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16hdi Diesel Turbo Dv6ted4 Fap Compress
16hdi Diesel Turbo Dv6ted4 Fap Compress
2. Location .......................................................................................... 10
Components of the pre-post heating system .
Components of the fuel circuit .
Components of the fuel additive system .
Components of the air circuit .
Components of the exhaust and particle filter circuit .
Components of the exhaust gas recycling system .
Components of the engine cooling system .
Identification of air conditioning circuit components .
Components of the lubrication circuit .
Engine speed sensor .
Cylinder reference sensor .
Components of the vacuum circuit . ...................................................................................... 27
3. Man/machine interface
The alert messages and warning lamps are displayed either in the instrument panel or on the
multifunction screen.
Refer to the document : "Principles of operation : Instrument panel ".
1
Linear pressure sensor for the air conditioning fluid (8009) .
Engine oil pressure switch (4110).
Engine oil level sensor (f4120).
Engine speed sensor (1313).
Cylinder reference sensor (1115).
2
Particulate filter regeneration .
Exhaust gas recycling (EGR) . ..................................................................................... 213
Fan regulation internal control (FRIC) .
Cooling requirement for the air conditioning (BRAC) .
1. recommendations
CAUTION : The addition of additives such as fuel circuit cleaner/remetalliser, is prohibited.
The operations must be carried out by specialist personnel informed of the safety advice and the
precautions to be taken.
Do not smoke in the immediate vicinity of the high pressure circuit when work is being carried
out
Avoid working near flames or sparks
Do not carry out any operations on the high pressure fuel circuit with the engine running
3
When the engine has stopped, use the diagnostic tool to check that the pressure in the rail
has dropped, before carrying out any work; this may take several minutes
N.B. : The waiting time is necessary to allow the high pressure fuel circuit to return to normal atmospheric
pressure.
engine running :
Always stay out of range of a possible jet of fuel which may cause serious injuries
Do not place your hands near the site of a leak on the high pressure fuel circuit
Fuel filter
high pressure fuel pump
Fuel high pressure common injection rail
High pressure fuel pipes
Low pressure fuel pipes
Injector holders
CAUTION : Following removal immediately plug the high pressure circuit unions to prevent entry of
impurities into the high pressure circuit.
CAUTION : Safety torques: always observe the high pressure circuit tightening torques (pipes, injector
holder clips), using a regularly checked torque wrench.
4
3. Replacement of parts - Operations to be performed
CAUTION : Before carrying out any operations on the engine, read the injection ECU memories.
Figure : E2AP02XD
5
Figure : B1HP2M4D
CAUTION : During the period of guarantee : Do not separate the fuel high pressure common injection
rail (6) from the fuel high pressure sensor (5) (Malfunction).
N.B. : During the warranty period, for removing-refitting the fuel high pressure sensor, refer to the
procedure for removing-refitting the fuel high pressure common injection rail.
N.B. : Outside the warranty period, removing-refitting the fuel high pressure sensor only is authorised.
6
Figure : B1HP2M5D
Do not detach the diesel injector holder (10) from the following components :
Possession of the analogue module access code (written on the customer's confidential card)
Possession of a new injection ECU and diagnostic equipment
Carry out a learning process for the engine ECU (Engine ECU Learning)
Configure the ECU
7
4. Packaging for warranty return
Injection system parts return.
Before return to the technical inspection centre, the following components must be plugged, placed in
a plastic bag and packed in the original packaging of the replacement parts :
Injectors
high pressure fuel pump
Supply rail
High pressure fuel sensor
8
Air flow management incorporating the EGR (exhaust gas recirculation)
Complies with emission standard Euro 5
9
LOCATION : COMPONENTS OF THE
B1HB012NP0
PRE-POST HEATING SYSTEM
Figure : B1HB0BXD
Figure : B1HB0BYD
10
LOCATION : COMPONENTS OF THE
B1HB012MP0
FUEL CIRCUIT
Figure : B1HB0BSD
11
Figure : B1HB0AHD
Figure : B1HB0AID
12
Figure : B1HB0BUD
Figure : B1HB0BVD
13
(12) Fuel high pressure common injection rail .
"b" High pressure fuel sensor .
Figure : B1HB0G2D
14
LOCATION : COMPONENTS OF THE AIR
B1HB012FP0
CIRCUIT
Figure : B1HB0BDD
15
Figure : B1HB0BED
Figure : B1HB0BFD
16
LOCATION : COMPONENTS OF THE
B1HB012YP0 EXHAUST AND PARTICLE FILTER
CIRCUIT
Figure : B1HB0D8D
17
Figure : B1HB0D9D
18
LOCATION : COMPONENTS OF THE
B1HB013CP0 EXHAUST GAS RECYCLING SYSTEM
(EGR)
Figure : B1HB0D6D
(2) Position repeat sensor for the flap of the discharge (by-pass) circuit of the exhaust gas recirculation
heat exchanger.
(3) Exhaust gas recirculation heat exchanger discharge (by-pass) circuit contro
19
LOCATION : COMPONENTS OF THE
B1HB012GP0
ENGINE COOLING SYSTEM
Figure : B1HB0BGD
20
Figure : B1HB0BHD
Figure : B1HB0BID
21
LOCATION : IDENTIFICATION OF AIR
B1HB012KP0
CONDITIONING CIRCUIT COMPONENTS
Figure : B1HB0BND
22
LOCATION : COMPONENTS OF THE
B1HB013DP0
LUBRICATION CIRCUIT
Figure : B1HB08CD
23
Figure : B1HB0DID
Figure : B1HB0DJD
24
B1HB0116P0 LOCATION : ENGINE SPEED SENSOR
Figure : B1HB081D
25
LOCATION : CYLINDER REFERENCE
B1HB0117P0
SENSOR
Figure : B1HB083D
26
LOCATION : COMPONENTS OF THE
B1HB012HP0
VACUUM CIRCUIT
Figure : B1BB0NDD
27
D4EA02QNP0 DESCRIPTION - FUNCTION : FUEL GAUGE
1. Description
Figure : B1HA0DXD
2. Role
The fuel gauge is for determining the level of fuel in the tank.
28
3. Function
Figure : B1HA0DYD
29
4. Electrical features
Figure : D4EA0H4D
194,3 48 50 58
The resistance value reduces when the depth of fuel in the tank increases.
The resistance value increases when the depth of fuel in the tank reduces.
30
Figure : D2AA043D
1 Not used
2 Not used
3 Not used
4 Not used
5. Learning / Initialisation
Not applicable.
31
D4EA02VJP0 DESCRIPTION - OPERATION : WATER PRESENT IN DIESEL SENSOR
1. Description
Figure : B1HA0EFD
2. Role
The sensor informs the engine ECU of the presence of water in the diesel fuel.
32
3. Operation
Figure : B1HA0EGD
"d" Water.
"e" Electrode.
1, 2, 3 Terminals of connector "a".
The presence of water in the diesel fuel signal is transmitted to the engine ECU, when the water
comes into contact with the electrode.
4. Electrical specifications
Output specification of the water presence sensor for a supply voltage of 13,5V.
33
Figure : B1HA0EHD
Figure : D2AA058D
34
"a" 3 way blue connector
2 Earth
3 Water in diesel information
Figure : D2AA059D
1 Electrode
2 Not used
35
4.3. Water detector connector
Figure : D2AA05AD
1 Electrode
5. Programming/initialisation
Not applicable.
36
D4EA02KMP0 DESCRIPTION - OPERATION : DIESEL FUEL TEMPERATURE SENSOR
1. Description
Figure : D2AA028D
2. Role
Diesel fuel temperature sensor :
The sensor informs the ECU about the temperature of the diesel fuel
The fuel temperature sensor contributes to the thermal protection of the engine
After receiving the fuel temperature information, the engine management ECU establishes an
estimate of the temperature and viscosity of the diesel fuel at the injector outlet
37
3. Operation
Figure : D2AA029D
When the temperature "T" increases, the resistance value "R" decreases
When the temperature "T" decreases, the resistance value "R" increases
38
4. Electrical specifications
Figure : D4EA0FBD
Temperature (°C) Minimum resistance (Ohms Nominal resistance Maximum resistance (Ohms
) )
39
80 259,2 273,5 288
130 59 61,5 64
Figure : D2AA02AD
5. Programming/initialisation
Not applicable.
40
D4EA02UQP0 DESCRIPTION - OPERATION : DIESEL FUEL HIGH PRESSURE SENSOR
1. Description
Figure : D2AA00AD
2. Role
The sensor measures the value of the high pressure in the fuel high pressure common injection rail.
41
3. Operation
Figure : B1HA0AKD
42
4. Electrical specifications
Figure : D4EA0F4D
"U" Output voltage of the diesel fuel high pressure sensor for a supply voltage of 5V (volts).
"P" Pressure of the fuel in the fuel injection rail (bar).
The output voltage of the diesel fuel high pressure sensor is proportional to the pressure of the fuel in
the fuel high pressure common injection rail.
Supply current 10 mA
43
Figure : D2AA00BD
1 Output signal
2 Earth
3 Supply voltage
5. Initialisation /Initialisation
Programming is necessary if the part is removed/refitted ; Refer to the diagnostic tools documentation
: Programming/initialisation.
44
D4EA02L5P0 DESCRIPTION - OPERATION : AIR FLOW METER
1. Description
Figure : B1HA0BKD
2. Role
Role of the air flowmeter :
45
3. Operation
3.1. Inlet air flow
Figure : B1HA0BLD
46
Figure : B1HA0BMD
When the temperature "T" increases, the resistance value "R" decreases
When the temperature "T" decreases, the resistance value "R" increases
47
4. Electrical specifications
Figure : B1HA0BOD
48
Air flow (Kg/hr ) "F" Minimum (Hz ) "F" Nominal (Hz ) "F" Maximum (Hz )
49
4.2. Air temperature
Figure : B1HA0BQD
25 1,9 2 2,1
50
30 1,562 1,653 1,746
Figure : D2AA02HD
51
4 way grey connector
2 Earth
3 Supply voltage
4 Air temperature signal
5. Initialisation /Initialisation
Not applicable.
Figure : D4EA0EZD
52
2. Role
The sensor measures the pressure and the temperature of the flow of air, passing around the sensor
inside the inlet manifold.
3. Function
Figure : D4EA023D
A part of the air exerts a pressure on the diaphragm of the pressure sensor
A part of the air varies the value of the CTN resistance (Negative Temperature Coefficient)
When the temperature "T" increases, the resistance value "R" decreases
When the temperature "T" decreases, the resistance value "R" increases
53
4. Electrical features
Pressure measured by the inlet air temperature and pressure sensor Between 300 and Mbar
3000
Figure : D4EA024D
"U" Output voltage of the inlet air temperature and pressure sensor (volts).
"P" Absolute pressure measured by the inlet air temperature and pressure sensor ( ± 30 Mbar ).
The pressure sensor provides digital electrical power that is proportional to the pressure measured.
54
4.2. Temperature sensor
Figure : D4EA02BD
-15 56 ± 2,5
-5 35 ± 2,5
55
0 27,9 ± 1,5
5 22,5 ± 1,5
10 18,2 ± 1,5
15 14,8 ± 1,5
20 12,1 ± 1,5
25 10 ± 1,5
30 8,29 ± 1,5
35 6,9 ± 1,5
40 5,8 ±1,5
45 4,8 ± 1,5
50 4,1 ± 1,5
55 3,5 ± 1,5
60 2,9 ± 1,5
65 2,54 ± 1,5
70 2,19 ± 1,5
75 1,89 ± 1,5
80 1,63 ± 1,5
85 1,41 ± 1,5
90 1,23 ± 1,5
95 1,08 ± 1,5
56
100 0,95 ± 1,5
4.3. Connections
Figure : D2AA00FD
57
"a" 4-way black connector
2 Supply voltage
3 Earth
4 Pressure output signal
5. Learning /Initialisation
Not applicable.
Figure : B1KA007D
58
2. Role
The gas temperature sensor upstream of the particle filter informs the engine ECU of the temperature
of the exhaust gases.
3. Operation
The NTC (Negative Temperature Coefficient) resistance value "R" changes in relation to the change in
the temperature "T" :
When the temperature "T" increases, the resistance value "R" decreases
When the temperature "T" decreases, the resistance value "R" increases
4. Electrical features
Figure : B1KA009D
Minimum value (°C) Temperature (°C) Maximum value (°C) Resistance R (In Kohms )
-10 0 10 34,49
59
10 20 30 19,86
40 50 60 9,748
60
Figure : D2AA02XD
2 Earth
5. Initialisation / Initialisation
Not applicable.
61
D4EA0359P0 DESCRIPTION - FUNCTION : PROPORTIONAL OXYGEN SENSOR
1. Description
Figure : B1KA00MD
2. Role
The proportional oxygen sensor measures the oxygen content of the exhaust gases relative to the
ambient air.
The proportional oxygen sensor determines the oxygen content of the exhaust gas and deduces the
exact richness of the mixture.
62
3. Function
Figure : B1KA00ND
63
The electrical output signal that is proportional to the oxygen content is obtained by measuring the
current necessary for the pumping cell to regulate the oxygen content in the measuring chamber.
4. Electrical features
4.1. Reference values
Figure : D4EA0UID
Oxygen rate (λ) 0,65 0,70 0,80 0,90 1,00 1,18 1,43 1,70 2,42 Air
Current (MA) -2,45 -1,99 -1,13 -0,49 -0,010 0,33 0,67 0,94 1,38 2,53
64
4.2. Connections
Figure : D2AA05BD
1 Compensation resistor
2 Pumping current
3 heating (-)
4 Nernst voltage
5 heating (+)
6 Earth
5. Learning/Initialisation
Not applicable.
65
DESCRIPTION - OPERATION : PARTICLE FILTER DIFFERENTIAL PRESSURE
D4EA02JLP0
SENSOR
1. Description
Figure : D4EA0A7D
2. Role
The particle filter differential pressure sensor measures the difference in pressure of the exhaust
gases between upstream and downstream of the particle filter.
66
3. Operation
Figure : D4EA0A8D
67
Figure : D4EA0AAD
4. Electrical features
68
Figure : D4EA0AED
Description Value
Maximum pressure admissible without irreversibly damaging the Maximum pressure upstream :
operation of the sensor 220 Kpa
Maximum pressure
downstream : 100 Kpa
Maximum pressure admissible without mechanically destroying the Pressure upstream : 310 Kpa
sensor
Pressure downstream : 110
Kpa
69
Figure : D4EA0AGD
1 Output voltage
2 Earth
3 Supply voltage
5. Programming/initialisation
Programming is necessary if the part is removed/refitted ; Refer to the documentation : Diagnostic
equipment functions : Programming/initialisation.
70
D4EA026HP0 DESCRIPTION - OPERATION : ENGINE COOLANT TEMPERATURE SENSOR
1. Description
Figure : B1GA0BMD
2. Role
The engine coolant temperature sensor informs the ECU of the temperature of the engine cooling
fluid.
3. Operation
The NTC (Negative Temperature Coefficient) resistance value "R" changes in relation to the change in
the temperature "T" :
When the temperature "T" increases, the resistance value "R" decreases
When the temperature "T" decreases, the resistance value "R" increases
71
4. Specification of the electrical system
Figure : B1GA0BND
-5 21160 ± 859
0 16325 ± 610
5 12695 ± 429
72
10 9950 ± 310
15 7855 ± 223
20 6245 ± 162
25 5000 ± 126
30 4028,5 ± 95
35 3266 ± 72
40 2663,5 ± 54
45 2184,5 ± 40
50 1801,5 ± 32
55 1493 ± 25
60 1244 ± 19
70 876 ± 12
80 629 ± 7,1
90 458,9 ± 6,9
130 150,5 ±3
73
Figure : D2AA00ED
2 Earth
5. Programming/initialisation
Not applicable.
74
D4EA027TP0 DESCRIPTION - OPERATION : AIR CON FLUID LINEAR PRESSURE SENSOR
1. Description
Figure : D4EA02ZD
2. Role
The aircon fluid linear pressure sensor measures the pressure in the cold loop of the air conditioning
circuit.
75
3. Operation
Figure : D4EA030D
76
4. Electrical features
Figure : D4EA031D
Supply current 7 mA
77
Figure : D2AA00MD
1 Supply voltage
3 Earth
5. Initialisation
Not applicable.
78
D4EA02AXP0 DESCRIPTION - OPERATION : ENGINE OIL PRESSURE SWITCH
1. Description
Figure : D4EA0AJD
2. Role
The engine oil pressure switch informs the engine ECU that the engine oil pressure is low.
79
3. Operation
Figure : D4EA0AKD
The electrical switch "c" closes the circuit between channel 2 and earth
The engine oil pressure low information is sent to the engine ECU
N.B. : The electrical switch "c" opens when the engine oil pressure reaches 1 bar.
4. Electrical features
Description Value
Supply voltage 12 V
80
Figure : D4EA0ALD
5. Initialisation/Initialisation
Not applicable.
81
D4EA02JTP0 DESCRIPTION - OPERATION : ENGINE OIL LEVEL SENSOR
1. Description
Figure : D4EA0E9D
2. Role
The engine oil level sensor is for measuring the level of engine oil present in the sump.
3. Operation
The engine oil level sensor only operates when the vehicle ignition is switched on, stopping as soon
as the engine is running.
The engine oil level sensor is supplied by a constant current provided by the engine ECU.
The engine oil level sensor provides an output voltage proportional to the level of engine oil that is
present in the sump.
82
Figure : D4EA0EAD
4. Electrical specifications
83
Figure : D4EA0EBD
2 Not used
3 Earth
5. Initialisation / Initialisation
Not applicable.
84
D4EA02KNP0 DESCRIPTION - OPERATION : ENGINE SPEED SENSOR
1. Description
Figure : D2AA02CD
2. Role
Role of the engine speed sensor :
3. Operation
The target is composed of 58 (60-2) pairs of magnetic poles distributed on its periphery, two poles
being absent in order to mark the top dead centre of pistons 1 and 4.
85
Figure : D4EA07TD
4. Electrical features
86
Figure : D2AA02DD
1 5V supply
2 Signal
3 Earth
5. Programming/initialisation
Not applicable.
87
D4EA02KLP0 DESCRIPTION - OPERATION : CYLINDER REFERENCE SENSOR
1. Description
Figure : D2AA025D
2. Role
The cylinder reference sensor informs the engine ECU of the position of the camshaft in order to know
which cylinder is in the compression phase.
88
3. Operation
Figure : D4EA0FAD
4. Electrical specifications
89
Figure : D2AA026D
1 Supply voltage
2 Output signal
3 Earth
5. Programming/initialisation
Not applicable.
90
5. Description of operation : Actuator
Figure : B1HA0AVD
2. Role
The pre-heater plugs enable a rapid rise in temperature in the combustion chambers during the
starting and cold-running phases.
The pre-heater plugs are also used for depollution, contributing to the reduction of nitrous oxides and
soots.
3. Operation
The preheater plug is an electric resistor element which heats up when it is supplied.
Regulation of the temperature is by regulation of the electrical supply (Open cycle ratio ).
91
Figure : B1HA0AXD
4. Electrical specifications
92
Figure : B1HA0AZD
5. Programming/initialisation
Not applicable.
93
D4EA02LRP0 DESCRIPTION - OPERATION : ELECTRIC DIESEL FUEL HEATER
1. Description
Figure : B1GA0CCD
2. Role
The electric heater heats up the diesel fuel upstream of the fuel high pressure pump.
3. Operation
The electrical resistor in the electric diesel fuel heater is operated by the engine ECU in the following
conditions :
Ignition on
Engine running
Air temperature below -2 ± 2°C
The engine ECU no longer operates the electrical resistor in the electric diesel fuel heater
when the air temperature reaches 3 ± 2°C
94
N.B. : A retention of the supply of the electric diesel fuel heater may be commanded for a few seconds
after the ignition is switched off, depending on the air temperature.
4. Electrical features
Figure : D2AA02VD
1 12 volts supply
2 Earth
5. Initialisation /Initialisation
Not applicable.
95
D4EA03HMP0 DESCRIPTION - FUNCTION : FUEL FLOW REGULATION VALVE
1. Description
Figure : B1HA0D4D
2. Role
The fuel flow regulation valve regulates the quantity of fuel sent to the pumping components of the
high pressure fuel pump.
The regulation of the flow entering the fuel high pressure pump compresses the required quantity of
fuel demanded by the engine ECU.
Role of the fuel flow regulator :
96
3. Function
Figure : D4EA158D
The fuel flow regulator electric coil "h" drives the magnetic core " c " (magnetic force)
The piston "g" moves
The connection between the 2 pipes is open
The inlet to the high pressure stage of the high pressure fuel pump is open
The fuel is directed to the high pressure stage of the high pressure fuel pump ( as "d")
The piston "g" is retained at the base of its location by means of the spring "f"
The connection between the 2 pipes is closed
97
N.B. : Le régulateur de débit carburant est fermé lorsqu'il n'est pas alimenté.
4. Electrical features
Designation Value
The fuel flow regulation valve is supplied by an open cycle ratio (OCR).
Variable voltage control (OCR) :
Figure : D2AA03KD
1 12 volts supply
2 control
5. Learning/Initialisation
Not applicable.
98
D4EA032DP0 DESCRIPTION - OPERATION : HIGH PRESSURE FUEL PUMP
1. Description
Figure : D4EA0QWD
99
Figure : D4EA0QXD
2. Role
Role of the high pressure fuel pump :
3. Operation
3.1. Transfer pump (pre-supply)
Figure : D4EA0QYD
100
Role of the transfer pump :
The transfer pump is incorporated in the high pressure fuel pump housing.
Figure : D4EA0QZD
101
The fuel coming from the transfer pump "e" via the fuel flow regulation valve "2" is drawn in
through the suction valve "h"
The fuel penetrates into the body of the pumping element
The plunger piston "j" descends
The roller encounters the attack face of the cam : The pressure suddenly increases inside the
body of the pumping element
The pressure inside the body of the pumping element becomes greater than the transfer
pressure : The suction valve of the high pressure pump compression chamber closes the duct
Figure : D4EA0R0D
102
Delivery phase :
When the cam "m" rotates, the pushrod "l" rises and pushes the plunger "j"
The roller encounters the attack face of the cam : The pressure suddenly increases inside the
body of the pumping element
The output valve of the compression chamber is subject to the pressure coming from the high
pressure fuel injection common rail on its external face and to the transfer pressure on its
internal face
The pressure inside the body of the pumping element becomes greater than the pressure
coming from the fuel high pressure common injection rail : The output valve of the
compression chamber of the high-pressure pump opens
The fuel is delivered to the high pressure pump compression chamber outlet valve
4. Data
Figure : D4EA0R1D
103
Description Minimum value Nominal value Maximum value
5. Initialisation /Initialisation
Not applicable.
Figure : B1HA0F7D
104
An electrical control part
A fuel spraying part
The diesel injectors have 7 symmetrical jet holes, for optimising the air/fuel mix.
The diesel injectors are connected together by the fuel return circuit.
A hex code on the diesel injector specification label indicates the classification of the injector.
This hex code indicates how the manufacture of the diesel injector differs from that of a standard
diesel injector.
Each diesel injector is commanded by the engine ECU in response to this differentiation.
2. ROLE
The diesel injectors inject the amount of fuel required for the engine to operate.
3. Operation
Figure : B1HA0F8D
105
Figure : B1HA0F9D
106
Figure : B1HA0FAD
107
3.3. Start of injection
Once the force applied above the needle becomes less than the force applied under the needle, so
the needle lifts and injection commences.
The diesel injector needle remains lifted during the valve opening phase.
The diesel injector is supplied, and the passage of fuel through its supply hole causes a loss of the
charge which depends on the pressure in the fuel high pressure common injection rail.
While the pressure in the fuel high pressure common injection rail is at maximum, the loss of charge
exceeds 100 bars : The pressure applied on the needle cone (injection pressure) is then less than the
pressure coming from the high pressure common injection rail.
3.4. End of injection
The coil is no longer energised, the communication holes are no longer in phase, the control chamber
fills via the filler hole.
When the pressure in the control chamber aided by the force of the spring becomes greater than the
pressure applied on the needle cone, the needle falls back onto its seat, the injection stops.
4. Electrical specifications
Description Value
Control voltage 40 V
Initial current 17 to 19 A
108
Figure : B1HA0D9D
1 + signal
2 - signal
5. Programming/initialisation
Programming is necessary if the part is removed/refitted.
N.B. : Refer to the diagnostic tools documentation : Programming/initialisation
109
D4EA03AJP0 DESCRIPTION - FUNCTION : DIESEL FUEL ADDITIVE PUMP
1. Description
Figure : B1HA0FWD
2. Role
The fuel additive pump injects a precise quantity of additive under pressure into the fuel additive circuit
each time the fuel tank is refilled according to the volume of fuel added.
110
3. Function
3.1. Suction phase
Figure : B1HA0FXD
111
3.2. Delivery phase
Figure : B1HA0FYD
112
4. Electrical features
Operating temperature - 30 - 80 °C
Figure : D2AA02ZD
113
"a" 3-way black connector
2 LIN
3 Earth
5. Learning / Initialisation
Programming is necessary if the part is removed/refitted ; Refer to the documentation : Diagnostic
equipment functions : Programming/initialisation.
Figure : D4EA0RED
114
"e" Turbo pressure regulator valve control rod.
"f" Turbo pressure regulator valve control vacuum capsule.
"g" 3-way black connector (Position repeat sensor ).
Supplier : MITSUBISHI.
2. Role
The fixed geometry turbocharger provides air turbo for the engine.
The repeat sensor indicates the position of the turbo pressure regulator valve to the engine ECU.
3. Operation
The engine is turbocharged by a fixed geometry turbocharger regulated by the engine ECU through
the intermediary of a regulated electrovalve.
The turbo pressure regulator valve position repeat sensor consists of a potentiometer situated on the
control vacuum capsule of the turbocharger.
The turbocharger position repeat sensor indicates precisely the exact position of the exhaust turbine
regulator valve.
Figure : D4EA0RFD
115
"f" Turbo pressure regulator valve control vacuum capsule.
"g" 3-way black connector (Position repeat sensor ).
"h" Boost pressure waste gate.
"j" Turbine discharge chamber.
"k" Inlet air compressor.
"l" Exhaust gas turbine.
The turbocharger is made of two separate chambers :
The exhaust turbine "l" and the inlet air compressor "k" are joined together by a shaft.
The exhaust turbine "l", sent into action by the exhaust gases "A", drives the inlet air compressor "k"
which compresses the incoming air "B".
The control vacuum capsule "f" changes the position of the regulator valve "h" through the
intermediary of the control rod "e".
The opening of the regulator valve "h" reduces the speed of rotation of the exhaust turbine "l".
The reduction in the speed of rotation of the exhaust turbine "l" in turn reduces the speed of rotation of
the inlet air compressor "k" and consequently the turbo pressure of the incoming air "b".
The regulation of the boost pressure is progressive and is managed by the engine management ECU.
The control rod "e" moves a maximum of 6 ± 1,1 mm.
Movement of the turbo regulator Vacuum value of the control vacuum capsule of the turbo
valve rod (Mm) pressure regulator valve (MBar)
1 159
4 110
CAUTION : Before stopping the engine, wait for the engine speed to drop to idle; failure to comply with
this condition will entail the destruction of the turbocharger over time (Lack of lubrication).
116
4. Electrical specifications
4.1. Data (Position repeat sensor )
Figure : D4EA0RGD
Supply voltage 5V
117
4.2. Connector (Position repeat sensor )
Figure : D4EA0RHD
1 Signal
2 Earth
3 5 volts supply
5. Programming/initialisation
Programming is necessary if the part is removed/refitted ; Refer to the diagnostic tools documentation
: Programming/initialisation.
118
D4EA02VMP0 DESCRIPTION - OPERATION : PROPORTIONAL ELECTROVALVE
1. Description
Figure : D4EA05CD
2. Role
The solenoid valve regulates and limits the control vacuum entering a pneumatic actuator, by means
of the vehicle's vacuum circuit.
3. Operation
The solenoid control is an OCR (Opening Cyclical Ratio) type control.
The proportional electrovalve controlled by an OCR voltage is connected to the following components :
Atmospheric pressure
Vacuum supplied by the vacuum pump
Pneumatic control actuator
119
Figure : D4EA05DD
120
4. Electrical features
Figure : D4EA05ED
0 0 50
10 10 80
20 20 120
30 80 200
95 650 780
121
Description Minimum tolerance Nominal value Maximum Unit
tolerance
Figure : D2AA015D
5. Initialisation/Initialisation
Not applicable.
122
DESCRIPTION - OPERATION : INLET AIR MIXER UNIT WITH POSITION
D4EA02TPP0
REPEAT SENSOR
1. Description
Figure : D4EA0LCD
2. Role
Role of the inlet air mixer unit with position repeat sensor :
To monitor the inlet pressure so as to optimise the exhaust gas recycling (EGR) rate
To prevent air from passing into the inlet circuit when the engine is switched off (cut-off
function)
123
3. Operation
Figure : D4EA0LDD
"b" Actuator of the inlet air unit with position repeat sensor.
"c" Butterfly.
The inlet air mixer unit actuator "b" receives a position reference value from the engine management
ECU.
The electric motor controls the butterfly "c".
The inlet air mixer unit actuator "b" receives a position reference value from the engine management
ECU.
124
4. Electrical specifications
Figure : D4EA0LED
125
Figure : D2AA052D
3 Earth
4 Output signal
5 5V supply
5. Initialisation /Initialisation
Programming is necessary if the part is removed/refitted ; Refer to the diagnostic tools documentation
: Programming/initialisation.
126
DESCRIPTION - OPERATION : ELECTRICALLY-CONTROLLED EXHAUST GAS
D4EA02MWP0
RECYCLING MODULE (WITH POSITION COPY SENSOR )
N.B. : EGR : Exhaust gas recycling.
1. Description
Figure : B1KA00DD
(1) Electrically-controlled exhaust gas recycling module (With integral position copy sensor ).
"a" Exhaust gas inlet.
"b" 5 way blue connector (Electrically-controlled exhaust gas recycling valve ).
"c" 3 way blue connector (Position copy sensor for the EGR heat exchanger by-pass flap ).
"d" Exhaust gas outlet.
"e" Water entry.
"f" Control capsule (By-pass flap with integral position copy sensor ).
"g"Water outlet.
Supplier : PIERBURG.
2. Role
Role of the exhaust gas recycling module (E.G.R) (With integral position copy sensor ) :
Allowing the intake of a specific quantity of recycled exhaust gas into the air supply circuit
Cooling or otherwise of the recycled exhaust gases
127
3. Operation
3.1. Exhaust gas recycling valve closed
Figure : B1KA00ED
(2) Barrel : Exhaust gas recycling valve (EGR).
(3) Exhaust gas recirculation heat exchanger .
"a" Exhaust gas inlet.
"h" Engine.
"j" Eccentric shaft .
"k" Valve : Exhaust gas recycling valve (EGR).
"l" By-pass flap /Exhaust gas recirculation heat exchanger .
Exhaust gas recycling valve closed : No recirculation of the exhaust gas.
128
3.2. Exhaust gas recycling valve open - By-pass flap /EGR heat exchanger closed
(By-pass position )
Figure : B1KA00FP
(2) Barrel : Exhaust gas recycling valve.
(3) Exhaust gas recirculation heat exchanger .
"a" Exhaust gas inlet.
"d" Exhaust gas outlet.
"h" Engine.
"j" Eccentric shaft .
"k" Valve : Exhaust gas recycling valve.
"l" By-pass flap /Exhaust gas recirculation heat exchanger .
The motor of the EGR valve is controlled by an open cycle ratio (OCR) signal : Opening of the EGR
valve is proportional.
129
Exhaust gas recycling valve open : Exhaust gas recycling.
By-pass flap /EGR heat exchanger closed :
The EGR heat exchanger/by-pass flap has only two positions (Open - Closed ).
3.3. Exhaust gas recycling valve open - By-pass flap /EGR heat exchanger open
(Exchanger position )
Figure : B1KA00GP
(2) Barrel : Exhaust gas recycling valve.
(3) Exhaust gas recirculation heat exchanger .
"a" Exhaust gas inlet.
"d" Exhaust gas outlet.
130
"h" Engine.
"j" Eccentric shaft .
"k" Valve : Exhaust gas recycling valve.
"l" By-pass flap /Exhaust gas recirculation heat exchanger .
Exhaust gas recycling valve open : Exhaust gas recycling.
EGR heat exchanger open :
The recycled exhaust gases pass through the EGR heat exchanger
The recycled exhaust gases are cooled
4. Electrical features
Range for signal in closed position, of the EGR valve 0,95 V 1V 1,05 V
position copy sensor
Range for signal in open position, of the EGR valve 3,95 V 4V 4,05 V
position copy sensor
Range for signal in exchanger position, of the by-pass Greater than - Less than 1,5
sensor /Exhaust gas recirculation heat exchanger 0,5 V V
Range for signal in by-pass position, of the by-pass Greater than - Less than 4,5
sensor /Exhaust gas recirculation heat exchanger 3,5 V V
131
4.1. Signal from the EGR valve position copy sensor
Figure : B1KA00HD
"A" Diagnosis zone .
"B" Valve open.
"C" Valve closed.
"U" Voltage ofthe signal in volts.
"P" Position of the valve (%).
132
4.2. Control signal of the EGR valve
Figure : B1KA00ID
"P" Opening of the valve (mm).
"R" RCO control (%).
N.B. : OCR = Open Cycle Ratio.
4.3. Signal from the by-pass flap position copy sensor /Exhaust gas recirculation heat
exchanger
Figure : B1KA00JD
133
"A" Diagnosis zone .
"D" By-pass mode.
"E" Exchanger mode.
"U" Voltage ofthe signal in volts.
"P" Position of the valve (%).
Figure : D2AA03FD
3 Earth
5 Sensor signal
134
4.5. By-pass connector /Exhaust gas recirculation heat exchanger
Figure : D2AA03GD
2 Earth
3 Supply +5V
5. Initialisation /Initialisation
Programming is necessary if the part is removed/refitted ; Refer to the diagnostic tools documentation
: Programming/initialisation.
135
DESCRIPTION - OPERATION : EXHAUST GAS RECYCLING EXCHANGER BY-
D4EA02UPP0
PASS ALL-OR-NOTHING SOLENOID VALVE
1. Description
Figure : D4EA0MID
"a" Venting
"b" 2-way black connector
"c" Vacuum outlet
"d" Vacuum inlet
Supplier : BITRON.
2. Role
The solenoid valve regulates and limits the control vacuum entering a pneumatic actuator, by means
of the vehicle's vacuum circuit.
3. Operation
Fixed cycle ratio control RCF.
The all-or-nothing solenoid valve, under fixed cycle ratio voltage, relates to the following elements :
136
Figure : D4EA08MD
The needle seating "e" closes off the air vent "a"
The vacuum outlet "c" is linked directly to the vacuum inlet "d"
"B" In idle position : The vacuum outlet "c" is linked to the air vent "a".
137
4. Electrical features
Figure : D4EA0MKD
"E" Status :
0 = Closed
1 = Open
138
Description Minimum Nominal Maximum Units
tolerance value tolerance
Resistance at 23 °C 18 20 22 Ohms
Figure : D4EA08OD
5. Initialisation / Initialisation
Not applicable.
139
D4EA02TXP0 DESCRIPTION - OPERATION : OIL PUMP
1. Description
Figure : B1FA01BD
2. Role
The oil pump provides a constant oil pressure inside the engine.
140
3. Operation
Figure : B1FA01CD
4. Data
5. Initialisation / Initialisation
Not applicable.
141
D4EA02MVP0 DESCRIPTION - FUNCTION : PARTICLE FILTER
1. Description
Figure : B1JA00ND
Carbon particles
Cerine
Deposits from the engine oil and engine wear
2. Role
The particle filter traps carbon particles as the exhaust gases pass through.
142
3. Function
Figure : B1JA00OD
4. Electrical features
Not applicable.
5. Learning /Initialisation
Programming is necessary if the component is replaced (Refer to the diagnostic).
143
DESCRIPTION - OPERATION : ELECTRIC HEATER FOR OIL VAPOUR
D4EA02MFP0
RECYCLING (BLOW-BY)
1. Description
Figure : B1KA00AD
2. Role
The electric heater reheats the recycled oil vapours coming from the oil decanter in order to prevent
the ducts from becoming clogged in very cold weather.
The cold causes the water normally present in the oil vapours to form an ice deposit blocking the
passage of the gases into the cylinder block, which can then entail the engine breaking up due to the
build-up of pressure in the sump.
3. Operation
The electrical resistor in the electric heater for oil vapour recycling is operated by the engine ECU in
the following conditions :
Ignition on
Engine running
Outside air temperature below -2 ± 2°C
144
The engine ECU no longer operates the electrical resistor in the electric diesel fuel heater
when the air temperature reaches + 3 ± 2°C
N.B. : A retention of the supply of the electric diesel fuel heater may be commanded for a few seconds
after the ignition is switched off, depending on the air temperature.
4. Electrical specifications
Figure : B1KA00BD
"R"Resistance (ohm).
"T" Temperature (°C).
145
Figure : D2AA03CD
1 12V supply
2 Earth
5. Initialisation /Initialisation
Not applicable.
146
D4EA02P4P0 DESCRIPTION - OPERATION : VACUUM PUMP
1. Description
Figure : B3FA04PD
2. Role
The vacuum pump supplies the vacuum required to control the following components :
147
3. Operation
Figure : B3FA04QD
148
Figure : B3FA04RD
4. Electrical specifications
Not applicable.
5. Programming/initialisation
Not applicable.
Figure : D4EA0GOD
149
"d" Water decanting outlet.
"e" Fuel filter outlet to the high pressure fuel pump.
2. Role
Role of the fuel filter :
3. Operation
The fuel enters the fuel filter.
The fuel is filtered by filtering element.
The water contained in the fuel is decanted and stored in the water collector of the fuel filter.
4. Electrical specifications
Not applicable.
5. Initialisation /Initialisation
Not applicable.
150
DESCRIPTION - OPERATION : FUEL HIGH PRESSURE COMMON INJECTION
D4EA02LYP0
RAIL
1. Description
Figure : B1HA0CDD
2. Role
Role of the high pressure fuel common injection rail :
To store the amount of fuel required by the engine regardless of the operating phase
To damp the pulses created by injections
To link the components of the fuel high pressure circuit
151
3. Operation
The fuel high pressure common injection rail is supplied at "c" by the fuel high pressure pump, then it
redirects the diesel fuel to the diesel injectors at "b".
4. Data
5. Programming/initialisation
Not applicable.
Figure : B1HA0EAD
2. Role
The diesel fuel cooler cools the fuel heated by the fuel high pressure pump, as it returns to the fuel
tank.
152
3. Operation
Figure : B1HA0EBD
4. Electrical specifications
Not applicable.
5. Initialisation /Initialisation
Not applicable.
153
D4EA02V8P0 DESCRIPTION - FUNCTION : TURBOCHARGER AIR COOLER
1. Description
Figure : B1HA0EDD
2. Role
The turbocharger air cooler cools the air entering the cylinders, to increase the density of air in the
cylinders.
Due to the increase of the air density, the motor's performances increase.
154
3. Function
Figure : B1HA0EED
4. Electrical features
Not applicable.
5. Programming/initialisation
Not applicable.
155
D4EA02MUP0 DESCRIPTION - FUNCTION : CATALYTIC CONVERTER
1. Description
Figure : B1JA00PD
2. Role
The purpose of the 2-way catalytic converter is to transform, by oxidation, the carbon monoxide (CO)
and the unburnt hydrocarbons (HC) into water (H2O) and carbon dioxide (CO2).
The second role of the catalytic converter is to permit an increase in the temperature of the exhaust
gas, by post-combustion of the unburnt hydrocarbons (HC) resulting from the post-injection.
156
3. Function
Figure : B1JA00QD
During the regeneration phase, the catalytic converter burns the fuel resulting from the post-injection
at the catalytic converter and allows the exhaust gas to reach 450°C.
4. Data
Not applicable.
5. Learning / Initialisation
Not applicable.
157
D4EA02MVP0 DESCRIPTION - FUNCTION : PARTICLE FILTER
1. Description
Figure : B1JA00ND
Carbon particles
Cerine
Deposits from the engine oil and engine wear
2. Role
The particle filter traps carbon particles as the exhaust gases pass through.
158
3. Function
Figure : B1JA00OD
159
7. Description of operation : Computer
Figure : B1HA0CTD
2. Role
The pre-postheating control unit manages the functioning of the preheater plugs in the following
phases :
3. Electrical specifications
160
Figure : D2AA03BD
1 Glow plug 3
2 Glow plug 1
3 Diagnosis
4 Battery positive
5 Earth
6 Glow plug 4
7 Glow plug 2
8 Control
4. Initialisation /Initialisation
Not applicable.
161
D4EA02YEP0 DESCRIPTION - FUNCTION : ENGINE ECU (BOSCH EDC17)
1. Description
Figure : D4EA0OYD
2. Role
The engine management ECU manages the entire injection system.
The engine management ECU software incorporates :
162
Diesel injectors
Fuel flow regulator
Control electrovalve for the EGR heat exchanger by-pass (EGR)
Turbocharger solenoid valve
Exhaust heat saver electrovalve (RTE) (*)
Pre and post-heating control unit
Diesel fuel heater
"Blow-by" heaters (*)
Exhaust gas recycling valve
3. Electrical features
3.1. 53-way black connector (CH)
Figure : D4EA09PD
163
3 Earth
4 Earth
5 Engine ECU supply input
9 Not used
10 Engine running information
11 Power relay control output
20 Not used
23 Not used
24 Not used
25 Not used
26 Cooling fan diagnostic information
31 Not used
32 Not used
164
38 Not used
41 Not used
42 Not used
43 Not used
48 Not used
49 Not used
50 Not used
51 Not used
52 Intersystem CAN Low
53 Earth
Figure : D4EA09QD
165
"b" 53-way brown connector (CMI)
6 Not used
8 Not used
10 Not used
11 Not used
12 Not used
13 Not used
16 Not used
18 Not used
166
19 Earth Particle emission filter upstream exhaust gas
temperature sensor
21 Not used
22 Not used
30 Not used
167
40 Engine oil pressure switch signal input
42 Not used
49 Not used
168
3.3. 48-way grey connector (CME)
Figure : D4EA09RD
A1 Not used
A4 Not used
B1 + 5 V supply of the EGR valve position repeat sensor
B2 Signal input : Turbocharger position copy sensor
D1 Not used
D2 Supply of cylinder reference sensor ( + 5V)
D3 Cylinder reference sensor signal input
169
D4 Earth Inlet air mixer flap position sensor
E1 Not used
E2 Not used
G1 Not used
G2 Not used
G3 Not used
G4 Not used
H1 Not used
H2 Not used
H3 Not used
J2 Not used
K1 Not used
K2 Not used
K3 Inlet air mixer motor control
170
4. Programming/initialisation
The engine management ECU software is updated by downloading (ECU fitted with a flash EPROM) ;
Refer to the diagnostic tools documentation : "Learning -Initialisation ".
8. Flow chart
Figure : D4EA0UYD
element Designation
BB00 Battery
BSI1 Built-in systems interface
171
Components description table
1374 Position repeat sensor for the control diaphragm of the dump
valve
1510 electric cooling fan unit
1522 Dual speed fan assembly electric control unit
172
Components description table
8007 pressostat
(*) According to version
8 Information on the diesel fuel high pressure (Fuel 1321 / 1320 Analogue
high pressure common injection rail )
173
Components description table
21 Cruise control or speed limiter reference values (7020 - 7800) (*) CAN Is
174
Components description table
28 Turbocharging air cooler electric mixer control 1320 / 1324 Open cycle
ratio
29 Turbocharging air cooler electric mixer position 1324 / 1320 Analogue
information
175
Components description table
43 (*) Oil vapours recirculation heating resistor control 1 1320 / 1273 All or
nothing
44 Fuel injector control cylinder 2 1320 / 1332 All or
nothing
176
9. Function
Figure
: D4EA0ZSD
BB00 Battery
PSF1 Engine compartment connection board-fuse box and electronic stability program -way
supply relay
0004 Instrument panel
177
1320 Engine ECU
2. Pre-heating
2.1. Role
The preheater plugs enable the temperature to rise rapidly in the combustion chambers prior to the
engine being started, when starting from cold or when the outside temperature is low.
Role of preheating :
To facilitate starting from cold (The air is heated up to enable the injected diesel fuel to
combust more easily)
To reduce smoke emissions (The heated air reduces the incidence of unburnt gases)
N.B. : The change from preheating to postheating occurs without interruption during the starting phase.
2.2. Function
The engine ECU controls the pre-postheating control unit by means of an open cycle ratio.
The electrical supply of the preheater plugs is via the pre-postheating control unit, as a function of the
commands from the engine ECU.
Phases of electrical supply of the preheater plugs :
Rapid heating
178
Stabilised heating
The maximum activation time for rapid heating is no more than 2 seconds.
The rapid heating phase enables the temperature of the preheater plugs to rise as rapidly as possible,
to aid combustion.
During the rapid heating phase, the pre-postheating control unit is controlled by an open cycle ratio of
99%.
The stabilised heating phase comes in after the rapid heating phase, to maintain the temperature of
the preheater plugs, while waiting for the engine to start.
During the stabilised phase, the pre-postheating control unit is controlled by an open cycle ratio of
around 60%.
If a pre-post heating control unit failure occurs, the engine management ECU memorises a fault.
The preheat times are determined by the engine management ECU according to the following
parameters :
Atmospheric pressure less than 700 1,9s 1,9s 1,9s 1,9s 1,9s 0
mbar
179
Atmospheric pressure : 1200 Mbar 1,9s 1,9s 1,9s 0 0 0
N.B. : Preheating can be ordered a second time if the engine does not start by the end of the first timing.
engine running
Preheat time exceeded
3. Post heating
3.1. Role
Within the first few seconds of the engine starting, the temperature in the combustion chambers does
not permit a combustion of sufficient quality, this causing the engine to be unstable at idle and to emit
excessive pollution.
Role of postheating :
To prolong the operation of the preheater plugs after the cold starting phase
To guarantee the correct quality of combustion after starting
Reducing the emissions of pollutants in the first few minutes after starting
To stabilise the engine at idle
To compensate wear of the cat converter
To reduce blue smoke emissions
3.2. Function
The engine ECU controls the pre-postheating control unit by means of an open cycle ratio.
The unit supplies the pre-heater plugs with power in accordance with the orders of the engine
management ECU.
If a pre-post heating control unit failure occurs, the engine management ECU memorises a fault.
The postheating times are determined by the engine ECU as a function of the following elements :
The temperature of the coolant fluid (measured by the engine coolant temperature sensor)
The inlet air temperature (Measurement taken by the mass air flow sensor)
The atmospheric pressure sensor (measured by the atmospheric pressure sensor internal to
the engine ECU)
180
N.B. : The postheating timing can vary as a function of the inlet air temperature.
(200s) Duration of activation of the postheating to compensate for wear of the catalytic converter,
mileage of the vehicle more than 15000 miles
Engine speed above 3000 rpm and injector flowrate above a threshold according to the
coolant temperature (See the table below)
Injector flowrate above a threshold according to the coolant temperature (see table below) for
a duration of more than 0,5 sec
-30,14 °C 85 mg/stroke
-18,14 °C 80 mg/stroke
181
-10,14 °C 74 mg/stroke
-0,14 °C 66 mg/stroke
4,86 °C 60 mg/stroke
9,86 °C 20 mg/stroke
14,86 °C 20 mg/stroke
19,86 °C 20 mg/stroke
The pre-heater plugs are only activated when the engine is operating under average load conditions,
to prevent overheating of the engine.
3.5. Activation of the postheating for compensation of wear of the cat converter
Damage to the cat converter is compensated by the activation of the postheating, provided the
following conditions are met :
Provided the activation conditions are met, the timing of the activation of the preheater plugs is
calculated as a function of a special calibration taking account of a cat converter ageing factor.
182
D4EA03DYP0 FUNCTION : FUEL SUPPLY
1. Schematic diagram
Figure : B1HA0G2P
Key :
183
"C" High pressure fuel circuit
"D" Heated low pressure fuel circuit
(6) Diesel injector (1) ; (2) ; (3) ; (4) (1331, 1332, 1333, 1334)
184
To comply with the pollution norms, to limit the noise of combustion, and to improve the driving quality,
the engine ECU determines the following parameters :
The minimum fuel injection pressure to allow starting of the engine varies according to the ambient
temperature :
4. Injection time
4.1. Generality
Fuel injection pressure being equal, a longer (or shorter) injection time allows more (or less) fuel to be
injected.
185
When there is a large engine load need, fuel injection pressure being equal, the fuel injection time is
extended to obtain the maximum engine torque.
The fuel injection time corresponds to the time during which the engine ECU commands the fuel
injectors to be open.
4.2. Specificities
The fuel injection time is calculated as a function of the following parameters :
Stabilising the injection pressure at different points (300, 450, 800 and 1300 bars) during a
"driver pedal release"
Controlling the fuel injectors one by one, progressively increasing the injection time
Recording the flywheel acceleration generated by the fuel injection
N.B. : When the flywheel acceleration corresponds to a fuel injection flow of 1 mg/stroke, the engine
ECU records in its memory the injection time necessary to obtain this flow.
The engine ECU detects the fuel injector drift when the following conditions are met :
186
The programming of the nominal mixture
The correction of the drift in the mixture
187
7. Fuel injection flow
7.1. Generality
Figure : B1HA0G3D
7.2. Specificities
The engine ECU determines the moment of injection as a function of the following parameters :
188
Air temperature
Engine coolant temperature
Vehicle speed
Atmospheric pressure
In the engine starting phase : The engine ECU increases the injection advance so as to facilitate
engine starting and reduce pollutant emissions.
During the particle emission filter regeneration phase :
Figure : B1HA0G4D
189
"n" Second post-injection.
Pre-injections inject a small quantity of fuel prior to the main injection, in order to increase the
temperature in the combustion chamber.
The rise in temperature in the combustion chamber enables the diesel fuel to ignite sooner and more
rapidly than in a main injection (reduction in the fuel combustion noise).
The majority of the fuel quantity is injected in the main injection; the combustion produced by the
diesel fuel igniting generates the movement of the piston (Creation of torque).
The main injection can be separated, giving rise to a second main injection called "Split injection".
"Split injection" generates an increase in the temperature of the exhaust gases, which reduces the
emissions of nitrous oxide (NOx).
Post-injection operates on vehicles that have a particle filter and consists of injecting a quantity of fuel
during the exhaust phase, in order to increase the temperature of the exhaust gases.
The number of post-injections during regeneration of the particle emission filter depends on the engine
load :
The increase in the temperature of the exhaust gases enables the destruction of the particulates that
are retained in the particle filter.
N.B. : The quantity of fuel needed for one engine cycle is spread over the 3 types of injection.
8.2. Specificities
The engine ECU can order up to 5 injections per engine cycle :
N.B. : "Split" injection cannot be activated during a regeneration of the particle filter.
190
Figure : B1HA0G5D
As the engine speed increases, so the duration of each engine cycle diminishes :
The engine ECU no longer has the time to order multiple injections
The number of injections per cycle diminishes
191
Such autocombustions are outside the control of the engine ECU, and can rapidly destroy the engine.
To prevent destruction of the engine, the engine ECU uses an oil ingestion strategy.
9.1. Detection of engine racing (Oil ingestion)
The engine ECU detects oil ingestion in the following instances :
Once the engine cuts out, the engine management ECU authorises restarting in down-grade mode:
with reduced flow only, limiting the engine speed.
An operation using the diagnostic tool is necessary in order to restore normal operation.
9.3. Reduced flow
The engine ECU can apply 4 injection flow limitation strategies in the event of a fault in a component
of the injection system or in the accelerator pedal sensor.
The flow limitation strategies authorise operation of the engine but with limited engine speed and
engine torque, the severity of the limitation depending on the fault.
When an accelerator pedal sensor fault is detected, the idle speed changes to 1300 rpm.
192
D4EA03ANP0 FUNCTION : FUEL ADDITIVE FUNCTION
1. Schematic diagram
Figure : D4EA0ZTP
Key :
193
"C" additive
"D" Diesel
1 Additive tank -
4 Fuel tank -
2. Role
The fuel additive function keeps the particle filter operational by aiding the combustion of the captured
particles, performing the following actions :
Fuel gauge
Wheel speed sensors
Depending on the quantity of fuel put in, the engine ECU takes the following actions :
194
The engine ECU sends a request for additive to a total volume made up of one or more individual
volumes each not exceeding 1265 mm³, to the fuel additive pump, via the BSI.
The engine ECU records in memory the weight of additive that is accumulated in the particle filter.
The engine ECU authorises or prohibits the applying of additive, as a function of the following
parameters :
N.B. : The engine ECU sends an alert on the risk of clogging of the particle filter and on the level of
additive being insufficient, as a function of the quantity of additive injected and of the weight of additive
accumulated in the particle filter.
The additive pump sends to the engine ECU, via the BSI, the following information :
When the vehicle is stationary (wheel speed sensor information) and the ignition switched off ; The
BSI1 memorises the level of fuel present in the tank.
When the ignition is switched on again and the vehicle starts moving, the BSI1 acquires and compares
the level of fuel with the latest value memorised. If the new value is higher, the BSI1 transmits to the
engine ECU the quantity of fuel that has been added.
The BSI receives the following information from the engine ECU :
195
The BSI sends the following information from the engine ECU :
Vehicle speed above 40 km/h or last fuel addition over 300 seconds
Internal combustion engine running
Starter switch in the ignition positive position
Adequate additive level
N.B. : When one of the necessary parameters disappears during the additive injection, the operation
continues until the end.
5. Learning / Initialisation
The fuel additive function is subject to personalised maintenance (See diagnostic tool functions :
Operations specific to the particle filter).
196
D4EA03ALP0 FUNCTION : AIR SUPPLY
1. Schematic diagram
Figure : D4EA0ZVP
Key :
197
"C" Hot compressed air
"D" Exhaust gas
"E" Control vacuum
"F" Electrical links
(*) Unused
Pneumatic control of the turbocharger discharge valve to vary the pressure of the
turbocharging air (Via a solenoid valve)
198
The EGR electrovalve, to vary the flow of air in certain phases of operation
The flowmeter for the air mass measures the flow and the temperature of the air entering the
turbocharger and transmits the information to the engine ECU.
The temperature and the pressure of the inlet air exiting the air mixer are measured and transmitted to
the engine ECU by the inlet air pressure and temperature sensor.
3.2. Specificities
The engine ECU manages the control of the turbo pressure regulation electrovalve in relation to a pre-
defined turbo air pressure setting.
The turbo air pressure reference is calculated from the following parameters :
Engine speed
Engine load
Engine coolant temperature
Inlet air temperature
The following strategies are used in the event of a turbocharging pressure sensor fault :
199
Piloted mode
Regulated mode
Piloted mode : The engine management ECU controls the turbocharger discharge valve control
solenoid valve to control the turbocharging pressure, in relation to a turbocharger discharge valve
position reference value.
Regulated mode : The engine management ECU controls the turbocharger discharge valve control
solenoid valve to regulate the turbocharging pressure, in relation to an absolute air pressure reference
value.
Figure : D4EA0ZXD
"G" Limit for changing from the controlled zone to the zone regulated by engine speed/Decreasing
torque.
"H" Limit for changing from the controlled zone to the zone regulated by engine speed/Increasing
torque.
"J" Indicated engine torque (N.m).
"K" Controlled zone.
"L" Regulated zone.
"N" Engine speed (Rpm).
"T" Torque indicated (N.m).
N.B. : The indicated torque corresponds to the torque provided by the combustion of fuel, the actual
torque corresponds to the indicated torque minus the various losses (Piston friction losses, heat losses,
etc.).
200
D4EA03CYP0 FUNCTION : PARTICULATE FILTER REGENERATION
1. General principal
The purpose of the regeneration is to eliminate the particulates retained on the walls of the particle
filter.
Regeneration consists of periodically burning off the particles accumulated in the particle filter.
Regeneration may occur naturally if the temperature of the exhaust gases is sufficient.
Regeneration may be triggered by the engine management ECU if the temperature of the exhaust gas
is too low and the particle filter is clogged.
The engine management ECU artificially increases the temperature of the exhaust gas by post
injection : This is the "regeneration assistance" phase.
N.B. : The driving conditions directly affect the temperature of the exhaust gases and consequently the
temperature inside the particle filter.
The condition of the filter with the function ; Monitoring of the particle filter load level
Regeneration assistance using the function ; Regeneration assistance management
N.B. : The first two pieces of data are dependent on the particle filter load level.
201
Emissions based on stabilised points (engine speed/torque) recorded in a mapping
A correction in accordance with the difference in the mixture
The combination of these two values determines the theoretical moment of the regeneration.
The amount of particles present in the filter causes its load loss to vary (input / output differential
pressure).
This permanently measured value represents the load level of the particle filter.
The engine management ECU's maps incorporate 4 levels of operation determined by graphs, from
the calculation of the volume of the flow of exhaust gas.
The volume flow rate of exhaust gases is essentially calculated from the following parameters :
Differential pressure
Inlet air flow
Atmospheric pressure
Exhaust gas temperature (downstream of the catalytic converter)
Figure : B1HA0FZD
202
"B" : Volume flow rate of exhaust gases (l/h).
"a" : Intermediate zone.
"b" : Filter overloaded.
"c" : Blocked filter.
N.B. : These states can be read using the diagnostic tool, in parameter measurements.
The objective of the engine management ECU is a continuous "a" status (whatever the vehicle
mileage).
The engine management ECU issues a regeneration assistance request to return to zone
"a" (depending on the driving conditions).
The engine management ECU requests activation of the regeneration assistance function in the
following case : Load level of the filter in zone "b" or "c".
The engine management ECU interrupts any regeneration assistance request and signals a fault
accompanied by lighting of a warning lamp on the instrument panel.
N.B. : The "filter punctured" fault may be due to an excess temperature during a regeneration as the
amount of burnt particles may be too great.
The engine management ECU interrupts any regeneration assistance request and signals a fault.
URGENT : If the "filter clogged" fault occurs, it is essential to locate the origin of the clogging or else the
filter will be damaged.
203
5. Correction of the load levels depending on the amount of cerine
The cerine present in the fuel :
Therefore, the engine management ECU continuously adapts its maps in relation to the quantity of
cerine accumulated in the particle filter.
Fuel consumption (fuel with additive) (quantity of additive present in the filter)
Vehicle driving conditions (activation of post injection)
Exhaust gas temperature
Speed of the exhaust gases in the particle filter
Figure : B1HA0G0D
204
Example "E" :
Example "F" :
CAUTION : For the same amount of albanite and for the same vehicle mileage, the differential pressure
may vary.
Regeneration consists of periodically burning the particles that have accumulated on the filter and
allowing it to remain in zone "a".
Filter regeneration depends on the temperature of the exhaust gases which must be above the soot
combustion limit.
There are 3 methods of regeneration :
Natural regeneration
Artificial regeneration (regeneration assistance)
Regeneration in after sales
In a natural regeneration, or in any type of assisted regeneration, the particle filter monitor records the
quantity of particles being burned.
7.2. Artificial regeneration (regeneration assistance)
The regeneration assistance is a set of provisions managed by the engine management ECU, the aim
of which is to increase the temperature of the exhaust gas to the regeneration threshold.
205
7.3. Ascertaining the required level of regeneration assistance
There are two types of regeneration assistance, depending on the thermal status of the exhaust line :
Level 1 regeneration assistance (cartographic maps for cold exhaust pipe and catalytic
converter) (catalytic converter pre-heating, up to 250°C)
Level 2 regeneration assistance (mapping for hot exhaust line. Temperature higher than 250°
C)
Exhaust temperature
Until the temperature has reached 250°C
The engine management ECU activates one or two post-injections depending on the engine speed
and the engine load.
7.6. Regeneration assistance activation conditions (through the monitoring function)
Parameters which can activate regeneration assistance :
206
parameters Nature of Regeneration assistance
signal
Amount of soots present in the Activation Amount of soots present in the particle filter since
particle filter (calculation) the last regeneration (above a threshold) (*)
To prevent a post injection time which is too long (engine deterioration, dilution of engine oil)
To limit the over-consumption of fuel
N.B. : The engine management ECU orders a regeneration of at least 10 minutes when there is a request
for regeneration due to an excessively high differential pressure.
207
History of vehicle usage ; The engine management ECU records the distances between the last 10
regenerations :
Regeneration capability : The engine management ECU determines a regeneration capability (in %)
according to the vehicle condition at a given moment "T" (exhaust gas temperature, speed,
acceleration under full load, etc.). Depending on the regeneration capability, the engine management
ECU can request regeneration assistance.
Distance travelled since the last regeneration : The engine management ECU records the distance
covered since the last regeneration and orders regeneration assistance when the distance exceeds a
certain threshold (between 800 and 1000 km).
N.B. : Regeneration of the particle filter can only be ordered when the engine coolant temperature is
above 60°C.
To increase the resistant torque of the alternator, leading to an increase in engine load
To aid the rise in temperature of the exhaust gases
To place the engine operating point quickly within the conditions allowing efficient post
injection
The engine management ECU activates electrical consumers which absorb a high level of
power (alternator saturation request).
In order to avoid a drop in voltage, the electrical consumers are activated in stages, the engine
management ECU applies a timed period of 10 seconds between each electrical consumer activation.
Chronology of activation of the electrical consumers (*) :
208
Request to the BSI 1 for activation of the heated rear screen
Control of the fan assembly
(*) Allowed by the load shedding level of the vehicle (for as long as the battery voltage is greater than
12,8 volts).
N.B. : The electrical consumers are deactivated in the reverse order to activation and in stages
separated by a timed period of 5 seconds.
8.4. Post-injection
The catalytic converter, located upstream of the particle filter, is an oxidation catalytic converter.
In the presence of unburned hydrocarbons (HC), the thermal efficiency of the catalytic converter
increases.
The temperature of the exhaust gases increases.
During post injection :
Once the regeneration limit has been reached, post injection is maintained until all particles have been
removed.
The flow and post injection time are determined by cartographic maps taking into account engine
operating conditions.
N.B. : Post-injection at idle or return to idle, to limit cooling of the particle filter.
209
Reduction in main injection flow
Boost pressure regulation
Figure : B1HA0G1D
210
Holed particle filter
When the particle filter is clogged, the particle filter clogged warning light is switched on on the
instrument panel.
211
The engine management ECU informs the BSI1.
The BSI1 requests the displaying of a message on the multifunction screen (risk of particle filter
clogging).
The aim is to encourage the customer to adapt his driving to facilitate particle filter regeneration.
Within 100 kilometres after the message appears, the customer must drive for at least 3 minutes at a
speed greater than 50 km/h which should cause the message to disappear.
Failure to comply with this recommendation will lead to the following fault : Clogged particle filter.
The engine management ECU informs the BSI1 which requests activation of the following components
:
212
D4EA03DZP0 FUNCTION : EXHAUST GAS RECYCLING (EGR)
1. Schematic diagram
1.1. Non-cooled exhaust gases
Figure : B1KA00OP
Key :
213
"B" Mixture of inlet air and recycled exhaust gas
"C" Exhaust gas
"D" Air inlet
"E" Electrical links
"F" Cooled exhaust gases
3 Cylinder head -
214
1.2. Cooled exhaust gases
Figure : B1HA0ELP
Key :
215
"D" Air inlet
"E" Electrical links
"F" Cooled exhaust gases
3 Cylinder head -
2. Role
To comply with the emission standards, the quantity of nitrous oxide NOx thrown out by the exhaust
must be the lowest possible.
The Exhaust Gas Recycling (EGR) device reduces the amount of nitrous oxides (NOx) emitted by the
exhaust.
3. Function
3.1. Exhaust gas recycling
The high temperatures, caused by the mode of combustion by excess of clean air to the diesel
engines, produce a large quantity of nitrous oxide (NOx).
The admission of exhaust gas into the combustion chamber reduces the quantity both of oxygen and
of nitrogen present at combustion.
The temperature of combustion is then lessened, which reduces the amount of nitrous oxide (NOx)
emitted.
Some of the exhaust gas is diverted into a duct linking the exhaust to the air intake.
This duct is closed by an electric EGR valve.
On the command of the engine ECU, the electric EGR valve opens, giving the exhaust gases a
controlled access to the inlet manifold.
N.B. : Too large a quantity of recycled exhaust gas causes an increase in emissions of soot, of carbon
monoxide (CO) and of hydrocarbons (HC) by reason of poor combustion due to lack of air.
216
In addition to opening the electric EGR valve, the engine ECU orders the air mixer to close partially.
The closing of the air mixer causes :
217
3.6. Antisticking
The engine ECU estimates the state of sticking of the electric EGR valve, as a function of the following
factors :
If the electric EGR valve begins to stick or sticks : The engine ECU controls the electric EGR valve via
a conventional control signal, followed by a vibratory signal to make the electric EGR valve vibrate and
thus avoid sticking.
N.B. : The amplitude of the vibratory signal depends on the degree of sticking detected by the engine
ECU. The antisticking strategy is used only during phases where the electric EGR valve is being
operated.
4. Activation conditions
Figure : B1KA00SD
218
N.B. : The indicated torque corresponds to the torque provided by the combustion of fuel, the actual
torque corresponds to the indicated torque minus the various losses (Piston friction losses, heat losses,
etc.).
Zone "G" defines the range in which the electric EGR valve is activated during an acceleration.
Zone "H" defines the range in which the electric EGR valve is activated during a deceleration.
The electric EGR valve is deactivated in certain operating conditions :
Under the engine speed and torque conditions defined by the activation zones "H" and "J"
At idle after 60 seconds
Above idle if the coolant temperature is higher than 110°C
Atmospheric pressure from 840 mbar
Air temperature higher than 55°C
Air temperature lower than -12°C
219
FUNCTION : COOLING FUNCTION INCORPORATED IN THE ENGINE
D4EA03HLP0
MANAGEMENT ECU (FRIC)
1. Schematic diagram
1.1. Cold circuit
Figure : B1GA0CWP
220
Key :
221
1.2. Hot circuit
Figure : B1GA0CXP
Key :
222
"D" Electrical connection
(3) Radiator -
2. Role
Functions of the engine management ECU :
Checking the operation and stopping of the cooling fan (Engine cooling)
Control of the post ventilation
To control the lighting of the coolant temperature warning lamp in the control panel
Control of the coolant temperature logometer on the instrument panel
Acquisition of the engine coolant temperature
To manage the back-up modes
3. Function
The engine cooling circuit is subject to two operating phases :
223
Temperature regulation phase (Hot circuit)
During the temperature increase phase (engine cold), the thermostat is closed, preventing the
circulation of coolant towards the cooling radiator so as to allow the engine temperature to increase
more rapidly.
Above a certain temperature (information not available) the thermostat starts to open, the cooling
system gets bigger and the coolant is cooled through the cooling radiator to regulate the engine
temperature.
N.B. : The thermostat is fully open above a certain temperature (Information unavailable).
224
4.4. Temperature : Particle filter
The engine ECU activates the cooling fan during phases of regeneration of the particle filter, so as to
cool the exhaust line and components close by.
The temperature of the particle filter is managed according to 4 phases :
The engine ECU fixes the required speed for the cooling fan as a functionof the following parameters :
6. Data
225
Number x electrical power Information unavailable
226
D4EA03HKP0 FUNCTION : COOLING REQUIREMENT FOR THE AIR CONDITIONING (BRAC)
1. Schematic diagram
Figure : D4EA101P
Key :
227
"C" Electrical links
2. Role
To operate, the air-conditioned circuit requires to be cooled by the refrigeration condenser.
The engine management ECU controls the activation of the fan to cool the refrigeration condenser.
3. Function
The engine management ECU controls the activation of the fan according to the internal pressure of
the air-conditioned circuit.
4. Activation conditions
4.1. electric cooling fan unit
The activation of the first speed of the fan is controlled for a pressure of the air-conditioned circuit
above 9,1 bars (The fan unit is cut when the pressure is below 7 bars).
The activation of the second speed of the fan is controlled for a pressure of the air-conditioned circuit
above 16,1 bars (The second speed of the fan is cut when the pressure is below 13 bars).
228
The conditions for cutting the refrigeration compressor are given by a mapping internal to the engine
management ECU taking the following parameters into account :
Engine speed
Engine load
Engine coolant temperature
Exterior air temperature
The engine management ECU prohibits the operation of the refrigeration condenser when the
temperature of the coolant is above or equal to 115°C.
The engine management ECU authorises the resumption of operation of the air conditioning
compressor when the engine coolant temperature is 112°C or below.
The engine management ECU prohibits operation of the air conditioning compressor when the outside
air temperature is 1°C or below.
The engine management ECU authorises the resumption of operation of the air conditioning
compressor when the outside air temperature is 3°C or above.
P0002 Control of the fuel flow regulator : Incoherence of the control current of the flow regulation
valve
P0016 Synchronisation : Incoherence between the information from the engine speed sensor and
the camshaft sensor
229
P0031 Oxygen sensor heating : Short circuit to earth
P0069 Coherence fault : At idle, lack of coherence between the manifold inlet pressure
measurement and the atmospheric pressure measurement
P0087 Fuel circuit : The pressure measured in the injection rail is less than the setting
P0088 Fuel circuit : Pressure measured in the injection rail above the reference
P0093 Fuel circuit : Incoherence on the fuel pressure with the flow regulator jammed open
P0097 Measurement of the manifold inlet air temperature : Short circuit to earth : Temperature
too high
P0098 Measurement of the manifold inlet air temperature : Short circuit to positive or open circuit
: Temperature too low
P0100 Air flow measure : Quantity of air above the maximum threshold
P0112 Measurement of the air temperature at the air flow sensor : Short circuit to earth :
Temperature too high
P0113 Measurement of the air temperature at the air flow sensor : Short circuit to positive or
open circuit : Temperature too low
P0117 Engine water temperature measure : Short circuit to earth : Value too high
P0118 Engine water temperature measure : Short circuit to positive or open circuit : Value too
low
230
P0130 Measurement of the concentration of oxygen : Open circuit on one of the pins of the
sensor (not heating)
P0134 Oxygen sensor heating : Heating of the sensor, or the sensor itself faulty
P0135 Oxygen sensor heating : Estimated temperature too high or too low, sensor heating no
longer working
P0182 Fuel temperature measure : Short circuit to earth : Value too high
P0183 Fuel temperature measure : Short circuit to positive or open circuit : Value too low
P0191 Measurement of the pressure in the fuel injection rail : Voltage variation outside the
tolerance
P0192 Measurement of the pressure in the fuel injection rail : Short circuit to earth : Pressure too
low
P0193 Measurement of the pressure in the fuel injection rail : Short circuit to positive : Pressure
too high
P0215 Main relay control : Poor operation of the relay, the ECU is not being supplied as it should
be
231
P0222 Measurement of the accelerator pedal position : Track 2 signal short circuit to earth
P0223 Measurement of the accelerator pedal position : Short-circuit to positive or open circuit on
the signal from track 1
P0227 Measurement of the accelerator pedal position : Track 2 signal short circuit to earth
P0228 Measurement of the accelerator pedal position : Short-circuit to positive or open circuit on
the signal from track 2
P0234 Charge pressure regulation : Air pressure above the reference value
P0237 Measurement of the manifold inlet pressure : Short circuit to earth : Pressure too low
P0238 Measurement of the manifold inlet pressure : Short circuit to positive : Pressure too high
P0261 Injector 1 signal. : Short circuit to earth on the circuit (harness, injector, ECU)
P0262 Injector 1 signal. : Short circuit to positive on the circuit (harness, injector, ECU)
P0264 Injector 2 signal. : Short circuit to earth on the circuit (harness, injector, ECU)
P0265 Injector 2 signal. : Short circuit to positive on the circuit (harness, injector, ECU)
P0267 Injector 3 signal. : Short circuit to earth on the circuit (harness, injector, ECU)
P0268 Injector 3 signal. : Short circuit to positive on the circuit (harness, injector, ECU)
232
P0270 Injector 4 signal. : Short circuit to earth on the circuit (harness, injector, ECU)
P0271 Injector 4 signal. : Short circuit to positive on the circuit (harness, injector, ECU)
P0299 Charge pressure regulation : Air pressure below the reference value
P0401 Air circuit : Quantity of fresh air above the reference value
P0402 Air circuit : Quantity of fresh air below the reference value
P0405 Measurement of the position of the EGR valve : Open circuit or short circuit to earth
P0406 Measurement of the position of the EGR valve : Short circuit to positive
P0493 electric cooling fan unit: Twin speed : Incoherence between the reference value (no
control) and the status of the fan assembly
233
P0494 electric cooling fan unit: Twin speed : Incoherence between the reference value (low
speed) and the status of the fan assembly
P0495 electric cooling fan unit: Twin speed : Incoherence between the reference value (high
speed) and the status of the fan assembly
P0504 Measurement of the brake pedal position : Incoherence between the two brake sensors
detected under acceleration
P0513 Starting surveillance : The time for unlocking the immobiliser is too long
P0533 Measurement of the air conditioning pressure : Short circuit to positive or open circuit
P0571 Intersystems CAN : Lack of coherence of the brake pedal position sent by the BSI
P0603 Computer : Fault internal to the EEPROM, malfunctioning of the non-volatile memory
234
P061C Computer : Engine speed not plausible
P0691 electric cooling fan unit: Short-circuit to earth or open circuit on the control of cooling fan
1
P0692 electric cooling fan unit: Short-circuit to positive on the control of cooling fan 1
P0693 electric cooling fan unit: Short circuit to earth on the fan assembly control 2
P0694 electric cooling fan unit: Short circuit to positive or open circuit on the fan assembly control
2
P0704 Measurement of the clutch pedal position : Absence of pedal presses on a great variation
of speed
P0812 Intersystems CAN : The engine receives the information that reverse gear is engaged
even though that is not possible
P0831 Measurement of the clutch pedal position : No pressing of the pedal while driving for a
certain time
235
P0832 Intersystems CAN : Information from the clutch switch received by the CAN erroneous
P107A Charge pressure regulation : Air pressure below the reference value (Service)
P1199 Fuel circuit : Incoherence on the reserve fuel pressure (Nearing no fuel)
P11B2 Measurement of the position of the EGR exchanger by-pass : Short circuit to positive
P11B3 Measurement of the position of the EGR exchanger by-pass : Short circuit to earth
P129F Air circuit : Quantity of fresh air above the reference value (Service)
P12A0 Air circuit : Quantity of fresh air below the reference value (Service)
P1349 Engine preheating : Short circuit to positive or open circuit on the relay control
P1403 Control of additional heating 1 : Open circuit or short circuit to positive or short circuit to
earth
236
P1404 Control of additional heating 2 : Open circuit or short circuit to positive or short circuit to
earth
P1412 Particle filter : Engine reconfiguration activated following an electrical fault of the
measurement of the differential pressure sensor or of the measurement of the particle
emission filter temperature
P1445 Additive adding : The quantity of additive injected into the particle emission filter has
exceeded the maximum threshold
The particulate emission filter must be changed
P1446 Additive adding : Calculated additive level below the critical threshold
P1461 EGR valve : EGR valve programming.Drift from the initialisation of the lower limit (valve
closed)
P1462 EGR valve : EGR valve programming. Discrepancy in the programming of the top stop (
valve open)
P1496 turbocharger : Position incorrect in relation to the setting, too much turbo (Service)
P1497 turbocharger : Position incorrect relative to requirement, not enough turbo (Service)
P1498 Air metering valve : Position incorrect (Closed too far) (Service)
P1499 Air metering valve : Position incorrect (Open too far) (Service)
P149C turbocharger : Excessive drift on the last initialisations of the lower limit
237
P14A3 EGR exchanger bypass : Confirmed jammed open (hot side)
P1505 Intersystems CAN : The air bag ECU has requested stopping of the engine (Following the
detection of an impact)
P1536 Measurement of the brake pedal position : Lack of coherence between the two brake
sensors detected on deceleration
P15B3 Additive adding : Additive level calculated lower than the minimum threshold
P1600 Downloading/Configuration : Downloading of the resetting of the injectors not carried out
P1641 Computer : Failure of the initialisation of the injector bank, or harness fault
238
P1667 Computer : Analogue / digital conversion not plausible
P1694 Controlled engine start and stop : Starter control line faulty
P1696 Controlled engine start and stop : Simultaneous starting and stopping request
P2031 Particle emission filter upstream temperature measurement : Plausibility when starting
P2032 Particle emission filter upstream temperature measurement : Short circuit to earth
P2033 Particle emission filter upstream temperature measurement : Short circuit to positive
P2118 Control of the air mixer : Limitation of current on the control of the air mixer
P2125 Air metering valve : Drift in the initialisations of the lower stop
P2126 Air metering valve : Drift in the initialisations of the upper limit
P2128 Measurement of the air mixer position : Short circuit to positive or open circuit
P2132 Accelerator pedal point of resistance switch measurement : Short circuit to earth
P2133 Accelerator pedal point of resistance switch measurement : Short circuit to positive
P2137 Measurement of the accelerator pedal position : Incoherence of the accelerator pedal
tracks
239
P2140 Accelerator pedal point of resistance switch measurement : Incoherence between the hard
point signal and the accelerator pedal position
P2191 Mixture of the system : Concentration of oxygen too high at full load
P2192 Mixture of the system : Concentration of oxygen too low at full load
P2231 Measurement of the concentration of oxygen : Coupling of the sensor signal with the
heating circuit
P2244 Mixture of the system : Integrated slave circuit of the sensor faulty
P2291 Starting surveillance : Pressure increase in the injection rail too slow when starting
240
P2297 Measurement of the concentration of oxygen : Oxygen concentration not plausible when
the pedal is released
P2299 Measurement of the accelerator pedal position : Pedal jammed or applied at the same
time as the brake pedal
P2426 Control of the Bypass of the EGR exchanger : Short circuit to earth
P2427 Control of the Bypass of the EGR exchanger : Short circuit to positive
P2453 Measurement of the particle emission filter differential pressure : Voltage variation outside
the tolerance
P2454 Measurement of the particle emission filter differential pressure : Voltage too low
P2455 Measurement of the particle emission filter differential pressure : Voltage too high
P2457 Control of the Bypass of the EGR exchanger : Overheating or excess current
P2563 turbocharger : Position incorrect in relation to the setting, too much turbo
P2565 Measurement of the position of the turbocharger : Short circuit to positive or open circuit
241
P2566 turbocharger : Excessive drift on the last initialisations of the upper stop
P2685 5V sensor supply no. 3 (Rail pressure sensor, Engine speed sensor, Camshaft sensor) :
Voltage outside the tolerance
U0019 Intersystems CAN : Fault on the BSM (engine fusebox) or on the network linking the latter
to the BSI
U0028 Intersystems CAN : Malfunctioning of the instrument panel, loss of lighting of the MIL
warning lamp
U0055 Intersystems CAN : Malfunction of the Comfort CAN, no more lighting of the MIL warning
lamp possible
U0315 Intersystems CAN : Error in length or prohibited value on the ABS/ESP datastream
U0322 Intersystems CAN : Error in length or prohibited value on the BSI datastream
U0422 Intersystems CAN : One of the parameters present in a datastream sent by the BSI is
invalid
242
U1000 Computer : The engine ECU is detected mute by one of the ECUs on the network
U1213 Intersystems CAN : One of the parameters present in a datastream sent by the ABS/ESP
is invalid
U1218 Intersystems CAN : One of the parameters present in a datastream sent by the BSI is
invalid
U1313 Intersystems CAN : Error in length or prohibited value on the ABS/ESP datastream
U1318 Intersystems CAN : Error in length or prohibited value on the BSI datastream
U1401 Alternator LIN network : Recording of a fault on the slave node of the alternator LIN
U2000 Intersystems CAN : Request for main ECU triggering not plausible or absent
U2003 Intersystems CAN : Request for ECU wake-up (wire signal) inconsistent with the CAN
data
U2118 Intersystems CAN : Request for partial ECU triggering not plausible or absent
243
11. Function : Diagnostic tool
Engine speed Information given to the engine management ECU XXXX Rpm
by the engine speed sensor
Fuel pressure Pressure in the fuel high pressure common injection XXXX bar
requirement rail requested by the engine management ECU
The pressure is determined in relation to the
required injection into the cylinders
Measured fuel pressure Pressure value given by the fuel pressure sensor to XXXX bar
the engine management ECU
The value should be fairly close to the reference
value
Calculated flow injected The ECU does not know the precise quantity of fuel XX,XX mg/stroke
injected. The ECU estimates the quantity of fuel
injected in relation to the pressure in the high
pressure common injection rail and the diesel
injector control times
244
ECU activates the fan assembly to assist in cooling
the engine
N°1 cylinder injection Total injection time (Pilot injections - Main - post- XX,XX ms
time injections)
N°2 cylinder injection Total injection time (Pilot injections - Main - post- XX,XX ms
time injections)
N°3 cylinder injection Total injection time (Pilot injections - Main - post- XX,XX ms
time injections)
N°4 cylinder injection Total injection time (Pilot injections - Main - post- XX,XX ms
time injections)
Strategy -
active
245
Cylinder 4 injector flow Factor of correction of the injection time on cylinder XX -
correction factor 4
Classification of injector A code engraved on the tab of the diesel injector XXXXXX -
1 corresponds to a measurement of the
characteristics of the injector when it was
manufactured
The code allows the ECU to adapt the injection
times in relation to the characteristics of each of the
diesel injectors
Classification of injector A code engraved on the tab of the diesel injector XXXXXX -
2 corresponds to a measurement of the
characteristics of the injector when it was
manufactured
The code allows the ECU to adapt the injection
times in relation to the characteristics of each of the
diesel injectors
Classification of injector A code engraved on the tab of the diesel injector XXXXXX -
3 corresponds to a measurement of the
characteristics of the injector when it was
manufactured
The code allows the ECU to adapt the injection
times in relation to the characteristics of each of the
diesel injectors
Classification of injector A code engraved on the tab of the diesel injector XXXXXX -
4 corresponds to a measurement of the
characteristics of the injector when it was
manufactured
The code allows the ECU to adapt the injection
times in relation to the characteristics of each of the
diesel injectors
246
Engine speed Information given to the engine management ECU by XXXX Rpm
the engine speed sensor
Air flow setting Quantity of fresh air in the air intake circuit, requested XXXX mg/stroke
by the engine management ECU
The engine management ECU determines the quantity
of air in relation to the requirements of the engine
(Observance of emission control - Performance,…
Measured air flow With the engine running, this information must be very XXXX mg/stroke
close to the air flow reference value
When the EGR valve is deactivated intentionally by the
engine management ECU (after idling for several
minutes for example), the value is no longer the same
as the reference value
Turbocharger pressure Turbocharging pressure that the engine management XXXX Mbar
reference value ECU requires in the air intake circuit after the
turbocharger
The engine management ECU determines the
turbocharging pressure in relation to the requirements
of the engine (Observance of emission control -
Performance,…)
Measured turbocharger Pressure measured at the air intake circuit XXXX Mbar
pressure The value measured should always be close to the
reference value
Atmospheric pressure Atmospheric pressure measured inside the engine XXXX Mbar
management ECU
The atmospheric pressure varies according to the
altitude and the weather
247
Air temperature at inlet - XXX °C
manifold
EGR valve : Position The engine management ECU determines the position XXX %
reference value that the EGR valve must take so that the recirculation of
the gas permits optimum depollution of the engine
EGR valve : Open cycle This is the reflection of the electric control by the engine XXX %
ratio management ECU. It is normal for this percentage not
to correspond to the position reference value. The value
may be positive or negative (for the openings and
closings)
EGR valve : Position This value should be close to the position reference XXX %
repeat value
turbocharger : Cyclical This is the reflection of the electric control by the engine XXX %
opening ratio of the management ECU. This control is applied to the
turbocharger pressure vacuum circuit solenoid valve. It is normal for this
solenoid valve percentage not to correspond to the position reference
value. The value can only be positive
turbocharger : Position This value should be close to the position reference XXX %
repeat value
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Air mixer : Position The engine management ECU determines the position XXX %
reference value of the air mixer in relation to the requirement for air
circulating in the air intake circuit
Air mixer : Open cycle This is the reflection of the electric control by the engine XXX %
ratio management ECU. It is normal for this percentage not
to correspond to the position reference value. The value
may be positive or negative (for the openings and
closings)
Air mixer : Position This value should be close to the position reference XXX %
repeat value
EGR exchanger by-pass Depending on the EGR gas cooling requirement, the XXX %
: Position reference engine management ECU determines the position of
value the EGR exchanger bypass. As the actuator only takes
two positions, the possible values are 0% or
100% (approx.)
EGR exchanger by-pass This value should be close to the position reference XXX %
: Position repeat value
3. Electrical information
Engine speed Information given to the engine management ECU by the engine XXXX Rpm
speed sensor
Battery voltage Battery voltage measured by the engine management ECU XX,XX V
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Power relay Indicates that the engine management ECU is requesting Active -
control activation of the power relay (availability of more electrical power);
this is normally always the case Inactive
4. Miscellaneous information
Engine speed Information given to the engine management ECU by XXXX Rpm
the engine speed sensor
Synchronisation of the The camshaft sensor and the engine speed sensor No OK -
camshaft - Crankshaft allow the engine management ECU to determine the
moment and the cylinder of injection when it is Yes
"synchronised" to start the engine
In preparation -
Driven starting -
Autonomous -
starting
engine running -
Driven -
restarting
Autonomous -
restarting
Accelerator pedal The accelerator pedal signal voltage 1 must be about XXXX MV
signal voltage 1 double the accelerator pedal signal voltage 2
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Accelerator pedal The accelerator pedal signal voltage 2 must be about XXXX MV
signal voltage 2 the same as the accelerator pedal signal voltage 1
divided by 2
Accelerator pedal point The various statuses are : "Passed" or "Not passed" Not crossed -
of resistance
information Crossed
Main brake pedal Brake pedal position information sent by the BSI Pressed -
Released
Gear 1
Gear 2
Gear 3
Gear 4
Gear 5
Gear 6
Gear 7
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Check that the
fixings hold
Reverse
engaged
park
automatic
gearbox
Controlled
manual
gearbox
Other
Active
Active
Oil pressure - OK -
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Insufficient
pressure
Engine speed Information given to the engine management ECU by the XXXX Rpm
engine speed sensor
Total mass of soot in This information concerns the soot deposited in the XX,XXX g/l
the particle emission particle emission filter. When the engine management
filter ECU estimates a high soot value, it triggers the
regeneration of the particle emission filter to destroy the
soot
Total weight of additive The addition of additive to the fuel results in deposits of XXX G
deposited in the particle additive in the particle emission filter. This value
emission filter increases in relation to the time and should be close to
zero when the particle emission filter is new
Ratio of ash in the This ratio of ash corresponds to the elements XXX %
particle emission filter accumulated in the particle emission filter which cannot
be destroyed during the regenerations of the filter. This
value increases in relation to the mileage and should be
close to zero when the particle emission filter is new
Distance remaining The engine management ECU continuously estimates the XXXXXX kms
before replacement of number of kilometres that the particle emission filter can
the particle emission still travel without causing a malfunction
filter This value is very high when the vehicle is new and more
coherent from 100 000 km
Difference in pressure When the exhaust gas passes through the particle XXX Mbar
between particulate emission filter, it is slowed down ; This phenomenon
results in a difference in pressure between the particle
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emission filter emission filter inlet and outlet
input/output This difference in pressure is a reflection of the clogging
of the particle emission filter and permits management of
the particle emission filter overload and clogging
diagnostics (Fault codes, regenerations...)
When the engine is off, the value should be close to 0
Particle emission filter This temperature is used for the management of the XXX °C
upstream temperature forced regenerations of the particle emission filter
Less than
100°C
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Capacity for effecting a This parameter, calculated by the engine ECU, indicates XXX %
regeneration (In short whether the vehicle usage conditions permit normal
term) regeneration in short or in long term
Capacity for effecting a This parameter, calculated by the engine ECU, indicates XXX %
regeneration (In long whether the vehicle usage conditions permit normal
term) regeneration in short or in long term
Additive reservoir Content of the additive reservoir at the time of production. XXXX Ml
volume This value does not change
Volume of additive Current content of the additive reservoir. This information XXXX Ml
remaining in the is only calculated by the ECU (No measuring sensor)
additive reservoir
Minimum additive level When the minimum level has been passed, the addition OK -
of additive to the diesel remains operational (There is
enough additive remaining to travel approximately 2000 Minimum
km). In this case, two warnings may appear level
A message on the multifunction screen or a particle passed
emission filter warning lamp on the instrument panel
This serves to inform the customer that he must visit his
dealership before the addition of additive to the diesel
stops completely, which could result in irreversible
regeneration failures
ACTIVE
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Engine speed Information given to the engine management ECU by XXXX Rpm
the engine speed sensor
Air conditioning Pressure measured by the engine management ECU by XX,X bar
circuit pressure means of the sensor in the refrigerant circuit
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- Programmed 1 times
- Programmed 2 times
- Programmed 3 times
First matching
Second matching
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Carried
out
Carried
out
Initial EGR valve lower This value corresponds to the position of the stop at the XXX %
stop position time of the very first programming (when new or following
programmed replacement of the part)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Last EGR valve lower stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very last programming (The last time the
engine fulfilled these conditions)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Carried
out
Carried
out
Initial turbo upper stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very first programming (when new or following
replacement of the part)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
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Last turbo upper stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very last programming (The last time the
engine fulfilled these conditions)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Initial turbo lower stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very first programming (when new or following
replacement of the part)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Last turbo lower stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very last programming (The last time the
engine fulfilled these conditions)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Carried
out
Carried
out
Initial air mixer upper stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very first programming (when new or following
replacement of the part)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Last air mixer upper stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very last programming (The last time the
engine fulfilled these conditions)
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The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Initial air mixer lower stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very first programming (when new or following
replacement of the part)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
Last air mixer lower stop This value corresponds to the position of the stop at the XXX %
position programmed time of the very last programming (The last time the
engine fulfilled these conditions)
The value is expressed as a percentage of the supply.
0% = 0V / 100% = 5V
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D4EA035AP0 DIAGNOSTIC EQUIPMENT FUNCTIONS : ACTUATOR TESTS
1. Tests with the engine running
Test of the EGR exchanger bypass After the test, the tool displays a report on the
behaviour of the actuator
Check of the pressurising of the air entering the The engine runs at a specific speed and actuates
engine the turbocharger
Following the test, the tool displays a report on the
efficiency of the pressurisation
Check of the engine timing The engine stalls because of lack of air
Check of the flow of circulating air The engine enters special conditions making it
possible to check the flow of air
This flow must be within the range given
Check of the operation of the EGR circuit The engine enters special conditions taking it
possible to check the EGR circuit (no cap)
This flow must be within the range given
Check of the operation of the air circuit assembly Following the test, the tool displays a report
(Turbocharger - Flowmeter - Leak…) according to the problems found during the test
Check of the manifold input pressure sensor The tool displays a report according to what is found
at start up
At the end of the actuator test, the diagnostic tool displays one of the following reports :
No fault
Short circuit to positive
Actuator jammed or clogged
Short circuit to earth
Open circuit
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Actuator jammed
Actuator clogged
Test stopped
Turbocharging pressure sensor fault
The actuator has moved correctly but the air has not been pressurised
The engine ECU does not manage to close the air mixer
Air hose disconnected
Fan unit at slow speed Check the correct operation of the cooling fan
Fuel flow regulation valve in the high-pressure Place your fingers on the component to feel it
pump vibrate
Miscellaneous tests
Power Supply relay of the engine Listen to the clicking of the relay
Control of the pre-post heating unit -
Electrical test of the additional -
heating
Electrical test of the additive pump This test is not functional when the vehicle is fitted with an
additive ECU (connected by a LIN network to the BSI)
262
Miscellaneous tests
No fault
Short circuit to positive
Short circuit to earth
Open circuit
Battery voltage incorrect
Actuator jammed
Actuator clogged
An electrical fault has been detected
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D4EA02YAP0 DIAGNOSTIC EQUIPMENT FUNCTIONS : CONFIGURATION - DOWNLOADING
1. Configuration
The diagnostic tool is used to configure the following parameters.
Description Condition
class 15
additional heating Pencils or plugs controlled by the BSI and driven by the engine
ECU
No additional heating
ABS : only
ABS/ESP : absent
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Water-in-diesel-fuel sensor Present
absent
absent
Present
Vehicle speed limiter
absent
2. Downloading
It is possible to download to the engine management ECU ; Using the diagnostic equipment.
Engine ECU
Diesel injectors
Electric EGR valve
Air mixer
turbocharger
Air flow meter
Motor unit without airflow meter
Motor unit with airflow meter
Additive reservoir for the pump or the pipes
Particle filter
Filling the additive reservoir
Oxygen sensor
The injector codes have to be indicated to the engine ECU via the diagnostic tool, when replacing
either just one injector or all the injectors.
N.B. : The injector codes may be demanded when replacing the engine ECU.
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DIAGNOSTIC EQUIPMENT FUNCTIONS : OPERATIONS SPECIFIC TO THE
D4EA02F7P0
PARTICLE FILTER
1. Forced regeneration of the particle emission filter
The diagnostic tool can order a forced regeneration of the particle filter at two levels :
2. Personalised maintenance
The diagnostic tool enables personalised maintenance; depending on the type of use of the vehicle,
replacement of the particle filter and refilling of the fuel additive can either be requested or carried over
to the next servicing interval.
2.1. Refilling : Fuel additive
The diagnostic tool interrogates the engine ECU on the following parameters :
The diagnostic tool compares these values with the additive consumption stored in memory, the
vehicle mileage and the distance remaining before the next servicing interval.
If the quantity of additive is estimated as sufficient, refilling of additive does not need to be done; the
diagnostic tool indicates : "Account taken of the vehicle history, it is not necessary to top up the level
of additive in the reservoir. Check the level of additive again at the next servicing interval".
If the quantity of additive is estimated as insufficient, refilling of additive is requested; the diagnostic
tool indicates : "Taking account of the vehicle's history, it is necessary to top up the level of additive in
the reservoir".
2.2. Replacement : Particle filter
The diagnostic tool interrogates the engine ECU about the distance remaining to be done before
replacement of the particle filter; this value is compared with the distance remaining before the next
servicing interval.
If the distance remaining to be done is greater than that to the next servicing interval, the particle filter
is not to be replaced; the diagnostic tool indicates : "Account taken of the vehicle history, it is not
necessary to replace the particle filter. Check the particle filter again at the next servicing interval".
If the distance remaining to be done is less than that to the next servicing interval, the particle filter
must be replaced; the diagnostic tool indicates : "Account taken of the vehicle history, the particle filter
must be replaced".
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