi
2-118 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
INJECTOR - HARNESS RESISTANCE

trouble code
P1286 Control for injector for cylinder 1 - harness Harness resistance for injector for cylinder 1 too low
resistance too low
P1287 Control for injector for cylinder 1 - harness Harness resistance for injector for cylinder 1 too high
resistance too high
resistance too low
resistance too high
resistance too low
resistance too high
y
resistance too low
p
Co
resistance too high
d
e
resistance too low
P1295
n
Control for injector for cylinder 5 - harness
c
Harness resistance for injector for cylinder 5 too high
a
resistance too high
v
Ad
=> Default value used for resistance of injector concerned
=> Rail discharge through injector concerned deactivated
Symptoms
=> Engine noisy
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-119

I DIAGNOSTIC
LSD
174
Injector-holder
Cylinder 1 HSD
125
HSD 126
Injector-holder
Cylinder 4 LSD 151
HSD
127
Injector-holder DCU
LSD
Cylinder 3 150
LSD
173
Injector-holder
Cylinder 2
101
HSD
HSD
102
Injector-holder
Cylinder 5 LSD 149
py
Co
CAUTION
d
- Limit the number of times injectors are disconnected as far as possible.
-
c e
When replacing an injector, the C3I for the new injector should be entered in the DCU.
an
v
Fault chart (Code P1286 - P1287 - P1288 - P1289 - P1290 - P1291 - P1292 - P1293 - P1294 - P1295)
Ad
1 Switch off the ignition and wait for 10 seconds. Disconnect the Carry out the repairs required.
injector and check the injector connection.
2 Check the electrical continuity between the two injector terminals Replace the injector.
using a multimeter
Open circuit?
4 Check the electrical continuity of the wires Change the wiring harness
5 Replace the injector. Change the DCU
© Delphi
2-120 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
EGR SOLENOID VALVE CONTROL

trouble code
P1405 EGR solenoid valve control - OC SC- Open circuit or short circuit to earth
P1406 EGR solenoid valve control - SC SC+ Short circuit or short circuit to +
On EGR control deactivated
Symptoms
=> Engine speed unstable
=> Smoke
OC EGR solenoid valve control - OC SC
SC- EGR solenoid valve control - OC SC
SC+ EGR solenoid valve control - SC SC+
py
Co
3
d
F1 KL87
e
58 channel
connector
1
F2
KL30
n c DCU power supply
a
5
DCU
v
F4
Ad
44
Vbatt
Flap control
Solenoid valve 75
Battery
12V flap ON/OFF
Earth Vbatt

1 Check the connection of the EGR solenoid valve Carry out the repairs required.
2 Measure the characteristics (voltage or resistance) at the EGR Change the EGR solenoid valve
solenoid valve terminals
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-121

I DIAGNOSTIC

5 Change the DCU
py
d Co
c e
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Ad
© Delphi
2-122 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
EGR closed programming

trouble code
P1407 EGR apprenticeship closed - Value out of Apprenticeship position of the EGR is out of the expected range
range
P1408 EGR apprenticeship closed - Abnormal It is a drift of the position read when the apprenticeship of the closed EGR goes
variation rate on. This value drifts in relation to previous apprenticeships.
Off • Plausibility diagnostic inhibition of flowmeter
Symptoms
Power loss
py
d Co
c e
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Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-123

I DIAGNOSTIC
FAN 1 CONTROL
trouble code
P1480 Fan 1 control - open circuit Open circuit?
P1481 Fan 1 control - short circuit Short circuit
P1482 Fan 1 control - short circuit to earth Short circuit to earth
On => AC function deactivated
Symptoms
=> No air conditioning
=> Fan 1 permanently activated
=> Engine overheat
OC Fan 1 control - open circuit
y
SC- Fan 1 control - short circuit to earth
p
Co
SC+ Fan 1 control - short circuit
d
GMV1 control relay
e
GMV1
c
Vbatt
an
v
40
Ad
GMV1 control
GMV2 control relay

GMV2 DCU
58 channel connector
57
GMV2 control

1 Check the connection of the fan control relay Carry out the repairs required.
4 Replace the relay and start the actuator test Change the DCU
© Delphi
2-124 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

py
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v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-125

I DIAGNOSTIC
Vehicle speed signal

trouble code
P1500 Vehicle speed signal - generic Fault P1501 or P1503 present
P1501 Vehicle speed signal - plausibility Vehicle speed not plausible
P1503 Vehicle speed signal - excessive Excessive vehicle speed
Off None
Symptoms
Speed information on the instrument panel incorrect
Vehicle speed information is delivered by the CAN.
DCU
y
48 47
p
Co
CAN High
ed
c
CAN Low
an
v
Ad
TCU TCCU ABS
(Optional)
Faults linked to the CAN require a specific tool to be processed. Because of this, only Ssangyong can effectively solve
this type of fault. © Delphi
2-126 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
FAN 2 CONTROL
trouble code
P1526 Fan 2 control - open circuit Open circuit?
P1527 Fan 2 control - short circuit Short circuit
P1528 Fan 2 control - short circuit to earth Short circuit to earth
Symptoms
=> Fan 2 permanently activated
=> Engine overheat
OC Fan 2 control - open circuit
y
SC- Fan 2 control - short circuit to earth
p
Co
SC+ Fan 2 control - short circuit
d
GMV1 control relay
e
GMV1
c
Vbatt
an
v
40
Ad
GMV1 control
GMV2 control relay

GMV2 DCU
58 channel connector
57
GMV2 control

1 Check the connection of the fan control relay Carry out the repairs required.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-127

I DIAGNOSTIC

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Ad
© Delphi
2-128 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Water heater 1 control

trouble code
P1530 Water heater 1 control - open circuit Open circuit?
P1531 Water heater 1 control - short circuit Short circuit
P1532 Water heater 1 control - SC to earth Short circuit to earth
Symptoms
Slow increase in temperature in passenger compartment
OC Water heater 1 control - open circuit
SC- Water heater 1 control - short circuit to earth
SC+ Water heater 1 control - short circuit
y
Immersion heater 1
p
control relay
Co
Vbatt Fuse
ed
c
8
n
+AC THP1 control
v a
Immersion heater 2
Ad
control relay
Fuse
DCU
THP2 control
56
Ventilation information 17
Passenger compartment
ventilation control

1 Check the connection of the water heater control relay Carry out the repairs required.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-129

I DIAGNOSTIC

py
d Co
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Ad
© Delphi
2-130 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Water heater 2 control

trouble code
P1534 Water heater 2 control - open circuit Open circuit?
P1535 Water heater 2 control - short circuit Short circuit
P1536 Water heater 2 control - SC to earth Short circuit to earth
Symptoms
Slow increase in temperature in passenger compartment
OC Water heater 2 control - open circuit
SC- Water heater 2 control - short circuit to earth
SC+ Water heater 2 control - short circuit
y
Immersion heater 1
p
control relay
Co
Vbatt Fuse
ed
c
8
n
+AC THP1 control
v a
Immersion heater 2
Ad
control relay
Fuse
DCU
THP2 control
56
Ventilation information 17
Passenger compartment
ventilation control

1 Check the connection of the water heater control relay Carry out the repairs required.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-131

I DIAGNOSTIC

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Ad
© Delphi
2-132 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
AIR CONDITIONING RELAY CONTROL

trouble code
P1540 Air conditioning relay control - open circuit Open circuit?
P1541 Air conditioning relay control - short circuit Short circuit
P1542 Air conditioning relay control - SC to earth Short circuit to earth
On AC function deactivated
Symptoms
=> Air conditioning operating permanently
OC Air conditioning relay control - open circuit
SC- Air conditioning relay control - short circuit to earth
SC+ Air conditioning relay control - short circuit
py
Co
Air conditioning control
relay
Compressor
d
Vbatt
Fuse
c e
an 55 DCU
v
+AC Air conditioning control
Ad
1 Check the connection of the compressor control relay Carry out the repairs required.
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-133

I DIAGNOSTIC
BRAKE PEDAL SIGNAL

trouble code
P1571 Safety brake switch signal Safety brake switch signal fault
P1572 Main brake switch signal Main brake switch signal fault
On Cruise control deactivated
Symptoms
None
Brakes contact
Vbatt 39
DCU
Stop contact signal
+AC 23
py
Stop indicator
d Co
c e
n
1 Check the brake switch connection
Ad
2 Check the switch supply Carry out the repairs required.
3 Check the mobility of the brake pedal Carry out the repairs required.
Is the pedal stuck?
© Delphi
2-134 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
DCU WATCHDOG
trouble code
P1600 Watchdog – interference on injector cut-off Interference on injector cut-off signal
signal
P1601 CPU or CPU clock CPU fault (microprocessor) or CPU clock
P1602 TPU or TPU clock TPU or TPU clock fault
On None
Symptoms
Engine stop

2 Change the DCU
py
d Co
c e
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Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-135

I DIAGNOSTIC
NON VOLATILE MEMORY

trouble code
P1606 Non volatile memory – CAN & KW The information in the NVM about the CAN and keyword 2000 communication is
corrupt.
=> Pressure control fault detection (loop error & trim) deactivated
Symptoms
y
=> Engine noisy
p
Co
d
c e
n
v a
Ad
2 Change the DCU
© Delphi
2-136 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
DCU WATCHDOG
trouble code
P1607 Watchdog – injector cut-out impossible Injector cut-out impossible
P1608 Watchdog DCU watchdog fault
On None
Symptoms
Engine stop

2 Change the DCU
py
d Co
c e
an
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Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-137

I DIAGNOSTIC
NON VOLATILE MEMORY

trouble code
P1614 Non volatile memory - MDP The non volatile memory of the DCU is damaged
P1615 Non volatile memory - configuration The non volatile memory of the DCU is damaged
P1616 Non volatile memory - rail pressure The non volatile memory of the DCU is damaged
P1617 Non volatile memory – SMC cut-off The non volatile memory of the DCU is damaged
y
p
Co
Symptoms
=> Engine noisy
d
c e
an
v
Ad
2 Change the DCU
© Delphi
2-138 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
NON VOLATILE MEMORY

trouble code
P1620 Non volatile memory - SC The non volatile memory of the DCU is damaged
P1621 Non volatile memory - fault management The non volatile memory of the DCU is damaged
P1622 Non volatile memory The non volatile memory of the DCU is damaged
y
Symptoms
p
Co
=> Engine noisy
d
c e
an
v
Ad
2 Change the DCU
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-139

I DIAGNOSTIC
ENGINE IMMOBILISER
trouble code
P1630 Immobiliser - transponder An incorrect key has been inserted or there is no communication between the
transponder and the immobiliser
P1631 Immobiliser - function not active Immobiliser function not active
P1632 Immobiliser - immobiliser deactivated The immobiliser has been deactivated
P1633 Immobiliser - no key memorised No key memorised in the immobiliser
P1634 Immobiliser - no response from the No response from the immobiliser
immobiliser
P1635 Immobiliser - incorrect immobiliser Incorrect immobiliser response
response
P1636 Immobiliser - immobiliser Internal immobiliser problem
On None
Symptoms
Starting impossible
py
d Co
e
DCU power supply
c
n
F1 KL30 58 channel
a
1
v
connector
Ad
F2 KL30
DCU power supply
5
44
F3 KL15 ADC indicator control
KL30
9
DCU
Ignition key
19
ISO K line
Vbatt Antenna Immobilizer 52
Key and transponder

Vehicle ISO K diagnostic line
Diagnostic plug 31
Faults linked to the immobiliser require a specific tool to be processed. Because of this, only Ssangyong can effectively
solve this type of fault.
© Delphi
2-140 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
PPH PLUG LINE - SHORT CIRCUIT

trouble code
P1671 PPH plug line cylinder 1 - short circuit Short circuit on the line connected to the preheating plug for cylinder 1
On None
Symptoms
=> Engine noisy
=> Smoke
y
Fuse
p
Co
Vbatt
d
96 channel
e
68
c
Pre-post heating
Cylinder 2
n
case Spark plugs
a
control DCU
v
Cylinder 3
Ad
+AC 52 58 channel
PPH indicator
Cylinder 5
Spark
plugs

the plug
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-141

I DIAGNOSTIC
PRE-POST HEATING UNIT

trouble code
P1676 Communication between the PPH unit and => The preheating unit is not responding to the injection DCU or,
the DCU => A checksum error has been detected or,
=> The number of bytes sent by the preheating unit is incomplete
P1677 Pre-post heating unit Internal fault in the pre-postheating unit
On None
Symptoms
=> Engine noisy
=> Smoke
OC Communication between the PPH unit and the DCU
y
p
Co
ed
Fuse
c
Vbatt
an
v
96 channel
Cylinder 1
Ad
connector
Pre-post heating 68
Cylinder 2 Spark plugs
case
control DCU
Cylinder 3
+AC 52 58 channel
PPH indicator
Cylinder 5
Spark
plugs

1 Is trouble code P1677 present? Replace the PPH unit
If the fault persists, change the DCU
4 Check the continuity and electrical insulation of the ISO K Carry out the repairs required.
communication line
© Delphi
2-142 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

5 Replace the preheating unit Change the DCU
py
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-143

I DIAGNOSTIC
PPH relay control

trouble code
P1678 PPH relay control - open circuit Open circuit?
P1679 PPH relay control - short circuit Short circuit
P1680 PPH relay control - short circuit to earth Short circuit to earth
On None
Symptoms
=> Engine noisy
=> Smoke
OC PPH relay control - open circuit
SC- PPH relay control - short circuit to earth
y
SC+ PPH relay control - short circuit
p
Co
Fuse
d
Vbatt
c e
n
96 channel
Cylinder 1
a
connector
v
Pre-post heating 68
Ad
Cylinder 2 Spark plugs
case
control DCU
Cylinder 3
+AC 52 58 channel
PPH indicator
Cylinder 5
Spark
plugs

1 Check the connection of the pre-postheating unit Carry out the repairs required.
3 Check the continuity and the electrical insulation of wires Repair the wiring harness
4 Replace the pre-post heating unit Change the DCU
© Delphi
2-144 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
PPH PLUG LINE - SHORT CIRCUIT

trouble code
On None
Symptoms
=> Engine noisy
=> Smoke
y
Fuse
p
Co
Vbatt
d
96 channel
e
68
c
Pre-post heating
Cylinder 2
n
case Spark plugs
a
control DCU
v
Cylinder 3
Ad
+AC 52 58 channel
PPH indicator
Cylinder 5
Spark
plugs

the plug
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-145

I DIAGNOSTIC
Butterfly valve control

trouble code
P2100 Butterfly valve control - Open circuit The diagnostic detected an open circuit problem on the steering of the EGR flap.
P2101 Butterfly valve control - short circuit at earth The diagnostic detected an open circuit problem on the steering of the EGR flap.
P2102 Butterfly valve control - short circuit The diagnostic detected a short circuit problem on the steering of the EGR flap.
P2103 Butterfly valve control - short circuit at + The diagnostic detected a short circuit problem at + on the steering of the EGR
flap.
P2104 Butterfly valve control - overheating The diagnostic detected an overheating problem on the steering of the EGR flap.
• Deactivation of the steering of the EGR flap (except for short circuit at earth)
Symptoms
py
d Co
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© Delphi
2-146 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
Butterfly valve request control

trouble code
P213B Butterfly valve control - Impossible to meet The diagnostic detected that the request cannot be met.
the instruction
Symptoms
Power loss
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 2-147

I DIAGNOSTIC
Butterfly position
trouble code
P213C Butterfly position - Signal too low The raw value read on the butterfly valve position is too low
P213D Butterfly position - Signal too low The raw value read on the butterfly valve position is too low
Symptoms
Power loss
py
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© Delphi
2-148 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
NON DETECTABLE FAULTS
3.1 LIST OF FAULTS / SYMPTOMS

These are the fault which cannot be detected by the injection DCU auto-diagnostic function.
3.1.1 Irregular acceleration - deceleration

1 Pedal sensor fault - Sensor mounting
- Sensor movement
- Conformity of the pedal signal (0 to 100%)
2 Rail pressure sensor offset not detected Read the rail pressure value when cranking
3 EGR valve stuck open - Vacuum circuit connection correct
- Solenoid valve breather
- Valve seized or broken
4 Intermittent connection fault - Injector connectors
- Rail pressure sensor connector
- IMV connector
y
- EGR solenoid valve connector
p
Co
5 Conformity of engine oil - Conformity of oil quality
- Conformity of oil level
d
- Oil diluted by fuel
c e - Condition of the oil vapour recycling circuit
an - Condition of turbo bearings
v
Ad
6 Fuel problem Conformity of the fuel
7 Condition of the exhaust system - Exhaust outlet
- Catalytic converter is free of debris
- Catalytic converter clogged
8 Software bug ECU download then change ECU if problem persists
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-149

I DIAGNOSTIC

3.1.2 Engine hesitation
CAUTION
Follow the cleanliness method during all operations

1 Is the tank empty? - Presence of fuel in the tank / fuel level / priming pump
- Sender unit operation
- Conformity of the fuel (petrol, water...) take a sample
2 - Conformity (cut, blocked, ...) of the injector return circuit
- Pump supply hose cut or blocked
Check the fuel supply circuit
- Sealing / clogging of the fuel filter
- LP connection inverted
- Fuel filter clogged
- Incorrect fuel filter (reference)
- LP fuel circuit blocked
-
py
Air leak in LP circuit
Co
- Pump return circuit blocked
- Tank sealing / breather
3 Engine mounting
ed Condition of the engine and transmission mountings
c
4 Check the mechanical and electrical systems - Alternator charging
an - BATTERY VOLTAGE
v
Ad
- Air conditioning compressor
- Auto
- Power assisted steering
5 C3I conformity Conformity cylinder by cylinder
6 Sensor drift - Read the flowmeter value
- Read the coolant temperature
- Read the vehicle speed
- Read the clutch pedal switch status
- Read the accelerator pedal setting
7 EGR VALVE - Vacuum circuit connection correct
8 Intermittent connection fault Known method (test the connector, wire, resistance, harness,...)
9 Heater plugs Conformity of the plugs/harness/unit
10 Engine compression Known method
11 - Injector contaminated
- Needle stuck
Injector problem
- Sealing washer (missing, double or incorrect)
© Delphi
3-150 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.3 Engine stop - stalling
CAUTION

1 Check the immobiliser function Immobiliser function diagnosis (immobiliser and DCU)
2 Immobiliser function diagnosis (immobiliser and DCU) - Fuses
- Supply
- ECU earth
- Harness connections
- Battery and charging circuit
3 - Presence of fuel in the tank / fuel level / priming pump
Check fuel conformity
4 - Injector return circuit conformity
py
Co
ed - Air leak in LP circuit
c
an - Tank sealing / breather
v
Ad
5 - Visual
- Smell
Is there an HP leak?
7 Check:
(Using the Delphi High Pressure diagnostic tool (H3PI))
HP circuit - The pump
- The injectors (if stuck open)
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-151

I DIAGNOSTIC

3.1.4 Rushing noise
CAUTION

3 Coolant temperature sensor offset not detected Measurement of the ambient value read
4 Intermittent connection fault - Injector connectors
- Rail pressure sensor connector
- IMV connector
- Accelerometer connector
5 - OCR control
- Verification of requested rail pressure/measured rail
IMV pressure
y
- Presence of pollution
p
Co
6 Conformity of the injector / engine
d
Unsuitable injector
c e
n
v a
Ad
© Delphi
3-152 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.5 Noise interference
CAUTION

1 Noise on injector - Injector "buzzer" noise (discharge from the injectors)
- Compare with the actuator test
- Incorrect injector flange fitting
2 Noise from mechanical & electrical equipment - Alternator
- Clutch
- Auto
- Turbo
- Other
3 Air noise -
py Air filter
Co
- Condition of the air line (flowmeter; exchanger...)
- Turbo
4 Exhaust noise
ed - Exhaust outlet
c
- Catalytic converter
an - EGR
v
Ad
5 Accessories noise Auxiliary heating
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-153

I DIAGNOSTIC

3.1.6 Engine noise
CAUTION

4 Airflow sensor offset Read the air flow value in comparison with a nominal value
5 EGR valve stuck open or closed - Vacuum circuit connection correct
6 Injector return circuit Check the conformity of the return circuit:
- Condition of the hoses
- Condition of the venturi
y
7 Heater plugs - PPH harness condition
p
Co
- PPH unit logic
- Condition of the plugs
d
9
c e - Conformity of the injector / engine
an - Sealing washer on the cylinder head
v
Unsuitable injector
Ad
- Needle stuck
Injector problem
© Delphi
3-154 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.7 Excessive consumption
CAUTION

1 Vehicle conformity - Conformity of the tyres
- Accessories (roofrack...)
- Parking brake
- Equipment...
- BATTERY VOLTAGE
- Auto
py
4 - Injector return pipes cut
Co
- Pump return circuit cut
d
5 Check the fuel quality - Conformity of the fuel (presence of petrol, water...)
c e - Take a sample
an
6 - Visual
v
- Smell
Ad
Is there a leak?
8 Condition of the air inlet system - Altitude
- Condition of the turbo
- Turbo air filter (exchanger, ducts...)
- Conformity of the line
- Operation of the air throttle (if present)
9 Conformity of oil level Oil level too high
12 Injector problem Conformity of the injector / engine
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-155

I DIAGNOSTIC

3.1.8 Engine difficult to start when hot
CAUTION

1 Check fuel conformity - Presence of fuel in the tank / fuel level / priming pump
2 Check the battery starter Charging/ battery voltage
3 Battery or starter US? Replace
- Pump supply hoses cut or leak
- Air leak in LP circuit
py
Co
5 - Visual
ed - Smell
c
Is there a major HP leak?
an
6 DCU supply US? - Supply
v
- DCU earths oxidised
Ad
7 Condition of the air inlet system - Flowmeter
- Air filter
12 - Rail pressure on starting
- IMV
IMV partially blocked
13 Known method (test the connector, wire...)
Intermittent connection fault

© Delphi
3-156 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

- Needle stuck
Injector problem
py
d Co
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Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-157

I DIAGNOSTIC

3.1.9 Engine starts then stalls
CAUTION

2 Check the battery starter Charging/ battery voltage
py
Co
ed
c
5 - Visual
an - Smell
v
Ad
6 DCU supply US? - Supply
- Air filter
13 CRANK signal lost after starting Conformity of the CRANK signal (engine speed)
© Delphi
3-158 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

14 - Rail pressure on starting
- IMV
Pump problem
15 Intermittent connection fault Known method (test the connector, wire...)
16 Heater plugs Conformity of the plugs/harness/unit
18 Injector problem - Injector contaminated
- Needle stuck or blocked open
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-159

I DIAGNOSTIC

3.1.10 Smoke on acceleration
CAUTION

1 Driving conditions Ask:
- Driving conditions during the phenomenon (town,
altitude, speed, towing...)
2 Driving conditions Conformity cylinder by cylinder
3 Airflow sensor offset Read the air flow value in comparison with a nominal value
5 Turbo pressure sensor offset not detected Read the turbo pressure value in comparison with a nominal
value
6 Atmospheric pressure sensor offset not detected Read the atmospheric pressure value in comparison with a
nominal value
8 EGR OCR control offset
py
Read the OCR value in comparison with a nominal value
Co
10 EGR circuit conformity - Condition of the valve (seized or broken)
ed
- Vacuum circuit connection correct
n c - Vacuum pump vacuum value
v a
Ad
- Valve condition
- Air filter
- Line sealing
12 Engine conformity - Coolant consumption
- Oil level (too high)
- Oil vapour circuit
- Turbo bearings
- Injector flange fitting
- Cylinder compression
- Injector sealing washer / cylinder head
13 - Presence of water in the filter
- Conformity of the fuel (mix, quality)
Conformity of the fuel
- Inappropriate additive
14 Condition of the exhaust system Catalytic converter clogged
© Delphi
3-160 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

15 - Conformity of the injector / engine
- Sealing washer on the cylinder head
Unsuitable injector
- Needle stuck
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-161

I DIAGNOSTIC

3.1.11 Blue & white smoke
CAUTION

1 Conformity of the fuel - Presence of water in the filter
- Conformity of the fuel (mix, quality)
- Inappropriate additive
2 Engine conformity - Coolant consumption
- Turbo bearings
3 Condition of the air inlet system -
py
Flowmeter
Co
- Air filter
- Line sealing
ed - Operation of the air throttle (if present)
c
4 Condition of the exhaust system Catalytic converter clogged
5 PPH circuit conformity
an - Control unit
v
Ad
- plugs
© Delphi
3-162 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.12 Black smoke
CAUTION

1 C3I conformity - Conformity of the C3I
- Consistency of the allocation / cylinder numbers
2 Coolant temperature sensor offset not detected Read the coolant temperature value
3 Rail pressure sensor offset not detected Read the rail pressure value
4 Inlet air sensor offset Read the inlet air value
- Air filter
- Line sealing
6 EGR circuit conformity - Vacuum circuit connection correct
y
p
Co
- Valve condition
7 Condition of the exhaust system
ed - "Town" type driving
c
- Going down a hill
an - Catalytic converter clogged
v
Ad
8 Check using the Delphi High Pressure diagnostic tool (H3PI)
"Drifting" injector
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-163

I DIAGNOSTIC

3.1.13 Lack of power
CAUTION

1 Vehicle conformity - Conformity of the tyres
- Accessories (roofrack)
- Parking brake
- Equipment...
- Sensor movement
- BATTERY VOLTAGE
py
Co
- Auto
5 Sensor drift
ed - Read the flowmeter value
c
- Read the turbocharging pressure
an - Read the accelerator pedal setting
v
Ad
6 - Pump supply hoses pinched or leak
- Fuel reheating
7 - Visual
- Smell
© Delphi
3-164 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

9 Condition of the air inlet system - Altitude
- Leak downstream from the turbo (exchanger, ducts...)
- Air filter (clogged & conformity)
- Needle stuck
py
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-165

I DIAGNOSTIC

3.1.14 Engine does not start
CAUTION

1 Check the immobiliser function Immobiliser function diagnosis (immobiliser and DCU)
- Conformity of the fuel
3 Check the battery/starter Charging/ battery voltage
5 - Pump supply hose cut
py
Co
ed
c
6 - Visual
an - Smell
v
Ad
7 DCU supply US? - Fuse
- Supply
- DCU earths
- Air filter
- Line sealing
13 Cam and CRANK signals missing at the same time (when cranking)
- CAM signal conformity
- CRANK signal conformity
© Delphi
3-166 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

14 IMV
IMV stuck closed

15 Take a fuel sample from the tank
Fuel quality (presence of water)

17 Heater plugs PPH unit logic
19 Transfer pump US Measure the pump return flow (if possible)
20 HP pump US Check using the Delphi High Pressure diagnostic tool (H3PI)
Injector US
py
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-167

I DIAGNOSTIC

3.1.15 Engine does not stop
CAUTION

1 Conformity of the electrical wiring Conformity of key information to the DCU (short circuit to
"positive" on this line)
2 - Oil quality
- Conformity of oil level
Conformity of engine oil
- Oil diluted by fuel
- Condition of the oil vapour recycling circuit
- Condition of turbo bearings
py
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© Delphi
3-168 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.16 Engine dies when moving off
CAUTION

- Sensor movement
3 Turbo pressure sensor offset not detected Read the turbo pressure value in comparison with a nominal
value
- BATTERY VOLTAGE
- Auto
y
p
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- Brakes stuck...
d
c e
an - LP fuel circuit blocked
v
Ad
6 Condition of the air inlet system - Air filter
- Conformity of the air line (flowmeter; exchanger...)
9 - Coolant consumption
Engine conformity
- Turbo bearings
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-169

I DIAGNOSTIC

3.1.17 Smell of fuel
CAUTION

1 - Condition of the tank (filler neck; breather connections...)
- Condition of the fuel filter (type; quick release
Condition of the LP fuel circuit connections; heater...)
- Condition of the pump (quick release connections)
- Condition of the venturi / fuel temperature sensor (type;
quick release connections; sensor flange fitting...)
- Condition of the priming bulb
- Condition of the injector return circuit
- Condition of the auxiliary heating (if present)
2 Conformity of the HP fuel circuit - Condition of the pump (IMV; limiter; HP pipes...)
y
- Condition of the rail / pressure sensor (type; thread...)
p
Co
- Condition of the injector (flange fitting; connections...)
ed
n c
v a
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© Delphi
3-170 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.18 Exhaust smells
CAUTION

3 Turbo problem Condition of the turbo bearings
- Particle filter - catalytic converter blocked
- Catalytic converter sealing
5 Injector problem - Conformity of the injector / engine
py
Co
- Sealing washers (conformity, double or missing)
6 Software bug DCU download then change DCU if problem persists
ed
n c
v a
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-171

I DIAGNOSTIC

3.1.19 Idle speed stuck (too high/too low) No engine brake
CAUTION

1 Coolant temperature sensor offset not detected - Conformity of the ambient value
- Check the sensor circuit (resistance; connector;
continuity)
- Bleed the cooling circuit
2 Offset for fuel injected at idle speed Consistency of the fuel injected (high residual torque)
- BATTERY VOLTAGE
- Auto
- Power assisted steering...
y
4 Battery US? Replace
p
Co
5 Check the accelerator function - Sensor mounting
- Pedal travel
d
c e
an
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© Delphi
3-172 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.20 Idle unstable - hunting
CAUTION

1 Check fuel conformity - Presence of fuel in the tank / fuel level / priming pump
- BATTERY VOLTAGE
- Auto
3 Battery US? Replace
4 - Condition (cut, blocked...)
py
Co
ed - Air leak in LP circuit
c
an - Tank sealing / breather
v
Ad
5 - Visual
- Smell
6 Harness not correct - Supply
- Connections...
7 Condition of the air inlet system - Air filter
10 Heater plugs circuit Conformity of the plugs (post heating)
12 EGR circuit - Vacuum circuit connection correct
13 Accelerometer circuit Conformity of the sensor tightness
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-173

I DIAGNOSTIC

14 IMV - Verification of requested rail pressure/measured rail
pressure + IMV parameters (current loop...)
- HP pump US
17 - Injector flange fitting
- Injector contaminated
Injector problem
- Needle stuck
py
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© Delphi
3-174 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.21 Engine overheat
CAUTION

1 Check fuel conformity - Fuel quality
- Conformity of the fuel (petrol, water...)
- Take a sample
- Auto
3 Coolant temperature sensor offset not detected - Conformity of the ambient value
- Check the sensor circuit (resistance; connector;
continuity)
y
- Bleed the cooling circuit
p
Co
4 Condition of the cooling system - Fans
- Harness
d
- Fan supply (fuses; relays...)
5 Condition of the exhaust system
c e - Exhaust outlet
an - Catalytic converter is free of debris
v
Ad
6 Heater plugs circuit Conformity of the plug supply
7 EGR circuit - Vacuum circuit connection correct
8 - Coolant consumption
Engine conformity
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-175

I DIAGNOSTIC

3.1.22 Excess engine speed on releasing accelerator pedal
CAUTION

1 Clutch problem - Clutch condition
- Mechanism adjustment
- Wear
3 Accelerator pedal sensor fault - Sensor mounting
- Sensor movement
4 Clutch pedal sensor fault - Sensor mounting
- Sensor movement
- Signal conformity (on/off)
py
Co
7 Conformity of the injector / engine
ed
c
Injector problem
n
8 Turbo problem DCU download then change DCU if problem persists
v a
Ad
© Delphi
3-176 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I

3.1.23 Too much power
CAUTION

2 Turbo problem - Conformity of the turbo
3 EGR valve stuck closed - Vacuum circuit connection correct
5 Injector problem Conformity of the injector / engine
py
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 3-177

I DIAGNOSTIC

3.1.24 Flat spot on acceleration
CAUTION

1 Condition of the air inlet system Sealing of the air line (all components)
2 Turbo pressure problem Comparison of the setting and feedback
3 Pedal sensor fault - Vacuum circuit connection correct
- Sensor mounting - Solenoid valve breather
- Sensor movement - Valve seized or broken
EGR valve stuck open
4 - Low pressure circuit
- Clogging of the fuel filter
py
Co
- BATTERY VOLTAGE
ed
c
- Auto
an - Power assisted steering
v
Ad
6 Engine compression Compression at each cylinder
7 - Visual
- Smell
Is there an HP leak in the transitory phase?
8 - OCR control
- Verification of requested rail pressure/measured rail
IMV pressure
- Presence of pollution
9 Condition of the exhaust system Condition of the exhaust system (catalytic converter)
Injector problem
© Delphi
3-178 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
CHECKS
4.1 DESCRIPTION OF THE CHECKS
4.1.1 Electrical supply circuit check

1 Checking the electrical supply: Check the battery charge and Carry out the repairs required.
the correct operation of the alternator
Is there a charging circuit problem?
2 Check the fuses Carry out the repairs required.
Is there a fuse problem?
3 Check the correct operation of the supply relay Replace the supply relay
Is there a supply relay problem?
Is there a DCU earth problem?
5 Electrical supply circuit OK
y
4.1.2 Checking the air inlet circuit
p
Co
1 Check the air inlet circuit: Check there are no air leaks Carry out the repairs required.
Are there any leaks?
ed
n c
2 Check the condition of the air filter Replace the air filter with a new component
a
Is there an air filter problem?
v
Ad
3 Ensure the inlet manifold is not blocked (contaminated) Inlet air circuit OK
Is the inlet manifold blocked?
4 Clean the inlet manifold
4.1.3 Checking the LP circuit
Fault chart (Code

1 Check there is fuel in the fuel tank Fill the tank
Is the tank empty?
- Look for leaks,
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 4-179

I DIAGNOSTIC
CHECKS
4.1.4 Looking for HP leaks

1 Check the HP circuit: Start the HP leak detection cycle Carry out the repairs required.
Are any HP leaks detected?
2 The HP circuit is OK
4.1.5 Checking engine parameters

1 Check the consistency of the dynamic parameters using the Carry out the repairs required.
diagnostic tool:
- Parameters within tolerances (see table on the next
page)
- Consistency of the parameter value (ensure there is no
drift)
- Stability of the values
y
Are the parameters incorrect?
p
Co
2 End
ed
n c
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© Delphi
4-180 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC I
CHECKS
Dynamic parameters Units Min Max Conditions

terminal terminal
Idle speed setting rpm 750 1400 1400 rpm corresponds to limp home mode. The idle speed setting
reduces as the engine temperature increases
Pedal position The value displayed should be between 0% and 100%. It increases when the accelerator pedal is pressed.
Typical value (accelerator pedal released) : 0%
Typical value (accelerator pedal depressed) : 100%
Coolant temperature The coolant temperature should be between -40°C and +140°C.
air temperature The air temperature should be between -40°C and +140°C.
Diesel temperature The diesel temperature should be between -40°C and +140°C.
BATTERY VOLTAGE Volt 10 14 Engine stopped
Measured rail pressure bar -5 15 Engine stopped and cold
The measured rail pressure Engine stopped and cold Engine running
should folllow the requested rail
pressure
Requested main engine -2,5 10 For pre-starting and the starting phase:
y
advance degrees
p
Note: A negative value corresponds to a retard (after TDC) and a
Co
positive value corresponds to an advance (before TDC).
d
-3 12 Engine running
c e Note: A negative value corresponds to a retard (after TDC) and a
an positive value corresponds to an advance (before TDC).
v
Requested pilot engine 2,5 17 During the starting phase
Ad
advance degrees 14 45 Engine running
Main fuel requested mg/rev - - The main requested fuel corresponds to the total fuel minus the
requested pilot fuel.
Total fuel mg/rev 0 138 During the starting phase
0 115 Engine running
The total fuel corresponds to the pilot fuel requested plus
the main fuel requested.
Pilot fuel requested mg/rev 0,6 9 During pre-starting
0 2,5 Engine running
EGR solenoid valve % 0 100 During pre-starting
control OCR 0 During pre-starting Engine running
Note: When the opening cycle ratio (OCR) is zero, the EGR solenoid
valve is not controlled (EGR valve closed).
EGR throttle solenoid % 0 100 0% = EGR throttle closed
valve control OCR 100% = EGR throttle open
Turbo solenoid valve % 0 100 0% = solenoid valve closed
OCR 100% = solenoid valve open
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 4-181

I DIAGNOSTIC
CHECKS
Dynamic parameters Units Min Max Conditions

terminal terminal
Linearised sensor Volt 4,8 5,2 Normal operation
supply
Fan setting 1 % 0 100 During normal operation
Solenoid valve setting mg/rev 200 300 At idle speed
EGR 0 1300 During normal operation
Requested manifold bar 1,09 2,5 During normal operation
pressure
Manifold pressure bar Idling when hot
Atmospheric pressure Idling when hot
Indicated engine torque Nm 0 430 During normal operation
4.1.6 Check C3I conformity
y
p
1 Read the C3I stored in the DCU Write the C3I to the memory using the diagnostic tool
Co
Does the C3I stored in the memory correspond to the injectors? Take care to ensure the cylinder number is correct.
d
2 End
c e
n
4.1.7 Checking the injectors and the HP pump
v a
Ad
Fault chart (Code
1 Refer to the user's manual for the H3PI DDNX208 or to the CD
DDRX113 Use the YDTT 411 tool
4.1.8 Checking the DCU
Step Procedure
1 Switch off the ignition and wait for the end of the power latch.
2 Unplug the calculator connector and do a visual check of terminals.
3 Search for traces of oxidation or silicone susceptible of creating bad contacts.
4 Visually check the connector's joint.
5 Check that the pins and terminals of connectors are intact and correctly inserted in their respective connector.
6 Make sure the terminals and pins are perfectly set or soldered on the conductor and that there is no reversing of terminals
or pins when connecting.
7 When the above checks are done, replug the component and check the clipping of connectors.
© Delphi
4-182 DDNX308(EN) - Issue 1 of 06/2007

TECHNICAL INFORMATION
5.1 TIGHTENING TORQUES

Components to tighten Torque
HP pipes (USUI type) 40 ± 10 N.m
Note: The HP pipe nuts are "GOLD" in colour.

Rail mounting bolt 25 N.m
Pump mounting bolt 24 N.m
Pump support mounting bolt 23 N.m
Pump pulley nut 65 ± 5 N.m
Pump sprocket mounting bolt 20 N.m then angle tighten to 90°
Injector holder flange bolt 10 N.m then angle tighten to 180°
Low Pressure actuator mounting bolt (IMV) 3 N.m then slacken by 1/2 turn then 1.5 ± 0.2, 3 ± 0.3 then 5.5 ± 0.6 N.m
Venturi mounting bolt 5.5 ± 0.6 Nm
Diesel temperature sensor 15 ± 1.5 Nm
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© Delphi
DDNX308(EN) - Issue 1 of 06/2007 5-183

5.2 RESISTANCE VALUES
CAUTION
It is impossible to measure resistances less than 1Ω using a conventional multimeter. To measure the injector resistance,
use the KELVIN (4 wire) method.
Components Terminals Resistance values

SENSOR DCU
IMV Non- 87 (OCR control) 5.3Ω ± 10%
polarised
HSD LSD Cyl
117 114 1
Non- 118 121 2

Injector 180 mΩ
polarised 117 116 3
117 115 4
y
117 115 5
p
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Pin A 25 (measurement)
Rail pressure sensor Pin B 26 (earth) Integrated circuit (resistance cannot be measured)
d
Pin C 6 (+ 5V supply)
Pin 1 99 (measurement)
c e
Turbocharging pressure sensor Pin 2
an
108 (+ 5V supply) Integrated circuit (resistance cannot be measured)
v
Pin 3 100 (earth)
Ad
Diesel temperature sensor Pin 1 109 (measurement) Depends on temperature
Pin 2 110 (earth)
Engine speed Pin 1 90 (+ signal) 1090 Ω ± 15%
Pin 2 82 (- signal)
EGR solenoid valve Pin 1 to + Bat of supply relay 15.4 Ω ±0.7 Ω at 20°C
Pin 2 96 (OCR control)
Pin 1 72 (+5V supply track 1)
Pin 2 14 (earth track 2)
Pin 3 71 (signal track 1) 1.25 k ± 20% between terminals 1 and 5 of the sensor
Pedal sensor
Pin 4 57 (2.5V supply track 2) 1.9 k ± 20% between terminals 2 and 4 of the sensor
Pin 5 53 (earth track 1)
Pin 6 32 (signal track 2)
Accelerometer 1 Pin 1 45 (+ signal) Piezzo electric sensor
Pin 2 46 (- signal)
Accelerometer 2 Pin 1 44 (+ signal) Piezzo electric sensor
Pin 2 63 (- signal)
© Delphi
5-184 DDNX308(EN) - Issue 1 of 06/2007

Components Terminals Resistance values

SENSOR DCU
Pin 1 111 (+5V supply)
Phase sensor Pin 2 103 (measurement) Hall effect sensor
Pin 3 104 (earth)
Pin 1 64 (air T° measurement)
Pin 2 to + Bat of supply relay
Hot air film flowmeter + NTC thermistor (resistance
Phase sensor Pin 3 84 (earth)
decreases as temperature increases)
Pin 4 86 (+5V supply)
Pin 5 83 (air flow measurement)
Coolant temperature sensor Pin 1 101 (measurement) Depends on temperature
Pin 4 102 (earth)
Pin 1 36 (measurement)
Vehicle speed sensor Pin 2 Not connected to the DCU Hall effect sensor
y
Pin 3 Not connected to the DCU
p
Co
Coolant temperature sensor
Temperature (°C) Nominal resistance between sensor Resistance tolerance between sensor
ed
terminals ( ) terminals ( )
c
20 2449,9 ± 159,1
50
an 826,3 ± 41,5
v
Ad
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 ( ) sensor terminals ( ) sensor terminals ( )
-40 35140 39260 43762
-20 12660 13850 15120
-10 7943 8609 9307
0 5119 5499 5892
20 2290 2420 2551
40 1096 1166 1238
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
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 5-185

Diesel temperature sensor

Temperature (°C) Nominal resistance between sensor Resistance tolerance between sensor
terminals ( ) terminals ( )
-40 75780 68780 to 82780
-20 21873 19713 to 24033
-10 12462 11334 to 13590
0 7355 6742 to 7968
20 2812 2645 to 2979
40 1199 1137 to 1260
50 811,2 772.3 to 850
70 394,8 383.2 to 406.4
90 206,6 201.2 to 211.9
110 115,1 112.45 to 117.7
120 87,7 85.8 to 89.6
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© Delphi
5-186 DDNX308(EN) - Issue 1 of 06/2007

5.3 WIRING DIAGRAM
187 1 Speed sensor 1

188 2 2
3
114 3 Camshaft 4
137 2 5
138 1 sensor
6
ISO K line
231 7
8 Diagnostic
124 9 plug
125 Track Sensor 10
1 Pedal 11
126 12
110 13
Track 14
113 15
2
114 16
211 1
216 2
215 3 Speed
4 regulation
5 control
Brakes contactor 6
y
139 Vbatt
p
Co
123 +AC
Defect indicator
237 Water level indicator
(GO filter)
d
179 Speed regulation
e
indicator
c
DCU +AC
n
Anti-start indicator
a
209
v
Preheating indicator
252
Ad
ISO K line Immobilizer and PPH
252
diagnostic
LEGEND
146 1
147 2
Accelerometer 1 1XX: channel XX on 96 channels
connector 2XX: channel XX on 58
116 1 Accelerometer 2 channels connector
141 2
101 1 Water temperature
102 4 sensor
154 1 LEGEND
2 Air flow meter and
161 3 air temperature
160 4 sensor
170 5 Shielding
125 Injector 1
174
101
Injector 4
173
126 Injector 2
151
102
Injector 5
149
127
150 Injector 3
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 5-187

187 1 Speed sensor 1

188 2 2
3
114 3 Camshaft 4
137 2 5
1 sensor
138 6
ISO K line
231 7
8 Diagnostic
124 9 plug
125 Track Sensor 10
1 Pedal 11
126 12
110 13
Track 14
113 15
2
114 16
211 1
216 2
215 3 Speed
4 regulation
5 control
Brakes contactor 6
139 Vbatt
123 +AC
y
Defect indicator
p
237 Water level indicator
Co
(GO filter)
179 Speed regulation
DCU indicator +AC
d
Anti-start indicator
e
209
c
Preheating indicator
n
252
a
ISO K line
v
Immobilizer and PPH
252
diagnostic
146
147
Ad 1
2
Accelerometer 1
LEGEND
1XX: channel XX on 96 channels
connector 2XX: channel XX on 58
116 1 Accelerometer 2 channels connector
141 2
101 1 Water temperature
102 4 sensor
154 1 LEGEND
2 Air flow meter and
161 3 air temperature
160 4 sensor
170 5 Shielding
125 Injector 1
174
101
Injector 4
173
126 Injector 2
151
102
Injector 5
149
127
150 Injector 3
© Delphi
5-188 DDNX308(EN) - Issue 1 of 06/2007

5.4 TOOLING REQUIRED
Special tooling Part number

Injector holder locking spanner YDT232
17 mm adjustable wrench YDT339
Long nose sealing washer extractor YDT256
Injector extractor YDT327
Well bottom cleaning tool YDT252
Viscous coupling pulley locking spanner YDT328
Long vacuum cleaner nozzle YDT255
Vacuum cleaner YDT205
DIAMAND diagnostic tool YDT300
M14 M14 tube YDT 411
Pump support extractor claw YDT 431
y
Standard tooling Part number
p
Co
1/4 - 3/8 adapter Facom R0.232 type
1/2 to 3/8 adapter Facom S.230 type
3/8 to 1/4 adapter
ed Facom J.230 type

1/2 square drive
n c Facom S.373 type

1/4 square drive
v a Facom R0.373 type
Ad
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
Angular tightening spanner Facom DM360 or D360 type
1/4 ratchet Facom R0.161 type
1/2 ratchet Facom S.161 type
Hexagonal socket Facom R.8 to R13 type
1/2 screwdriver socket Facom SHP.6L type
3/8 OGV socket Facom J.10 type
3/8 OGV socket Facom J.22LA type
3/8 OGV socket Facom J.13LA type
3/8 OGV socket Facom SJ.27 type
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 5-189

Standard tooling Part number

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
y
Outside pullers
p
Parts, consumables and cleaning kit Part number
Co
Plug kit 9109-917
d
Clean brush
Cleaning solution
c e Careclean type
Clean container
an
v
Ad
© Delphi
5-190 DDNX308(EN) - Issue 1 of 06/2007

FAULT CODE INDEX
Diagnostic trouble code Diagnostic tool title Page number

P0100 Flowmeter supply - Vext 2-23
P0101 Air flowmeter signal 2-23
P0102 Flowmeter signal - low 2-23
P0103 Flowmeter signal - high 2-23
P0105 Turbo pressure sensor supply - Vext 2-25
P0106 Turbo pressure signal - high - ignition on 2-25
P0107 Turbo pressure signal - low 2-25
P0108 Turbo pressure signal - high 2-25
P0109 Turbo pressure signal - low - ignition on 2-25
P0110 Air temperature sensor supply - Vext 2-27
P0112 Air temperature signal - low 2-27
P0113 Air temperature signal - high 2-27
P0115 Coolant temperature sensor supply - Vext 2-29
P0117 Coolant temperature signal - low 2-29
y
P0118 Coolant temperature signal - high 2-29
p
Co
P0120 Pedal sensor track 1 supply – Vext 2-30
P0122 Pedal sensor track 1 signal – low 2-30
d
P0123 Pedal sensor track 1 signal – high 2-30
P0147
c
Number of MDP updates (Low Pressure)
e 2-32
n
P0148 Number of MDP updates (Low Pressure) 2-32
P0171
v a
Injector-holder cylinder 1 - MDP drift 2-33
Ad
P0172 Injector-holder cylinder 2 - MDP drift 2-33
P0180 Fuel temperature sensor supply - Vext 2-35
P0182 Fuel temperature signal - low 2-35
P0183 Fuel temperature signal - high 2-35
P0190 Rail pressure sensor supply - Vext 2-37
P0191 Rail pressure signal - pressure drop 2-37
P0192 Rail pressure signal - low 2-37
P0193 Rail pressure signal - high 2-37
P0201 Injector cylinder no. 1 - open circuit 2-39
P0215 DCU supply control - relay stuck 2-41
P0219 Engine speed signal - too early 2-43
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 6-191

FAULT CODE INDEX

P0220 Pedal sensor track 2 supply – Vext 2-44
P0222 Pedal sensor track 2 signal – low 2-44
P0223 Pedal sensor track 2 signal – high 2-44
P0243 Turbo solenoid valve control 2-46
P0245 Turbo solenoid valve control - OC SC- 2-46
P0246 Turbo solenoid valve control - SC SC+ 2-46
P0251 Inlet metering valve control - short circuit 2-48
P0253 Inlet metering valve control - short circuit to earth 2-48
P0255 Inlet metering valve control - open circuit 2-48
P0263 Injector for cylinder no.1 - acyclism - combustion too low 2-50
y
P0325 Accelerometer 1 – (no signal at idle speed) 2-52
p
Co
P0330 Accelerometer 2 – (no signal at idle speed) 2-52
P0335 Engine speed signal - loss of signal 2-54
d
P0336 Engine speed signal - loss of gap 2-54
P0337 Engine speed signal - engine stalls
c e 2-54
n
P0341 Camshaft signal - synchronisation 2-55
P0344
v a
Camshaft signal - loss of signal 2-55
Ad
P0372 Engine speed signal - loss of teeth 2-57
P0400 EGR regulation - generic 2-58
P0405 EGR regulation - negative drift - low 2-58
P0406 EGR regulation - positive drift - upwards 2-58
P0407 EGR flap position signal - Below minimum threshold 2-58
P0408 EGR flap position signal - Above maximum threshold 2-58
P0480 Fan 1 control - open circuit 2-60
P0481 GMV1 control short circuit 2-60
P0482 Fan 1 control - short circuit to earth 2-60
P0483 GMV - PWM control 2-60
P0503 Vehicle speed signal - excessive 2-61
P0530 AC pressure signal - Low 2-62
P0532 AC pressure signal - Low 2-62
P0533 AC pressure signal - High 2-62
© Delphi
6-192 DDNX308(EN) - Issue 1 of 06/2007

FAULT CODE INDEX

P0560 Battery voltage signal - A/D converter 2-63
P0562 Battery voltage signal - low 2-63
P0563 Battery voltage signal - high 2-63
P0571 Brake switch signal - generic 2-65
P0606 Watchdog – Reset CPU 2-67
P0608 CAN - ABS/ESP 2-68
P0611 C2I/C3I fault 2-69
P0612 C2I/C3I fault 2-69
P0613 CAN - TCU 2-70
P0614 CAN TCCU 2-70
P062D Bank 1 injectors - low 2-71
P062E Bank 2 injectors - low 2-73
P0630 CAN - Configuration 2-75
P0631 Can Configuration 2-75
y
P0633 Immobiliser - key memory 2-76
p
Co
P0641 5V supply (Vext1) – A/D converter 2-77
P0642 5V sensor supply (Vext1) - low 2-77
d
P0643 5V sensor supply (Vext1) - high 2-77
P0651 5V supply (Vext2) – A/D converter
c e 2-77
n
P0652 5V sensor supply (Vext2) - low 2-77
P0653
v a
5V sensor supply (Vext2) - high 2-77
Ad
P0670 Heater plugs circuit 2-79
P0671 PPH plug line cylinder 1 - open circuit 2-79
P0685 DCU supply control - relay open 2-80
P0697 2.5V supply - A/D converter 2-82
P0698 2.5V supply - low 2-82
P0699 2.5V supply - high 2-82
P0700 CAN - TCU 2-84
P0704 Clutch pedal switch signal 2-85
P0805 MANUAL GEARBOX SWITCH 2-86
P1101 Generic atmospheric pressure signal 2-87
P1105 Atmospheric pressure sensor supply - Vext 2-87
P1106 Turbo pressure signal - plausibility 2-89
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 6-193

FAULT CODE INDEX

P1107 Atmospheric pressure signal - low 2-91
P1108 Atmospheric pressure signal - high 2-91
P1109 Turbo pressure signal - plausibility 2-92
P1115 Coolant temperature signal - plausibility 2-94
P1116 Coolant temperature signal - generic 2-94
P1120 Pedal sensor - correlation track 1&2 (1 > 2) 2-96
P1121 Pedal sensor - correlation track 1&2 (2 > 1) 2-96
P1122 Limp home mode 2-97
P1123 Reduced fuel mode activated 2-97
P1124 Accelerator pedal - stuck - correlation with brake pedal 2-98
P1147 MDP UPDATE 2-100
P1148 MDP UPDATE 2-100
P1149 Diesel filter - presence of water 2-101
P1170 Fuel correction too high – VLC strategy 2-102
y
P1171 CYLINDER 1 INJECTOR - MDP DRIFT 2-104
p
Co
d
P1175 CYLINDER 5 INJECTOR - MDP DRIFT
c e 2-104
n
P1190 Rail pressure signal - sensor drift 2-106
P1191
v a
Time for pressure to rise when starting fault 2-108
Ad
P1192 Rail pressure signal - low - when ignition switched on 2-110
P1193 Rail pressure signal - high - when ignition switched on 2-110
P1201 Injector cylinder no. 1 - short circuit 2-112
P1234 Turbo pressure regulation - generic 2-114
P1252 Rail pressure check - overpressure 2-116
P1253 Rail pressure check - negative error 2-116
P1254 Rail pressure check - positive error 2-116
P1256 Rail pressure check - trim low and fuel low 2-116
P1257 Rail pressure check - trim low and fuel high 2-116
P1258 Rail pressure check - trim low and fuel low 2-116
P1259 Rail pressure check - trim low and fuel high 2-116
P1260 IMV rail - trim pressure control 2-116
© Delphi
6-194 DDNX308(EN) - Issue 1 of 06/2007

FAULT CODE INDEX

P1286 Control for injector for cylinder 1 - harness resistance too low 2-119
P1287 Control for injector for cylinder 1 - harness resistance too high 2-119
P1405 EGR solenoid valve control - OC SC- 2-121
P1406 EGR solenoid valve control - SC SC+ 2-121
P1407 EGR apprenticeship closed - Value out of range 2-123
P1408 EGR apprenticeship closed - Abnormal variation rate 2-123
y
P1480 Fan 1 control - open circuit 2-124
p
Co
P1481 Fan 1 control - short circuit 2-124
d
P1500 Vehicle speed signal - generic 2-126
P1501
c
Vehicle speed signal - plausibility
e 2-126
n
P1503 Vehicle speed signal - excessive 2-126
P1526
v a
Fan 2 control - open circuit 2-127
Ad
P1527 Fan 2 control - short circuit 2-127
P1530 Water heater 1 control - open circuit 2-129
P1531 Water heater 1 control - short circuit 2-129
P1532 Water heater 1 control - SC to earth 2-129
P1534 Water heater 2 control - open circuit 2-131
P1535 Water heater 2 control - short circuit 2-131
P1536 Water heater 2 control - SC to earth 2-131
P1540 Air conditioning relay control - open circuit 2-133
P1541 Air conditioning relay control - short circuit 2-133
P1542 Air conditioning relay control - SC to earth 2-133
P1571 Safety brake switch signal 2-134
P1572 Main brake switch signal 2-134
P1600 Watchdog – interference on injector cut-off signal 2-135
P1601 CPU or CPU clock 2-135
P1602 TPU or TPU clock 2-135
P1606 Non volatile memory – CAN & KW 2-136
P1607 Watchdog – injector cut-out impossible 2-137
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 6-195

FAULT CODE INDEX

P1608 Watchdog 2-137
P1614 Non volatile memory - MDP 2-138
P1615 Non volatile memory - configuration 2-138
P1616 Non volatile memory - rail pressure 2-138
P1617 Non volatile memory – SMC cut-off 2-138
P1620 Non volatile memory - SC 2-139
P1621 Non volatile memory - fault management 2-139
P1622 Non volatile memory 2-139
P162D Bank 1 injectors - high 2-71
P162E Bank 2 injectors - high 2-73
P1630 Immobiliser - transponder 2-140
P1631 Immobiliser - function not active 2-140
P1632 Immobiliser - immobiliser deactivated 2-140
P1633 Immobiliser - no key memorised 2-140
y
P1634 Immobiliser - no response from the immobiliser 2-140
p
Co
P1635 Immobiliser - incorrect immobiliser response 2-140
P1636 Immobiliser - immobiliser 2-140
d
P1671 PPH plug line cylinder 1 - short circuit 2-141
P1672 PPH plug line cylinder 2 - short circuit
c e 2-141
n
P1674
v a
PPH plug line cylinder 4 - short circuit 2-141
Ad
P1676 Communication between the PPH unit and the DCU 2-142
P1677 Pre-post heating unit 2-142
P1678 PPH relay control - open circuit 2-144
P1679 PPH relay control - short circuit 2-144
P1680 PPH relay control - short circuit to earth 2-144
P2100 Butterfly valve control - Open circuit 2-146
P2101 Butterfly valve control - short circuit at earth 2-146
P2102 Butterfly valve control - short circuit 2-146
P2103 Butterfly valve control - short circuit at + 2-146
P2104 Butterfly valve control - overheating 2-146
P213B Butterfly valve control - Impossible to meet the instruction 2-147
P213C Butterfly position - Signal too low 2-148
P213D Butterfly position - Signal too low 2-148
© Delphi
6-196 DDNX308(EN) - Issue 1 of 06/2007

FAULT CODE INDEX

P600 CAN NETWORK ANOMALY 2-66
P602 CAN - Configuration 2-66
py
d Co
c e
an
v
Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 6-197

NOTES
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Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 7-198

NOTES
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Ad
© Delphi
DDNX308(EN) - Issue 1 of 06/2007 7-199

NOTES
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Ad
© Delphi
7-200 DDNX308(EN) - Issue 1 of 06/2007

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TABLE OF CONTENTS

Produced and published by:

DDNX308(EN) - Issue 1 of 06/2007 i

1. DIAGNOSTIC TOOL FUNCTIONS

ii DDNX308(EN) - Issue 1 of 06/2007

DDNX308(EN) - Issue 1 of 06/2007 iii

iv DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

1.1 DIAGNOSTIC TOOL CONNECTION

YDT300 DIAMAND diagnostic tool

YDT182 Diagnostic lead OBD16

DDNX308(EN) - Issue 1 of 06/2007 1-1

DIAGNOSTIC TOOL FUNCTIONS

YDT233 Auxiliary harness

YDT175 Terminal box

1-2 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

YDT374 Terminal box interface for DCU DCM3.2 -

Terminal box covers for DCU DCM3.2 -

Pins No. of pins available

Note: Connector 1: 96 way Connector 2: 58 way

DDNX308(EN) - Issue 1 of 06/2007 1-3

DIAGNOSTIC TOOL FUNCTIONS

Diagnostic socket type: Pin no. Description

Diagnostic socket location

1-4 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

1.2 READING THE DEFECT CODES

DDNX308(EN) - Issue 1 of 06/2007 1-5

DIAGNOSTIC TOOL FUNCTIONS

1.2.2 The environment data.

1-6 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX308(EN) - Issue 1 of 06/2007 1-7

DIAGNOSTIC TOOL FUNCTIONS

1.3 READING OF DYNAMIC PARAMETERS

Note: Some variables may be represented in three different ways:

The linearised value

1-8 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

1.3.1 List of parameters

Variable Definition Units

DDNX308(EN) - Issue 1 of 06/2007 1-9

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1-10 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX308(EN) - Issue 1 of 06/2007 1-11

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1-12 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX308(EN) - Issue 1 of 06/2007 1-13

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1.4 DCU identification

This service allows identifying:

DCU identification Meaning

1-14 DDNX308(EN) - Issue 1 of 06/2007

DIAGNOSTIC TOOL FUNCTIONS