Pdffile 47530 101122111 00000738.005

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

Delphi France SAS
Diesel Aftermarket
12 - 14 Boulevard de l’industrie
41042 Blois Cedex Tel: (+33) (0) 2 54 55 39 39
France Fax: (+33) (0) 2 54 55 39 12
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 i

I DIAGNOSTICS
TABLE OF CONTENTS
1. DIAGNOSTIC TOOL FUNCTIONS

1.1 DIAGNOSTIC TOOL CONNECTION..............................................................................................................................1-1
1.1.1 Equipment required ....................................................................................................................................1-1
1.1.2 Direct connection to the DCU......................................................................................................................1-4
1.1.3 Diagnostic socket description.....................................................................................................................1-4
1.1.4 Diagnostic socket location...........................................................................................................................1-4
1.1.5 Equipment for electrical diagnosis.............................................................................................................1-6
1.1.6 Managing diagnostic tool - DCU communication.....................................................................................1-8
1.2 READING FAULT CODES..............................................................................................................................................1-9
1.2.1 Principle........................................................................................................................................................1-9
1.2.2 Using the diagnostic tool.............................................................................................................................1-9
1.2.3 Environmental data....................................................................................................................................1-10
1.3 READING THE DYNAMIC PARAMETERS..................................................................................................................1-15
1.3.1 List of parameters......................................................................................................................................1-16
1.4 DCU IDENTIFICATION.................................................................................................................................................1-23
1.5 ACTUATOR CONTROL................................................................................................................................................1-24
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1.6 TEST ROUTINES..........................................................................................................................................................1-25
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1.6.1 Pump capacity test.....................................................................................................................................1-25
1.6.2
1.6.3
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Pump capacity test under cranking..........................................................................................................1-27
Leak detection cycle...................................................................................................................................1-28
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1.6.4 DPF regeneration........................................................................................................................................1-29
1.6.6
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EGR valve....................................................................................................................................................1-30
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1.6.7 Inlet air flap valve.......................................................................................................................................1-31
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1.6.8 VGT solenoid valve....................................................................................................................................1-31
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1.6.9 Air heater bypass flap valve......................................................................................................................1-32
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1.6.10 EGR bypass valve.......................................................................................................................................1-32
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1.6.11 VGT / Boost pressure.................................................................................................................................1-33
1.6.12 Turbocharging pressure............................................................................................................................1-33
1.6.13 Stall test......................................................................................................................................................1-34
1.6.14 Air flow........................................................................................................................................................1-34
1.6.15 EGR flow.....................................................................................................................................................1-35
1.6.16 Additional heating......................................................................................................................................1-35
1.6.17 DPF additive pump.....................................................................................................................................1-36
1.6.18 CTR solenoid valve.....................................................................................................................................1-36
1.7 C3I MANAGEMENT.....................................................................................................................................................1-37
1.7.1 Definition of C3I..........................................................................................................................................1-37
1.7.2 Reading the C3I..........................................................................................................................................1-38
1.7.3 Writing the C3I............................................................................................................................................1-38
1.8 PROGRAMMING MANAGEMENT..............................................................................................................................1-38
1.8.1 Reading programming values...................................................................................................................1-38
1.8.2 List of programming values......................................................................................................................1-39
1.8.3 Erasing programming values....................................................................................................................1-43
1.8.4 Copying programming values..................................................................................................................1-44
1.9 OPERATIONS REQUIRING USE OF THE DIAGNOSTIC TOOL.................................................................................1-44
1.9.1 Replacing the injectors..............................................................................................................................1-44
1.9.2 Replacing the DCU.....................................................................................................................................1-44
1.9.3 System replacement..................................................................................................................................1-44
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DIAGNOSTICS I
TABLE OF CONTENTS
1.9.4 Replacing the HP pump.............................................................................................................................1-44
1.9.5 Replacing the rail........................................................................................................................................1-44
1.9.6 Replacing the IMV......................................................................................................................................1-44
1.9.7 Replacing the EGR valve............................................................................................................................1-45
1.9.8 Inlet air flap replacement...........................................................................................................................1-45
1.9.9 Inlet air heater bypass flap valve replacement........................................................................................1-45
1.9.10 Replacing the flowmeter............................................................................................................................1-45
1.9.11 Replacing the flowmeter and the cylinder head......................................................................................1-45
1.9.12 Replacing the cylinder head......................................................................................................................1-45
1.9.13 Replacing the Variable Geometry Turbo (VGT).......................................................................................1-45
1.9.14 Replacing the oxygen probe.....................................................................................................................1-45
1.9.15 Replacing the Particle Filter (DPF).............................................................................................................1-45
1.9.16 Replacing the DPF differential pressure sensor.......................................................................................1-45
1.9.17 Replacing an additive system component (pump, tank, tubing etc...)..................................................1-46
1.9.18 Replacing the DPF additive tank...............................................................................................................1-46
2. DETECTABLE FAULTS
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2.1 DIAGNOSTIC CHARTS / FAULT CODES....................................................................................................................2-47
3. NON DETECTABLE FAULTS
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3.1 LIST OF FAULTS / SYMPTOMS................................................................................................................................3-197
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3.1.1 Irregular acceleration - deceleration.......................................................................................................3-197
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3.1.2 Engine hesitation / instability..................................................................................................................3-198
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3.1.3 Engine stop - stalling...............................................................................................................................3-200
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3.1.4 Rushing noise...........................................................................................................................................3-202
3.1.5
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Noise interference....................................................................................................................................3-203
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3.1.6 Engine noise.............................................................................................................................................3-204
3.1.7 Excessive consumption...........................................................................................................................3-205
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3.1.8 Engine difficult to start when hot............................................................................................................3-207
3.1.9 Engine starts then stalls...........................................................................................................................3-209
3.1.10 Smoke on acceleration............................................................................................................................3-211
3.1.11 Blue & white smoke.................................................................................................................................3-213
3.1.12 Lack of power...........................................................................................................................................3-214
3.1.13 Engine does not start...............................................................................................................................3-216
3.1.14 Engine does not stop...............................................................................................................................3-218
3.1.15 Engine dies when moving off.................................................................................................................3-219
3.1.16 Smell of fuel..............................................................................................................................................3-221
3.1.17 Exhaust smells..........................................................................................................................................3-222
3.1.18 Idle speed stuck........................................................................................................................................3-223
3.1.19 Idle unstable - Hunting.............................................................................................................................3-224
3.1.20 Engine overheat.......................................................................................................................................3-226
3.1.21 Acceleration flat spots.............................................................................................................................3-228
4. CHECKS
4.1 DESCRIPTION OF THE CHECKS...............................................................................................................................4-231
4.1.1 Earthing Checks........................................................................................................................................4-231
4.1.2 Checking the electrical supply circuits...................................................................................................4-231
4.1.3 Line insulation and continuity checks....................................................................................................4-232
4.1.4 Checking a component connection........................................................................................................4-235
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I DIAGNOSTICS
TABLE OF CONTENTS
4.1.5 DCU connections check...........................................................................................................................4-235
4.1.6 Checking the low pressure circuit...........................................................................................................4-235
4.1.7 Checking the injectors and the high pressure circuit............................................................................4-236
4.1.8 Checking engine parameters...................................................................................................................4-236
4.1.9 C3I conformance check............................................................................................................................4-237
4.1.10 Checking the air inlet circuit....................................................................................................................4-237
4.2 REFERENCE CURVES................................................................................................................................................4-237
4.2.1 RPM signal engine and camshaft...........................................................................................................4-237
4.2.2 Injector control.........................................................................................................................................4-239
4.2.3 IMV control...............................................................................................................................................4-240
4.2.4 Rail pressure and flow control................................................................................................................4-241
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iv DDNX340A(EN) - Issue 1 of 06/2010

TABLE OF CONTENTS
5. TECHNICAL INFORMATION
5.1 TIGHTENING TORQUES...........................................................................................................................................5-243
5.2 REFERENCE VALUES................................................................................................................................................5-244
5.3 TOOLING REQUIRED................................................................................................................................................5-255
5.3.1 Changes in diagnostic cables..................................................................................................................5-255
5.3.2 Changes to "SICMA" connectors.............................................................................................................5-255
5.3.3 Special tooling summary.........................................................................................................................5-255
5.3.4 General tooling summary........................................................................................................................5-256
5.3.5 Consumables summary...........................................................................................................................5-257
5.3.6 Wiring diagrams.......................................................................................................................................5-258
5.4 ABBREVIATIONS AND DESCRIPTIONS...................................................................................................................5-261
6. FAULT CODE INDEX
6.1 Fault code index........................................................................................................................................................6-264
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© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 v

II TECHNICAL INFORMATION
TABLE OF CONTENTS
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© Delphi
vi DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DIAGNOSTIC TOOL FUNCTIONS
1.1 DIAGNOSTIC TOOL CONNECTION
1.1.1 Equipment required

Electronic diagnostics can be performed using the computerised diagnostic tool DIAMAND (installed from the
DDRX107E CD or later) used with a YDT450 or YDT460 kit.
The kit DIAMAND YDT300 is not compatible with this application.
YDT460 DIAMAND diagnostic tool
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YDT452
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Diagnostic EOBD 16 way cable
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© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-1

I DIAGNOSTICS

Alternative configuration :
YDT450 DIAMAND diagnostic tool
YDT182 Diagnostic EOBD 16 way cable
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YDT453 Diagnostic adaptor cable
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YDT452 Diagnostic EOBD 16 way cable © Delphi
1-2 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

The diagnostic tool is connected using auxiliary harness YDT233 and the terminal box kit for DCU DCM3.5 :
YDT481.
YDT233 Auxiliary harness
YDT453 Diagnostic adaptor cable
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YDT481154 way Terminal box interface for DCU DCM3.5 /
DCU terminal box
harness kit (for the
48 way grey -YDT482
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48 and 53 way
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CINCH)
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Terminal box interface for DCU DCM3.5 /
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53 way brown - YDT483
Terminal box interface for DCU DCM3.5 /

53 way brown - YDT483
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I DIAGNOSTICS

1.1.2 Direct connection to the DCU
Pins No. of pins available

Vbatt PCC-1, PCC-2, PCC-5, PCC-6,PCC-10,PCC-30
Earth PCC-3, PCC-4
CAN positive PC -40
CAN negative PC -52
1.1.3 Diagnostic socket description

It is of the EOBD - 16 pin type.
Allocation:
Diagnostic socket type: Pin no. Description

1 positive IGN
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4 and 5 Earth
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7 Line K
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14 CAN L
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16 positive batt
1.1.4 Diagnostic socket location

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On3008 and 5008 :
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Left Hand Drive: in the compartment on the left of the steering wheel.
• Right Hand Drive: in the glove box.
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1-4 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

On 407:
It is installed in the central armrest :
On 308:
It is installed in the centre of the dashboard, behind
the protective cover:
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On 807:
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It is located in the centre console :
© Delphi
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I DIAGNOSTICS

On Expert :
• Left Hand Drive: in the compartment on the
left of the steering wheel.
• Right Hand Drive: in the glove box.
1.1.5 Equipment for electrical diagnosis

In order to carry out the electrical checks described in this manual, the complementary equipment described below
must be used in addition to that described above.
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YDT246 Mini-harness kit n°1
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Refer to the Technical Bulletin DT444 for
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the kit update for use on this application.
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DIAGNOSTICS I
YDT471 Mini-harness injector FCI
YDT471
YDT471
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V
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ORPM
Ω (TR/MIN.)
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VCI / DIAMAND
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YDT521
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Mini-harness kit n°4
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* This equipment can be ordered separately or in the "mini harness" carrying case YDT526.
© Delphi
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I DIAGNOSTICS
1.1.6 Managing diagnostic tool - DCU communication
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When an ignition off request is received, the BSI sends a sleep order to all of the DCUs on the CAN network.
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However, the injection DCU can only sleep once communication with the diagnostic tool has stopped. This causes
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fault codes to be raised in the injection DCU (U2003) and in the BSI.
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To prevent this, DIAMAND stops communication with the DCU whenever it is not required and whenever
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possible (no dynamic reading). The Tool - DCU communication LED on the DIAMAND software flashes green
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when communication with the DCU is stopped.
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As DIAMAND restarts communication for each request, access to the different diagnostic functions may seem
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slower than on other vehicles. This is completely normal.
List of communication functions:
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Reading the dynamic parameters
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• Monitoring the fault codes
• Activating a test actuator (communication is stopped at the end of the test)
• Activating a diagnostic routine (communication is stopped at the end of the routine)
Switching off, even just for a short time, when one of these functions is active will cause a fault code to be raised.
Disconnecting the diagnostic socket when one of these functions is active will not cause communication to stop
before 5 seconds has elapsed. As a result, switching off the ignition before this time has elapsed will also cause
a fault code to be raised. © Delphi
1-8 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
1.2 READING FAULT CODES
1.2.1 Principle
This function allows the reading of data relating to faults stored in the DCU memory. This information is:
• The number of defects stored in the DCU memory.
• The fault code.
• The (permanent or temporary) status.
• The order in which the faults appeared.
• The number of times the fault appeared.
• The age of the last fault appearance.
• The environmental data.
Information relating to a fault is automatically erased if the defect is not detected again within 40 operating cycles.
1.2.2 Using the diagnostic tool

Reading the fault codes
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• In the main menu, click the "Fault Code" button.
•
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The DCU reads the fault code and the environment data.
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• The tool displays the list of fault codes found. To read the fault codes again, return to the main menu using
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the back button and click the "Fault Code" button.
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Erasing the fault codes
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• In the main menu, click the "Fault Code" button.
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• Click the "Erase" button.
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Then click "Yes" to confirm the erase
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Erasing one or more fault codes is only effective if they have been consulted beforehand
When the erase command is used, the After Sales area parameters need to be completed.
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This area ensures traceability of the diagnostic tools which have been used on the DCU.
This area comprises:
• The date
• The mileage
• The signature of the diagnostic tool :
“0xxxxx” for PSA (xxxxx corresponds to the identity of the Peugeot or Citroën dealer).
“1yyyyy” for Delphi (yyyyy corresponds to the identity of the Delphi representative).
• The number of the area completed (between 1 and 50. Memorisation is no longer active after this point).
Writing to this A-S area is automatic if the parameters to enter are valid.
If not, the user must enter them by hand.
It is possible to consult the A-S area log.
To validate an erase procedure a "key Off / key On" must be performed for a minimum of three seconds.
Note:
Erasing can only be carried out with the engine stopped and ignition on.
Fault code monitoring function

The diagnostic tool includes a dynamic fault code monitoring function that can detect the occurrence or status
change of fault codes in "real time".
To launch the monitoring function:
© Delphi
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I DIAGNOSTICS

In the "DIAGNOSTIC MENU", click the "Fault Code" button. The system displays a list of fault codes stored in the
DCU or a message indicating that no fault codes were found. To launch the monitoring function, click "Start
monitoring"; the fault codes are then highlighted in the following manner:
- Fault code pending: Orange
- Fault code present: Red
- Fault code temporary: Green
A beep sounds when a fault code switches to the "Present" status (the PC volume should be set at an appropriate
volume to be heard).
To exit the fault code screen or to display details of the fault codes, stop monitoring by clicking "Stop monitoring".
Note:
As ongoing diagnostic communication with the DCU prevents it from switching to standby, maintaining diagnostic
communication after switching off the ignition can cause a fault code to be raised. To prevent this, ensure that
communication stops before switching off the ignition.
1.2.3 Environmental data
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Environmental data allows the system's operating conditions to be known when a defect appears (fault
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context).
CAUTION
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Care must be taken when interpreting environmental data as the information is recorded in the memory at the
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same time as the fault. This means that the environmental data does not describe the engine's operating conditions
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when the fault is first detected, but when it is detected for the Nth time (N being the number of detections needed
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to register the fault in the memory).
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Furthermore, the defect having already been present when it was saved in memory, it could be that some of the
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environmental data has been corrupted. In this case, linearized data obtained through the conversion of the raw
signal is sometimes used, this is the first usable data available in the DCU.
Variable
DPF differential pressure
Definition
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DPF differential pressure programming
Units
programming
CAN - Vehicle speed Vehicle speed setting sent by the CAN km/h
Air conditioning activated Air conditioning active (A/C compressor activation)
• NO
• YES
Fan 1 control Fan 1 speed setting. %
Fan 2 control Fan2 control status :
• Deactivated
• Activated
Starter control Starter setting
• NO
• YES
Pre-post heating control Pre-post heating control %
EGR ByPass setting EGR ByPass setting %
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DIAGNOSTICS I
Variable Definition Units

TAR (Turbo Air Reheat) TAR (Turbo Air Reheat) ByPass setting %
ByPass setting
CTR (Coolant Temperature CTR (Coolant Temperature Reheat) Valve setting
Reheat) Valve setting • NO
• YES
EGR solenoid valve setting EGR Valve setting %
Redundant brake switch Redundant brake depress status
• Brake pedal released
• Brake pedal depressed
Ignition on Ignition switch status
• NO
• YES
EGR Bypass ON / OFF EGR Bypass ON / OFF switch
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switch • NO
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• YES
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TAR (Turbo Air Reheat) TAR (Turbo Air Reheat) ByPass lower stop last programming
ByPass lower stop last
programming c
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Air doser lower stop last
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Air doser lower stop last programming
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programming
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TAR (Turbo Air Reheat) TAR (Turbo Air Reheat) ByPass upper stop last programming
ByPass upper stop last
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Air doser upper stop last Air doser upper stop last programming
programming
Last EGR closed EGR Valve lower stop last programming
programming valid
Last EGR open EGR Valve upper stop last programming
programming valid
Last turbo valve closed Turbo lower stop last programming
programming valid
Last turbo valve open Turbo upper stop last programming
programming valid
Last synchronised engine Last synchronised engine rpm value rpm
rpm value
Distance travelled since Distance travelled since last RG km
regeneration
DPF air flow Estimated air flow passing through the particle filter. l/h
Requested air flow Air flow setting mg/stroke
Measured airflow Inlet air flow measurement. mg/stroke
Main fuel requested Main fuel requested mg/stroke
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I DIAGNOSTICS

Main brake switch status Main brake
• NO
• YES
Redundant brake switch Redundant brake switch status
status • NO
• YES
Engine status Indicates the engine status :
• Locked
• Preparing
• Engine stalled
• Restarting under way
• Self-starting
• Running
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• Stopped
• Starting
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• Invalid
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Accelerator pedal Accelerator pedal resistance status
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resistance status • Deactivated
•
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Activated
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Clutch pedal status Clutch pedal status
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• Deactivated
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• Activated
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Synchronisation status Synchronisation status
• NO
• YES
Diesel filter - presence of Diesel filter - presence of water
water • NO
• YES
Fan - PWM control Fan return signal status %
MILEAGE Mileage km
TAR (Turbo Air Reheat) TAR (Turbo Air Reheat) Bypass position %
Bypass position
Pedal position Measurement of the accelerator pedal position %
Pedal position track 1 Pedal position track 1 %
Raw pedal position track 1 Raw value on track 1 of the accelerator pedal sensor
Pedal position track 2 Filtered accelerator pedal signal track 2 %
Raw pedal position track 2 Raw value on track 2 of the accelerator pedal sensor
EGR valve position Measurement of the EGR valve position %
Raw EGR valve position EGR valve position sensor voltage
Raw air flap position Air doser position sensor voltage
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DIAGNOSTICS I

Inlet air flap position Air doser position %
VGT solenoid valve position VGT position %
Requested VGT solenoid VGT setting %
valve position
TAR (Turbo Air Reheat) TAR (Turbo Air Reheat) ByPass lower stop first programming
ByPass lower stop first
programming
Air doser lower stop first Air doser lower stop first programming
programming
Turbo lower stop first Turbo lower stop first programming
programming
TAR (Turbo Air Reheat) TAR (Turbo Air Reheat) ByPass upper stop first programming
ByPass upper stop first
programming
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Air doser upper stop first Air doser upper stop first programming
programming
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Turbo upper stop first Turbo upper stop first programming
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programming
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First EGR closed EGR Valve lower stop first programming
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programming
First EGR open
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EGR Valve upper stop first programming
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programming
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Atmospheric pressure Measurement of atmospheric pressure (the sensor is integrated into the DCU). mbar
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Measured AC pressure Refrigerant pressure measurement. bar
Engine oil pressure – Oil pressure mechanical switch sensor voltage
Sensor/switch circuit • NO
• YES
DPF differential pressure Measurement of the differential pressure between the inlet and outlet of the mbar
particle filter.
Raw DPF differential DPF differential pressure sensor voltage
pressure
Refrigerant fluid pressure Refrigerant fluid pressure sensor voltage
Rail pressure Measurement of the rail pressure bar
Raw rail pressure Raw rail pressure
Requested rail pressure Rail pressure setting bar
Turbocharging pressure Measurement of the pressure in the inlet manifold. This value is calculated mbar
using raw manifold pressures 1 and 2 to compensate for fluctuations in the
manifold pressure during an engine cycle.
Turbocharging pressure Turbocharging pressure setting mbar
requested
Air flowmeter sensor signal Air flowmeter sensor voltage (Period) μs
period
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I DIAGNOSTICS

Quantity of DPF additive Quantity of additive used mg
used
IMV control OCR IMV control OCR %
Air doser position OCR Air doser setting %
Gearbox ratio Value indicating the gear engaged in the gearbox for automatic transmission.
• Declutched
• 1
• 2
• 3
• 4
• 5
• 6
• Reverse
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• Invalid
Fan 1 relay
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Additional heating relay 1 setting
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• Deactivated
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• Activated
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Fan 2 relay Additional heating relay 2 setting
•
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Deactivated
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• Activated
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Supply relay Secondary relay status
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• Deactivated
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• Activated
Main supply relay Main relay status
• Deactivated
• Activated
Engine speed Engine speed measured over a complete cycle (720°). rpm
Engine oil level sensor Engine oil level sensor voltage
signal
Fuel temperature signal Fuel temperature sensor voltage
Lambda probe Lambda measured by the O2 probe -
Lambda probe ready Lambda probe heating setting
• NO
• YES
Time elapsed since starting Time elapsed since starting s
Post catalyser temperature Post catalyser temperature °C
Raw air temperature Flowmeter air temperature sensor voltage (T1)
Air inlet temperature Measurement of the inlet air temperature after the air filter (sensor integral °C
with air flowmeter). The measured value corresponds to the temperature of
the outside air.
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1-14 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

External air temperature External air temperature °C
Linearised air temperature. Raw air temperature °C
Coolant temperature Measurement of the engine coolant temperature °C
Raw coolant temperature Engine coolant temperature sensor voltage
Diesel temperature Fuel temperature measurement. °C
Battery voltage Battery voltage measurement. V
Minimum battery voltage Minimum battery voltage for start V
for start
Inlet air temperature sensor Inlet air temperature sensor voltage (T2')
voltage (T2')
LVS resistance sensor LVS resistance sensor voltage
voltage
TAR ByPass position sensor TAR ByPass position sensor voltage
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voltage
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VGT position sensor VGT position sensor voltage
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voltage
OBD vehicle speed
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Vehicle speed. OBD parameter
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km/h
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1.3 READING THE DYNAMIC PARAMETERS
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The dynamic parameters allow checking of system status in real time.
Note:
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Some variables may be represented in three different ways:
• Raw value
• Linearized value
• Physical value
The diagram below shows the processing sequence for an analogue signal with the various representations of the
variable associated with it.
DCU hardware DCU software
Electrical Measurement Raw Linearized Fault Filtered

value and value Conversion value detection value
conversion and filtering
SENSOR
(V, F, T, RCO...) (0..1023) (°C, bar...) (°C, bar...)
DCU input
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I DIAGNOSTICS

The raw value
(Example: Raw atmospheric pressure, raw air flow, raw diesel temperature etc...)
The raw value is the electric value (voltage, current, frequency, cycle ratio, period, etc.) transmitted by the sensor (voltage)
and measurable by the DCU. Measurement and conversion are carried out by the analogue/digital converter or directly
by the microprocessor depending on the signal type,
It is usually expressed without units with a value between 0 and 1023, 0 corresponds to a zero voltage measured and
1023 corresponds to a measured value equal to the internal DCU reference voltage (i.e. around 5V).
The raw value is difficult to interpret, but may allow a fault in the sensor or the DCU or a fault in the harness to be
detected. A value very close to 0 is generally a short circuit to earth and a value close to 1023 is an open circuit or a short
circuit with a potential greater or equal to 5V.
In certain cases it can also be converted into a physical value by the diagnostic tool (°C, bar etc...)
Linearised value
(Example: Linearised atmospheric pressure, raw linearised air flow, linearised diesel temperature etc...)
This is the "default" value of a variable used in the diagnostic tool. The linearized value of a variable is the raw value
transmitted by the sensor, to which a conversion function is applied to obtain a physical value representative of the value
measured. Values may be obtained in this way in degrees Celsius, bar etc . for example The linearised value represents
a snapshot of the measurement carried out by the sensor.
y
The physical value
p
(Example: Atmospheric pressure, measured air flow, diesel temperature etc...)
o
c
Under normal conditions, the linearized value and the physical value are practically the same. It is taken from fault
detection and filtering.
c e 10
If a fault appears on a sensor (fault code present), the physical variable associated with the sensor then takes a recovery
n /20
value, while the linearised variable displayed is a corrupted value.
a
If a fault is detected but is not yet stored in the diagnostic tool (no fault code as the fault has not yet been sufficiently
v 09
detected), the physical value generally takes the last valid value read.
d
To prevent a significant difference in the physical value when switching a real value to a recovery value, the physical
A 9/
value is "filtered" to eventually reach the recovery value.
0
Note:
As ongoing diagnostic communication with the DCU prevents it from switching to standby, maintaining diagnostic
communication after switching off the ignition can cause a fault code to be raised. To prevent this, ensure that
communication stops before switching off the ignition.
1.3.1 List of parameters

Values are for illustrative purposes only

Activation of electrical Possible values :
consumers • NO
• YES
5V sensor supply (Vext1) Measurement of the voltage applied at the terminals of the sensors supplied mV
by Vext1
EGR closed programming Value taken for the EGR closed position (stop) %
EGR open programming Value taken for the EGR open position (stop) %
Turbo valve closed Value taken for Turbo valve closed position (stop) %
programming
© Delphi
1-16 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

Turbo valve open Value taken for Turbo valve open position (stop) %
programming
Air flap programming - Value taken for air flap valve closed position (stop) %
Closed position
Air flap programming - Value taken for air flap valve open position (stop) %
Open position
DPF load Estimation of particle filter clogging level %
EGR bypass control Value indicating the EGR bypass control opening cycle ratio %
Additional heating control Heater control status. Possible values :
• Deactivated
• Activated
Turbo solenoid valve Value indicating the VGT solenoid valve control opening cycle ratio %
control
Fan 1 control Fan 1 control status. Possible values : %
•
p
Deactivated
y
o
• Activated
Fan 2 control
• c
Fan 2 control status. Possible values :
e 10
Deactivated
•
c
n /20
Activated
a
IMV control Value indicating the IMV control opening cycle ratio. %
v 09
• Fully open (the IMV is not supplied) ~0%.
•
• d
A 9/
Closed (Maximum current to the IMV) ~100%.
Pre-start : ~12%
EGR valve control

•
• 0
Idling when hot : ~40%
2000 rpm no load : 30 to 50%
Value indicating the EGR solenoid valve control opening cycle ratio. %
• Hot idle, EGR closed : ~ -5%
• Hot idle, EGR regulated : between 10 and 30%
• 2000RPM no load : between 15 and 30%
A negative value indicates a valve closing signal and a positive value
indicates a valve opening signal
Air flap control Value indicating the EGR solenoid valve flap control opening cycle ratio. %
• Hot idle, outside regeneration : 0%
• At engine stop : 70% then 100%
Main brake switch Possible values :
• Deactivated
• Activated
Safety brake switch Possible values :
• Activated
• Deactivated
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DDNX340A(EN) - Issue 1 of 06/2010 1-17

I DIAGNOSTICS

Kick-down switch Possible values :
• Activated
• Deactivated
Clutch pedal switch Possible values :
• Deactivated
• Activated
Measured IMV current Measurement of IMV control current. A
Note:
The accuracy of this parameter is only 500mA.
Fuel flow Total injected flow for a cycle. Possible values : mg/stroke
• Idling when hot : 4 to 6 mg/st
• 2000 rpm no load :5 to 8 mg/st
Requested air flow The air flow request is determined by the injection DCU as a function of the mg/stroke
y
engine operating conditions.
p
• Hot idle, EGR closed : 450 to 550 mg/st
•
c o
Hot idle, EGR regulated : 250 to 300 mg/st
e 10
• 2000 rpm no load : 270 to 300 mg/st
c
Measured airflow Post air filter flow measurement expressed as the quantity of air aspirated mg/stroke
n /20
per cylinder and per cycle.
a
v 09
• Hot idle, EGR closed : 450 to 550 mg/st
d
• Hot idle, EGR regulated : 250 to 300 mg/st
A 9/
• 2000 rpm no load : 350 to 400 mg/st
0
A/C compressor request Possible values :
• Activated
• Deactivated
Distance travelled since Distance travelled since the last successful regeneration km
regeneration
Immobiliser status Indicates the DCU immobiliser locking status.
• Not locked
• Locked
Matching status Indicates the DCU matching status. If the DCU has not yet been matched to
one or two other ECUs (BSI and ESP), this parameter indicates the ADC code
writing number. Only a matched DCU can be unlocked.
• Factory delivered and A-S mode (New DCU, so no programmed code)
• Programmed once
• Programmed twice
• Programmed three times
• DCU matched with the BSI
• ECU matched
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1-18 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

A/C compressor status Indicates the A/C compressor clutch control status. Possible values :
• Deactivated
• Activated
Speed limiter status Indicates if the speed limiter is running. Possible values :
• Activated
• Deactivated
Engine status Indicates engine operating status. Possible values :
• Running
• Engine stalled
• Preparing
• Starting
• Self-starting
Pre-post heating status Preheating plugs control status. Possible values :
y
• Activated
p
• Deactivated
Cruise control status
c o
Indicates if the cruise control is running. Possible values :
e 10
• Activated
c
• Deactivated
n /20
Synchronisation status Indicates the Crankshaft / Camshaft synchronisation status. Possible values :
a
• Waiting for synchronisation
•
d v 09
Synchronised
A 9/
Engine at idle Indicates if the engine is at idle speed. Possible values :
• NO
EGR Bypass position

•
0
YES
Measurement of the EGR valve bypass control position.
• Hot idle, EGR closed : 0%
%
• Hot idle, EGR regulated : ~50%

• 2000 rpm no load : ~50%
VGT solenoid valve position Measurement of the diaphragm control rod position on the variable geometry %
turbo
Requested VGT solenoid Measurement of the diaphragm control rod position on the variable geometry %
valve position turbo requested by the DCU.
Pedal position Measurement of the accelerator pedal position. %
Typical value (accelerator pedal released) : 0%
Typical value (accelerator pedal depressed) : 100%
Raw pedal position track 1 Raw value of the pedal position sent by track 1 of the accelerator pedal sensor mV
• Pedal released : 380 to 400 mV
Raw pedal position track 2 Raw value of the pedal position sent by track 2 of the accelerator pedal sensor mV
• Pedal released : 190 to 200 mV
Requested EGR valve Measurement of the EGR valve position requested by the DCU %
position
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-19

I DIAGNOSTICS

Air heater bypass flap The air heater bypass flap opening value %
position
Air heater bypass flap The air heater bypass flap position value requested by the DCU %
position requested
Air flap position Measure air flap position %
Air flap position requested Measurement of the air flap position requested by the DCU %
First EGR closed Initial programming value for the EGR valve closed position %
programming
First EGR open Initial programming value for the EGR valve open position %
programming
First flap closed Initial programming value for the air flap valve closed position %
programming
First flap open Initial programming value for the air flap valve open position %
programming
Atmospheric pressure
p y
Measurement of atmospheric pressure (the sensor is integrated into the DCU). bar
o
DPF differential pressure Measurement of the differential pressure upstream and downstream of the mbar
c
particle filter
e 10
Air conditioning gas Measurement of the pressure in the air conditioning circuit bar
c
pressure
Requested rail pressure
a n /20
Pressure request determined by DCU as a function of engine operating bar
v 09
conditions. The gap between the pressure measured and the setting must
d
not exceed an absolute value of 250bar.
A 9/
• When cranking / before starting: 300 bar
0
• Idling when hot : 290 to 320 bar
• 2000RPM no load : 640 to 700 bar
• Maximum value : 1800 bar
Measured rail pressure Rail pressure measurement. bar
• Idling when hot : 290 to 320 bar
• 2000RPM no load : 640 to 700 bar
• Maximum value : 1800 bar
Raw turbocharging Signal for boost pressure sensor bar
pressure • Idling when hot : 900 to 1200 bar
• 2000rpm no load : 1000 to 1300 bar
Turbocharging pressure Boost pressure requested by the DCU bar
requested • Idling when hot : 900 to 1200 bar
• 2000rpm no load : 1000 to 1300 bar
Main pulse - Cylinder 1 Total injection time (pilots + main + posts) on one cycle of cylinder 1. μs
Note:
On certain versions of the DCU software, the value is fixed at 1μs. In this
case ignore this value.
© Delphi
1-20 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

Note:
Note:
Note:
y
Quantity of DPF additive Total quantity of additive used since filling the tank. mg
p
used
Total additive quantity
c o
Volume of additive available in the tank. mm3
e 10
Gearbox ratio Gearbox ratio selected (calculated). Possible values :
c
• Declutched
n /20
• 1
• 2
a
v 09
d
• 3
A 9/
• 4
0
• 5
• 6
• 1
• Neutral
• Indeterminate
• Recovery mode
DPF regeneration DPF regeneration assistance status. Possible values :
• Activated
• Deactivated
Engine speed Engine speed measured over a complete cycle (720 degrees) rpm
Supply relay Main relay control status. Possible values :
• Activated
• Deactivated
© Delphi
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I DIAGNOSTICS

Matching result Immobiliser3 DCU matching result. Only a DCU with "No fault detected" status
may be unlocked. Possible values :
• Impossible to read immobiliser code
• Impossible to read immobiliser status
• No problem detected
• Waiting for BSI response
• Waiting for ESP response
• BSI response incorrect
Engine oil level signal Engine oil level sensor signal mV
Pre-DPF temperature Pre-DPF temperature measurement °C
Raw manifold air Measurement of air temperature in the intake manifold. This sensor is °C
temperature installed on the plenum, adjacent to the inlet pressure sensor.
Raw inlet air temperature Measurement of the inlet air temperature after the air filter (sensor integral °C
y
with air flowmeter). The measured value corresponds to the temperature of
p
the outside air
o
Raw coolant temperature Coolant temperature measurement at cylinder head outlet. °C
Raw oil temperature
c
Engine oil temperature measurement
e 10
°C
c
Raw diesel temperature Fuel temperature measurement °C
n /20
Raw battery voltage. Measurement of the battery voltage at the DCU input V
a
• During normal operation: 6.5 to 14.9
HSD 1 voltage
d v 09
Measurement of the HSD voltage for the injector control stage (internal DCU) V
A 9/
HSD 2 voltage Measurement of the HSD voltage for the injector control stage (internal DCU) V
0
Fan 1 speed Indicates the low speed fan rotation proportion compared to the maximum %
speed possible.
Programmed speed (limiter) Programme speed to speed limiter km/h
Programmed speed (cruise Programme speed to cruise control km/h
control)
Vehicle speed Vehicle speed (received by the CAN) km/h
DPF additive tank volume Quantity of additive available in the tank mm3
Total weight of DPF soot Total weight of particle filter soot g/l
Idle speed setting Idle speed setting. rpm
© Delphi
1-22 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
1.4 DCU IDENTIFICATION
Parameters Description Value Comments

Hardware reference Hardware reference 96 XX XX XX XX
Supplier code DCU supplier code 0013 0013 = Delphi
DCU reference Calibrated DCU reference 96 XX XX XX XX This reference changes after
reprogramming the DCU
Diagnostic version Diagnostic index applicable to XX
the DCU
DCU manufacturing date DCU manufacturing date. XX / XX / XX
System Indicates the engine type for 10 10 = DW10CTED4
which the system was designed.
Application type Indicates the DCU type for this 01 01 = DCM3.5
system
Software ID
p y
Program version appropriate for XX 56 = Picasso Manual
o
each vehicle type. Transmission, 54 = Picasso Auto
c
Transmission etc..
e 10
Software version Indicates the version of the XX XX
c
program and the calibration
Programming date
a n /20
Date last DCU reprogramming XX / XX / XX
v 09
done.
Download Site
d
A 9/
Site ID where last DCU
reprogramming carried out.
XX FD = PSA A-S network, the other
values correspond to various
0
PSA production sites
Tool signature ID of the tool that carried out the XXXXXX
last DCU reprogramming.
Reprogramming Number of DCU reprogramming XX
events.
Note: The identification above is given for illustrative purposes only.

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-23

I DIAGNOSTICS
1.5 ACTUATOR CONTROL
The diagnostic tool can control the status of some DCU outputs.
Output Verification conditions Normal consequences for system

Injector - Cylinder 1 Ignition on, pre-starting The valve of the injector for cylinder 1 vibrates.
Supply relay Ignition on, pre-starting
Preheating relay Ignition on, pre-starting The preheating plugs are controlled
Additional heating Ignition on, pre-starting The relays oscillate between two states.
Fan2 (low speed) Ignition on, pre-starting Fan activation
If dual speed: for 20 s.
y
If PWM: accelerates for 25 s then stabilises for 10 s.
Fan1 (high speed)
op
Ignition on, pre-starting Fan activation
c
If dual speed:
e 10
Slow speed 5 s.
c
n /20
High speed 20 s.
a
If PWM: Fan optional for 20 s
IMV
d v 09
Ignition on, pre-starting The IMV piston vibrates (audible in a quiet environment).
A 9/
O2 probe heating Ignition on, pre-starting The oxygen probe heating is deactivated.
0
© Delphi
1-24 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
1.6 TEST ROUTINES
1.6.1 Pump capacity test

A) Principle
When there is a problem in the high pressure circuit, it is necessary to check that there is no pump failure. The
DCU has a pump capacity cycle with the engine running available, to avoid road testing.
The pump capacity with the engine running test is a no load acceleration while the rail pressure is held at the
maximum for around 40 seconds. This cycle can only be activated when the following conditions are met:
• Vehicle speed zero.
• The gearbox is in neutral (manual transmission) or the P/N position (automatic transmission).
• System detects no failures.
• All pedals are released.
This cycle can be launched using the diagnostic tool.
This cycle must be used in conjunction with the installation of the Kit "HP-T" YDT465 on the injection system. For
more details, please refer to the manual DDNX331 on the CD DDRX113B included in the kit.
y
Note:
p
For safety reasons, the test activation conditions are continuously monitored throughout the routine. If one of the
o
conditions is no longer met, the test is stopped automatically.
Note: c
e 10
c
This cycle can not be reactivated without resetting the DCU.
a n /20
v 09
Engine
d
Requested rail speed
A 9/
pressure 60s
1500rpm
0
1600bar
40s
1800bar
10s
10
s
5s
5s
10s 750rpm
500bar
10s 10s
10
s
s
10
200bar
Rail pressure error < 200bar

0rpm
Time
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-25

I DIAGNOSTICS

B) Procedure
• Switch on ignition.
• Start the engine
• Launch the routine.
CAUTION
In order to avoid any risk of injury from a jet of high pressure diesel, it is recommended that this test be carried
out with the bonnet closed and all safety recommendations are applied.
DELPHI declines any responsibility in the event of injury sustained at the time or after the test.
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
1-26 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

1.6.2 Pump capacity test under cranking
A) Principle
if there is an HP circuit fault that prevents starting, high pressure pump testing is not possible with the standard
test for pump capacity. This routine makes it possible by requiring the pump to deliver and maintain a rail pressure
of 500 bar under cranking.
This cycle can only be activated when the following conditions are met:
• Vehicle speed zero.
• The gearbox is in neutral (manual transmission) or the P/N position (automatic transmission).
This cycle can be launched using the diagnostic tool.
This cycle must be used in conjunction with the installation of the Kit "HP-T" YDT465 on the injection system. For
more details, please refer to the manual DDNX331 on the CD DDRX113B included in the kit.
Note:
Note:
p y
o
Note:
c
e 10
c
This routine is not operational in all DCUs.
a n /20
Pressur
d v 09 3-4s
A 9/
e
500bar
0
1-
2s
30 x
ma
s
Rail pressure error > 50bars
Test running
Starter activation
30s max
Injection shut off
IMV closed
IMV open Time
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-27

I DIAGNOSTICS

B) Procedure
• Switch on ignition.
• Launch the routine.
• Operate the starter manually for 30 seconds.
CAUTION
In order to avoid any risk of injury from a jet of high pressure diesel, it is recommended that this test be carried
out with the bonnet closed and all safety recommendations are applied.
1.6.3 Leak detection cycle

Principle
After working on the high pressure circuit, it is necessary to check for the absence of high pressure leaks. To avoid
having to carry out a road test, the DCU has a leak detection cycle that puts the injection system under high
pressure.
The leak detection cycle consists of performing a no load acceleration, during which the pressure request is forced
y
up to a value close to the maximum pressure authorised by the system (1800 bar) for approximately a second
p
and a half. This cycle can only be activated when the following conditions are met:
o
• The coolant temperature should be between 50 and 100°C.
•
•
Vehicle speed zero.
c
e 10
The gearbox is in neutral (manual transmission).
c
n /20
Note:
a
v 09
d
A 9/
0
Note:
Procedure
• Apply leak detector solution to the connectors removed during the procedure.
• Start the engine.
• Let the engine idle until the coolant temperature exceeds 50 .
• Close bonnet.
• Start the routine and wait until it has finished
• Wait a few seconds then switch off ignition.
• Open bonnet and visually check for any diesel leaks revealed by the leak detector solution previously applied
to the connectors removed during the operation.
• Remove leak detection solution using "CARCLEAN"-type solvent.
DANGER
In case of leaks, it is essential to carefully remove all traces of leak detection solution before opening the high
pressure circuit, particles of the leak detection solution may pollute the injection system. It is equally important
to clean up any fuel spills from leaks before restarting the engine. Remember to check that the braking system is
not contaminated by fuel.
© Delphi
1-28 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

1.6.4 DPF regeneration

Principle
This function allows DPF regeneration to be started or stopped in the After Market network. There are two types
of regeneration: Regeneration with the vehicle moving and regeneration with the vehicle stationary.
CAUTION
If this service is used too frequently it can damage the particle filter.
A) Principle
This process allows forced regeneration of the DPF by increasing the exhaust temperature and triggering the
combustion of the particles trapped in the filter.
B) When should I use this service?
This routine must be used in the following cases:
• DPF overload faults, critical load, full of ash, are only present on the diagnostic. If other faults are present,
y
then deal with these first.
•
op
A lack of power is noted but no fault is recorded.
c
• When a boost control fault is flagged. It could be that excessive exhaust back-pressure causes a turbocharger
e 10
control malfunction.
c
n /20
DPF regeneration launch vehicle moving
C) Procedure
a
v 09
d
• Switch off the ignition and wait for the end of the power latch (approx 10 seconds).
A 9/
• Switch on the ignition and read the fault codes using the diagnostic tool. Only the DPF fault codes must be
present. If another fault is present, deal with this first.
0
• Drive for 10 minutes to heat up the engine.
• Launch the "particle filter regeneration" test routine using the diagnostic tool and let the vehicle run until
the end of the routine.
Note:
The time required for regeneration depends on the quantity of soot in the filter and its temperature. The total
regeneration cycle (reheating phase + regeneration) can last between 10 and 30 minutes. The remaining time can
be estimated by looking at the values of the dynamic parameters "Time remaining: particle combustion" and "Time
remaining: recalibration". These two parameters should not lapse frequently. Regeneration is finished when the
"DPF regeneration progress" value reaches 100%.
D) Conditions for cancelling the routine

The regeneration cycles can be cancelled if :
• The ignition has been switched off.
• The routine was stopped deliberately.
• The "regeneration requested" status has remained active for 30 minutes.
• A fault has been recorded.
• The "regeneration in progress" status has remained active for more than 30 minutes.
• The particle filter temperature has remained below 300°C for 2 minutes.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-29

I DIAGNOSTICS

Starting DPF regeneration with the vehicle stationary
CAUTION
DPF regeneration causes very high temperatures in the exhaust system that may damage extraction systems or
cause a fire. The use of the regeneration routine while driving the vehicle is strongly recommended.
C) Procedure
• Switch off the ignition and wait for the end of the power latch (approx 10 seconds).
• Switch on the ignition and read the fault codes using the diagnostic tool. Only the DPF fault codes must be
present. If another fault is present, deal with this first.
• Drive for 10 minutes to heat up the engine.
• Launch the "particle filter regeneration" test using the diagnostic tool.
Note:
The time required for regeneration depends on the quantity of soot in the filter and its temperature. The total
regeneration cycle (reheating phase + regeneration) can last between 10 and 30 minutes. The remaining time can
be estimated by looking at the values of the dynamic parameters "Time remaining: particle combustion" and "Time
y
remaining: recalibration". These two parameters should not lapse frequently. Regeneration is finished when the
p
"DPF regeneration progress" value reaches 100%.
D) Conditions for cancelling the routine

c o
e 10
The regeneration cycles can be cancelled if :
c
• The ignition has been switched off.
•
a n /20
The routine was stopped deliberately.
v 09
• One of the pedals had been fully depressed
d
• A fault has been recorded.
A 9/
• The regeneration time exceeded 30 minutes.
0
• The particle filter temperature has remained below 300°C for 2 minutes.
Note:
If the soot weight is below a certain threshold, then the regeneration was successful (the DPF is taken as
regenerated), if not, the test is taken as failed
1.6.6 EGR valve

Principle
The routine is designed to check the EGR valve mechanical function and to detect fouling or seizure.
Initial conditions
• Engine at idle
• Vehicle speed between 0 and 5 km/h
• Battery voltage between 10V and 15V
• Accelerator pedal released
• Clutch pedal released
• Gearbox in neutral
© Delphi
1-30 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

Procedure
• Start the test
• Wait for the test to finish and read the result
Note:
This cycle is not available on all DCU software versions.
1.6.7 Inlet air flap valve

Principle
The routine is designed to check the air inlet flap valve mechanical function and to detect fouling or seizure.
Initial conditions
• Engine at idle
• Vehicle stationary (speed zero)
y
p
o
c
e 10
c
Procedure
n /20
a
v 09
• Start the test
d
Note:
A 9/
0
1.6.8 VGT solenoid valve

Principle
The routine is designed to check the VGT mechanical function and to detect fouling or seizure.
Initial conditions
• Engine running
Procedure
• Start the test
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-31

I DIAGNOSTICS

Note:
1.6.9 Air heater bypass flap valve

Principle
The routine is designed to check the air heater bypass flap valve mechanical function and to detect fouling or
seizure.
Initial conditions
• Engine at idle
• Accelerator pedal position greater than or equal to 0%
Procedure
p y
o
c
• Start the test
e 10
Note:
c
n /20
a
d v 09
A 9/
1.6.10 EGR bypass valve
Principle
Initial conditions
• Engine running
0
The routine is designed to check the EGR cooler flap valve mechanical function and to detect fouling or seizure.
• Engine speed between 600 and 1000 rpm

• Engine temperature above 50°C
Procedure
• Start the test
Note:
© Delphi
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DIAGNOSTICS I

1.6.11 VGT / Boost pressure
Principle
The test is designed to check the VGT mechanical operation (fouling or seizure) and to check the boost pressure
consistency during the test.
Initial conditions
• Engine running
• Vehicle speed between 0 and 5Km/h (vehicle stationary)
CAUTION
y
If one of these conditions is not met or a VGT request stop will cause all the tests in this routine to stop.
Procedure
op
•
•
Start the engine
Start the test c
e 10
•
c
n /20
Wait for the test to finish and read the result
Note:
a
v 09
d
1.6.12 Turbocharging pressure

A 9/
Principle
0
This routine is designed to check the boost pressure sensor operation and to find a possible leak in the circuit by
correlation with the measured air flow.
The test checks the boost pressure oscillation (normal) under cranking. If there is no variation, or if the variation
is too weak, the boost pressure read is correlated with the measured air flow to detect a possible leak.
Initial conditions
• Engine stopped
• No boost pressure sensor fault
Procedure
• Start the test
• Operate the starter until the end of the test
• read the result
Note:
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-33

I DIAGNOSTICS

1.6.13 Stall test
Principle
This operation is designed to force the engine to stall by closing the inlet air, the reheat bypass and the EGR flap
valves. If the engine does not stall and if the mechanical function of the valves is not at fault, the inlet air circuit
has a leak.
Initial conditions
• Engine temperature must be above 50°C
• Vehicle speed zero
• Clutch released
Procedure
• Start the test
p y
o
c
• read the result
Note:
c e 10
n /20
1.6.14 Air flow

a
v 09
Principle
d
A 9/
This routine is designed to check the air flow values measured at different rpm depending on the position of the
maps.
Initial conditions
0
various flaps and valves in the air circuit. The measured flow values are compared with those in the reference
• Engine at idle
• Clutch released
• Gearbox ratio neutral
Procedure
• Start the test
• read the result
Note:
© Delphi
1-34 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

1.6.15 EGR flow
Principle
This routine is designed to check the air flow values measured when the EGR valve is closed an open at different
rpm and depending on the position of the various flaps and valves in the air circuit. If the difference is too small,
the EGR is leaking.
Initial conditions
• Engine at idle
• Clutch released
• Gearbox ratio neutral
Procedure
• Start the test
p y
o
c
• read the result
Note:
c e 10
n /20
1.6.16 Additional heating

a
v 09
Principle
d
A 9/
This test is designed to diagnose the additional heater module (burner or heater element).
Initial conditions
•
•
Engine at idle 0
Battery voltage between 10V and 15V
Procedure
• Start the test
• read the result
Note:
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-35

I DIAGNOSTICS

1.6.17 DPF additive pump
Principle
This routine is for electrical diagnosis of the DPF additive pump (wired) in the After Market Network.
Initial conditions
• Engine at idle
• The additive level in the tank is adequate
Procedure
• Start the test
• read the result
Note:
p y
o
1.6.18 CTR solenoid valve
Principle
c
e 10
This routine is for the electrical diagnosis of the Coolant Temperature Reheat solenoid valve.
Initial conditions
c
n /20
a
v 09
d
• Engine stopped, ignition on
Procedure
A 9/
•
•
•
Check the initial conditions
Start the test 0
Observe the result to see if the test has been completed, if not, check the initial conditions and restart the
test.
Note:
This cycle is not available on all DCU software versions. © Delphi
1-36 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
1.7 C3I MANAGEMENT
1.7.1 Definition of C3I

C3I is a calibration which is unique to each injector. It describes the initial specifications of the injector in question.
The C3I is determined at injector test after assembly. It is represented by a 20 character alphanumerical code,
which is clearly shown on a label applied to the injector body.
The programming elements are the corrective terms that trace the life of the injector. They are determined by the
PICL strategy (Pilot Injection Closed Loop) that closed-loop corrects injector MDPs.
The DCU determines the pulse to be applied to the injector as a function of:
• The target which represents the initial average characteristics of a representative set of injectors.
• The C3I which represents the initial characteristics of each individual injector.
• Programming which represents the current state of each injector (taking into account wear and ageing of
components).
The DCU must therefore know the C3I to determine the pulse to be applied to each injector with precision. This
is necessary to ensure optimum operation of the injection system. If the C3I of an injector is not entered into the
DCU, the DCU applies an uncorrected pulse to the injector as a function of the injector's own characteristics, which
y
may lead to serious degradation in the engines performance. In this case, the DCU applies a recovery strategy of
p
the "limp home" type, that is, the engine speed is set to 1300 rpm with no pedal control.
o
In the same way, the DCU must also learn the MDP settings relative to each injector. If these settings are lost, the
c
pulse applied to each injector does not take component life into account, resulting in a temporary degradation in
e 10
engine performance.
c
In after sales:
n /20
When replacing an injector , the following must be performed:
a
• Enter the C3I for this injector into the DCU.
d v 09
The DCU automatically reinitializes the programming values for this injector when the C3I is entered.
A 9/
The DCU performs several "quick" injector resets to optimize its control.
0
When replacing a DCU , the following must be performed:
• To match up the new DCU.
• Record the C3I values from the old DCU then enter the C3I into the new DCU.
It is possible to save the information recorded in the memory of the DCU that is to be replaced.
Note: If it is not possible to copy the programming values from the faulty DCU into the new DCU, the new DCU
uses neutral default values to define the pulse to be applied to each injector. It is therefore possible that vehicle
performance may be degraded during the first few hundred kilometres following repair. However, this degraded
performance is rapidly corrected by the PICL strategy which allows the acquisition of the actual characteristics of
the injectors as they are reset.
If the system is replaced , perform the following operations:
• Enter the C3I for all the injectors into the DCU. Pay attention to the cylinder numbers.
Note: When replacing the system, the programming does not need to be reinitialised for this application.
• If an injector is replaced, the C3I for that injector must be entered into the DCU. The DCU automatically
reinitializes the programming values for this injector when the C3I is entered.
Special functions are available in the diagnostic tool to carry out these operations easily through the after
sales network.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-37

I DIAGNOSTICS

1.7.2 Reading the C3I
To read a C3I using the diagnostic tool, proceed as follows:
• In the "MAIN MENU", click "SPECIAL FUNCTIONS".
• Click the "C3I" button.
• Click the "Read C3I" button.
1.7.3 Writing the C3I

To write a C3I using the diagnostic tool, proceed as follows:
• Click the "C3I" button.
• Click the "Write C3I" button.
• Enter the C3I in the area provided. C3I data is shown on the new injector label.
• Click the "Cylinder n" button corresponding to the cylinder linked to the injector for which the C3I must be
written. A photo of the engine shows the cylinder layout.
• Click "YES" to confirm writing or "NO" to cancel writing.
y
• If writing fails check that the C3I entered does not contain any errors.
•
op
To check that the C3I has been recorded correctly, click the "Back" button then "READ C3I".
Note:
c
e 10
The C3I can only be written when the engine has stopped, ignition on.
c
n /20
a
1.8 PROGRAMMING MANAGEMENT
1.8.1 Reading programming values

d v 09
A 9/
To read the programming values using the diagnostic tool, proceed as follows:
0
• Click the "PROGRAMMING" button.
• Click the "Read" button.
The programming values are grouped according to function or component. Click the corresponding button
to display the list of related values.
© Delphi
1-38 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

1.8.2 List of programming values
Note:
The programming values for the actuator stop (flap, EGR etc...) are expressed as raw values. refer to the
section Reading dynamic parameters for more detail on the interpretation of raw values.
A) Particle filter

Number of failed Number of regenerations that failed Without
regenerations
DPF status Particle filter status. Possible values : -
• Clogged
• Normal
• Overloaded
Distance travelled since Distance travelled since particle filter replacement km
y
DPF replacement
Time elapsed since the last
op
Time elapsed since the last time the tank was filled s
c
time the tank was filled
e 10
DPF additive level Total quantity of additive remaining since the first regeneration mm3
c
Quantity of DPF additive Total quantity of additive used since the first regeneration mg
used
a n /20
v 09
DPF differential pressure Programming offset for the particle filter differential pressure (0 calibration) Without
d
programming
A 9/
DPF differential pressure Possible values : -
0
programming performed • NO
• YES
Distance travelled since Distance travelled since the last successful regeneration km
regeneration
Distance travelled since Distance travelled since particle filter replacement km
DPF replacement
Fuel used for regeneration Total quantity of fuel used since the first regeneration. This corresponds to L
the total quantity of fuel injected by the post injections.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-39

I DIAGNOSTICS

B) System (pump programming)

Least maximum torque Value of the least maximum VLC correction torque reached Nm
reached (VLC)
IMV correction update Possible values : -
available • NO
• YES
First start Possible values : -
• NO
• YES
C) EGR

First EGR closed Initial programming value for the EGR valve closed position. Normal value : Without
programming <150.
p y
o
First EGR open Initial programming value for the EGR valve open position Normal value : Without
c
programming between 700 and 900.
e 10
EGR open programming Value programmed for EGR valve open position. Normal value : between 650 Without
c
and 950.
Last EGR open
a n /20
Indicates if the last programming attempt for the EGR valve open position -
v 09
programming valid was successful. Possible values :
d
• NO
A 9/
• YES
0
EGR closed programming Value programmed for EGR valve closed position. Its value must not differ by Without
more than 110 compared with the first programming.
Last EGR closed Indicates if the last programming attempt for the EGR valve closed position -
programming valid was successful. Possible values :
• NO
• YES
D) Variable Geometry Turbo

First VGT max programming Indicates if the first programming attempt for the maximum VGT control Without
position was successful
First VGT min programming Indicates if the first programming attempt for the minimum VGT control Without
VGT max programming Indicates if the last programming attempt for the minimum VGT control Without
VGT max programming - Possible values : -
Valid • NO
• YES
VGT min programming Value programmed for minimum VGT control position Without
© Delphi
1-40 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

VGT min programming - Possible values : -
Valid • NO
• YES
E) Inlet air flap valve

First flap open Indicates if the first inlet air flap open position programming attempt was Without
programming successful.
First flap closed Indicates if the first inlet air flap closed position programming attempt was Without
programming successful.
Air flap programming - Inlet air flap open position programmed value. Without
Open position
Air flap programming - Possible values : -
y
Open position - Valid • NO
p
• YES
o
Air flap programming - Inlet air flap closed position programmed value Without
Closed position
c
e 10
c
Air flap programming - Possible values : -
n /20
Closed position - Valid • NO
a
• YES
F) Air heater bypass flap valve

d v 09
A 9/
0
First flap open Indicates if the first inlet air reheat bypass flap open position programming Without
programming attempt was successful.
First flap closed Indicates if the first inlet air reheat bypass flap closed position programming Without
programming attempt was successful.
Air heater bypass flap Inlet air heater bypass flap open position programmed value Without
programming - Open
position
Air heater bypass flap Possible values : -
programming - Open • NO
position - Valid • YES
Air heater bypass flap Inlet air heater bypass flap closed position programmed value Without
programming - Closed
position
Air heater bypass flap Possible values : -
programming - Closed • NO
position - Valid • YES
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-41

I DIAGNOSTICS

G) Air flowmeter
Note:
This strategy is not active in all DCU software versions.

Flowmeter mileage Distance travelled since the air flowmeter replacement. km
H) MDP corrections
Note:
The minimum drive pulse for the injectors is defined as a function of the rail pressure. The rail pressure is divided
into 6 zones (200, 250, 450, 800, 1300 and 2000 bar) which are each assigned a calculated MDP programming (i.e.
correction) value.
y
MDP – Cylinder 1 (200) Indicates the value of the injector minimum drive pulse for cylinder 1 for the μs
p
200 bar pressure zone. This value must be between -200 and 300μs.
o
c
e 10
c
n /20
a
v 09
MDP – Cylinder 1 (1300)
d
Indicates the value of the injector minimum drive pulse for cylinder 1 for the
A 9/
μs
0
© Delphi
1-42 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

MDP – Cylinder 2 (200) Indicates the value of the injector minimum drive pulse correction for cylinder μs
2 for the 200 bar pressure zone. This value must be between -200 and 300μs.
y
op
c
e 10
c
n /20
a
v 09
d
1.8.3 Erasing programming values
A 9/
To reset the programming values using the diagnostic tool, proceed as follows:
0
• Click the "Erase" button.
CAUTION
The programming values must not normally be reinitialised unless a part is replaced. Refer to the section
"OPERATIONS REQUIRING THE USE OF THE DIAGNOSTIC TOOL" for more details on using this function.
The programming values are grouped according to function or component. Click the corresponding button
to display the list of related values.
• Engine control ECU
• EGR solenoid valve
• Turbocharger
• Air flowmeter
• Particle filter differential pressure sensor
• High pressure fuel pump (With IMV
• IMV only
• High pressure common fuel injection rail (With fuel high pressure sensor)
• Pump or tube additive tank
• Replacement : Particle filter
• Additive tank filling
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-43

I DIAGNOSTICS

• Air doser
• Boost air cooler bypass
• EGR By-pass
• Oxygen probe
WARNING
If the DPF programming data is deleted without replacing the filter itself, clogging of the DPF may occur without
being detected by the DCU, which can lead to engine and gearbox damage. If the programming data is
inadvertently deleted, run the regeneration program in the diagnostic tool ROUTINES function to force a DPF
programming data reset.
1.8.4 Copying programming values

To reset the programming values using the diagnostic tool, proceed as follows:
• Click the "Store" button.
y
All the programming values are stored in the computer memory. To copy these values into another DCU,
p
click on the "Copy to" button.
c o
e 10
1.9 OPERATIONS REQUIRING USE OF THE DIAGNOSTIC TOOL
c
n /20
a
1.9.1 Replacing the injectors
d v 09
If an injector has to be replaced, the C3I for the new injector must be entered into the DCU. To do this, perform
A 9/
the operations described in the section Writing a C3I:
0
1.9.2 Replacing the DCU
The DCU may only be replaced by the vehicle manufacturer's network so that the new DCU may be matched,
coded and programmed.
1.9.3 System replacement

If it is necessary to replace the injection system (pump, injectors, HP pipes…) apart from the DCU, the C3I for the
four injectors and the programming data reset must be entered manually.
• HP pump
• Rail
1.9.4 Replacing the HP pump

The pump programming values must be reinitialised (erased) when replacing the HP pump.
1.9.5 Replacing the rail

The rail programming values must be reinitialised (erased) when the rail is replaced.
1.9.6 Replacing the IMV

The IMV programming values must be reinitialised (erased) when replacing the IMV.
© Delphi
1-44 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

1.9.7 Replacing the EGR valve
The EGR programming values must be reinitialised (erased) when replacing the EGR valve.
1.9.8 Inlet air flap replacement

The inlet air flap valve end stop programming values must be reinitialised (erased) when replacing the inlet air
flap valve.
This operation is not strictly necessary when only the flap drive solenoid valve is replaced.
1.9.9 Inlet air heater bypass flap valve replacement

The inlet air heater bypass flap valve programming values must be reinitialised (erased) when replacing the inlet
air heater bypass flap valve.
1.9.10 Replacing the flowmeter
y
The flowmeter programming values must be reinitialised (erased) when replacing the flowmeter.
op
1.9.11 Replacing the flowmeter and the cylinder head
c
e 10
The flowmeter and cylinder head programming values must be reinitialised (erased) when replacing the flowmeter
c
and the cylinder head.
1.9.12 Replacing the cylinder head

a n /20
d v 09
The flowmeter and cylinder head programming values must be reinitialised (erased) when replacing the flowmeter
A 9/
and the cylinder head.
0
1.9.13 Replacing the Variable Geometry Turbo (VGT)
The VGT actuator end stop programming values must be reinitialised (erased) when replacing the VGT.
1.9.14 Replacing the oxygen probe

The oxygen probe programming values must be reinitialised (erased) when replacing the oxygen probe.
1.9.15 Replacing the Particle Filter (DPF)

The DPF programming values must be reinitialised (erased) when replacing the DPF.
WARNING
If the DPF programming data is deleted without replacing the filter itself, clogging of the DPF may occur without
being detected by the DCU, which can lead to engine and gearbox damage. If the programming data is
inadvertently deleted, run the regeneration program in the diagnostic tool ROUTINES function to force a DPF
programming data reset.
1.9.16 Replacing the DPF differential pressure sensor

The DPF differential pressure sensor programming values must be reinitialised (erased) in when replacing the
DPF differential pressure sensor.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 1-45

I DIAGNOSTICS

1.9.17 Replacing an additive system component (pump, tank, tubing etc...)
The DPF additive pump programming values must be reinitialised (erased) when replacing the DPF additive pump.
1.9.18 Replacing the DPF additive tank

The DPF additive tank and the DPF additive system programming values must be reinitialised (erased) when
replacing the DPF additive tank.
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
1-46 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
2.1 DIAGNOSTIC CHARTS / FAULT CODES

5V SUPPLY
Diagnostic Diagnostic tool title Detection
trouble code
P0658 5V sensor supply (Vext1) - Low Sensor supply voltage less than 4.75 V
P0659 5V sensor supply (Vext1) - High Sensor supply voltage greater than 5.35 V
Fault LED Recovery mode
Certain recovery modes cannot be activated depending on the fault detection mode.
Accelerator pedal kickdown prevented
Illumination of the fault warning LED
y
Codes P0658, P0659, P2670, P2671, P2686 only :
p
ASR strategy in recovery mode
c
EGR control deactivated
o
e 10
VSL deactivated until the next DCU reset
c
Cruise Control deactivated until the next DCU reset
a n /20
Codes P0658, P0659, P2670, P2671 only :
v 09
Forced regeneration (after-market) forbidden
d
A 9/
Codes P2670, P2671, P0659 only :
"Degraded" performances (reduced flow mode)
0
Codes P0658, P0659 only :
Flowmeter plausibility strategy deactivated
Boost pressure regulation deactivated
EGR programming strategy deactivated
EGR diagnostics deactivated
CTR shut off
Engine speed set to 1300 rpm (limp home mode)
Air flap valve programming strategy deactivated
Air flap valve control deactivated
Air heater bypass valve programming strategy deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso
Manual, 308 Manual only)
Air heater bypass close request (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual only)
VGT "moving off" strategy prevented
VGT control deactivated
VGT programming strategy deactivated
Cruise control / Speed limiter deactivated
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-47

I DIAGNOSTICS
DETECTABLE FAULTS
5V SUPPLY
Air conditioning prevented
Illumination of the engine temperature warning LED
ASR deactivated
Timed engine stop
Rail discharge through injector for cylinder 1 deactivated
Post to post balancing strategy prevented
Inlet metering valve fully open
Multiple injection hydraulic compensation strategies deactivated
Rail overpressure detection strategy deactivated
y
Measurement of pressure rise time prevented
op
Rail pressure control fault detection prevented
c
Code P0659 only :
e 10
Speed limiter deactivated
c
n /20
Cruise control deactivated
a
v 09
d
A 9/
0
© Delphi
2-48 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Clutch position
Accel. pedal
46
Regulator 5V Air conditioning pressure
n°1 21
20
CH
Regulator 5V
n°2
EGR By-pass position
16
Internal DCU supply to 27
sensors Distribution of 5V 28
y
regulators EGR position TAR position
p
14 VGT position
o
15 Rail pressure
c
13
e 10
Regulator 5V CMI
c
n°3
a n /20
v 09
CRANK CAM
d
F1
A 9/
DPF ΔP
C4
0
B4 Manifold pressure
F2
E2
CME TAR By-pass position
DCU – DW10CTED4
Fault chart (Code P0658 - P0659 - P2670 - P2671 - P2685 - P2686)

Stage Operation / Decision Result
1 Check the component connections connected to the supply under Carry out required repairs.
investigation (see section Supply distribution)
Connection problem?
2 Visually inspect each component Replace the component
Component problem ?
3 Check DCU connection Carry out required repairs.
Connection problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-49

I DIAGNOSTICS
DETECTABLE FAULTS

4 Check the component line continuity and insulation connected to Carry out required repairs.
the supply under investigation (see section Supply distribution)
Line problem?
5 Disconnect each of the components connected to the supply under Replace the sensor or actuator that caused the fault.
investigation one by one (see section supply distribution) and delete
the fault codes after each disconnection and before reading the
fault codes again.
Did the fault disappear when one of the sensors or actuators was
disconnected?
6 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-50 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
BATTERY VOLTAGE
trouble code
P0562 Battery voltage - Low Battery voltage less than 6.5 Volts when the engine speed is greater than 1000
rpm.
P0563 Battery voltage - High Battery voltage greater than 16 Volts when the engine speed is greater than 1000
rpm.
BRC strategy for cylinder 1 injector deactivated
y
p
c o
e 10
c
Inhibited IMV drift detection strategy
n /20
Torque reduction under heavy load
a
v 09
d
Maximum rail pressure limit
A 9/
0
+ batt
Main supply relay
PC 28
20A
+ batt F1
PCC02 & PCC05
5A
F21 Fan
ERU unit
Secondary relay
PC 11
+ batt 15 A PCC 06
F05
F10 30 A PCC 01
F19 15 A PC 10
10 A PC 30
F20
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-51

I DIAGNOSTICS
DETECTABLE FAULTS
Fault chart (Code P0562 - P0563)

1 Check the battery voltage, ignition on Check and charge battery
Incorrect voltage ?
2 Check the battery voltage with the engine running Check charging circuit
Incorrect voltage ?
3 With the ignition on, check that the voltage reading using the Check the DCU supply line and the DCU earth
diagnostic tool corresponds to the voltage at the battery terminals
Is the value wrong?
4 With the engine running, check that the voltage reading using the Check the DCU supply line and the DCU earth
diagnostic tool corresponds to the voltage at the battery terminals
Is the value wrong?
5 Has the problem been resolved? Carry out required repairs.
Check the starter circuit (Wiring condition, terminals and starter
y
mounting tightness
p
Starter wiring problem
c o
6 Replace DCU
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-52 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU SUPPLY RELAY CONTROL

trouble code
P0215 DCU supply relay - Plausibility Relay closed without DCU request
or
Relay open without DCU request
P0685 Main relay control - Open circuit (OC) Main relay control circuit fault.
P0686 Main relay control - Short circuit to earth Main relay control circuit fault.
(SC-)
P0687 Main relay control - Short circuit to Vbat (SC Main relay control circuit fault.
+)
y
p
Code P0215 only :
c o
e 10
z +Batt ERU DCU ctrl
c
Injectors
Main supply relay PCC 05 + Batt DCU Injectors
Injectors
Gr.4
Injectors
.4.4
Gr
n /20
20A Gr
F1 PCC 02
Control
a
5A EGR valve
F21 Fan 1
v 09
Fan 2 By SV
d
DCU ctrl - pass TAR
PCC 06 IMC 17
15 A TAR SV
Relay
A 9/
F5 Managed by
DPF additive pump O2 probe heating Managed by
the DCU + Batt by the DCU
Dedicated CAN By SV-pass
shunt in
0
secondary EGR exchanger
the DCU
ERU Air flowmeter
Denox probe heater

(if present) Fuel heater
30A
PCC 01 IMC 05
F10 TM earth
TM earth
Blowby heater
ERU + Batt by
shunt in
the DCU IMV
Managed by
15A
F19 PC 18 IMC 29 VGT SV the DCU
Coolant temp
ERU heating SV + Batt by
shunt in
Managed by
the DCU the DCU
10A
F20
PC 30 IMC 41 Water detector TM earth
Pulsair pump relay CAN
30A
F14 fuse
Temp. heating pump
Coolant (PC heat
ERU depending on vehicles)
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-53

I DIAGNOSTICS
DETECTABLE FAULTS
Fault chart (Code P0215 - P0685 - P0686 - P0687)

1 Check relay connection Carry out required repairs.
Connection problem?
2 Check relay coil for on-line power Carry out required repairs.
Supply problem?
3 Check electrical continuity between relay coil terminals Replace relay
Open circuit?
Connection problem?
5 Use terminal box to check line continuity and electrical insulation Carry out required repairs.
Line problem?
6 Check the earthing points Carry out repairs required.
Earthing problem?
7 Does the problem persist?
p y Replace relay
o
8 Does the problem persist? Replace DCU
c
e 10
c
n /20
a
v 09
d
A 9/
0
© Delphi
2-54 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Rail pressure signal

trouble code
P0191 Rail pressure signal - Variation rate Instantaneous pressure variation too high.
P0192 Rail pressure signal - Low Rail pressure less than -112 bar
P0193 Rail pressure signal - High Rail pressure greater than 1912 bar
ASR deactivated
Timed engine stop
y
op
c
e 10
c
a n /20
v 09
d
A 9/
0
DCU
3 - 5v IMC 13 - 5V
Rail pressure IMC 40 - 0V
2 - 0V
sensor 1-S IMC 20 - S
Fault chart (Code P0191 - P0192 - P0193)

1 Check supply to sensor terminals Carry out required repairs.
Supply problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-55

I DIAGNOSTICS
DETECTABLE FAULTS

2 Check sensor connection Carry out required repairs.
Connection problem?
3 Check the electrical features (See Reference values Chapter) and Replace sensor / rail assembly
correlative value read with the expected value
Wrong features?
Connection problem?
Line problem?
6 Check the high pressure system (absence of leaks) Carry out required repairs.
Any leaks?
7 Replace sensor / rail assembly Replace DCU
y
Does the problem persist?
Note:
op
Check high pressure system:
c
e 10
c
n /20
a
1
d v 09
Carry out a hydraulic diagnostic check on the system using the Carry out required repairs.
A 9/
method supplied with the kit YDT465
High pressure problem detected
0
© Delphi
2-56 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
RAIL PRESSURE SIGNAL - DRIFT

trouble code
P1164 Rail pressure signal - drift Rail pressure sensor fault invalid value at startup ( Voltage < threshold Negative
drift of rail pressure at startup )
or
Rail pressure sensor fault invalid value at startup ( Voltage > threshold Positive
drift of rail pressure at startup )
or
Rail pressure sensor fault invalid value at startup ( Slow drift of rail pressure before
startup )
ASR deactivated
p y
o
c
e 10
c
n /20
Fast idle
a
v 09
d
A 9/
0
DCU
3 - 5v IMC 13 - 5V
2 - 0V
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-57

I DIAGNOSTICS
DETECTABLE FAULTS
Fault chart (Code P1164)

Supply problem?
Connection problem?
Wrong features?
Connection problem?
Line problem?
6 Replace sensor / rail assembly Replace DCU
y
op
c
e 10
c
n /20
a
v 09
d
A 9/
0
© Delphi
2-58 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
RAIL PRESSURE REGULATION

trouble code
P0087 Rail pressure regulation - Pressure Rail pressure too low compared with request
difference - Negative error
P0088 Rail pressure regulation - Pressure Rail pressure too high compared with request
difference - Positive error
P1166 Rail pressure regulation - Overpressure The measured rail pressure exceeds 1800 bar
P11AC IMV control - IMV current requested - The IMV is kept open for long periods, indicating a leak or an under capacity system.
Blocked open
P11AD Rail pressure signal - Pressure drop 250bar pressure drop in 30ms (probably an electrical problem, but that does not
exclude hydraulic faults).
P2291 Rail pressure regulation - Pressure rise - too Pressure rise in the rail too slow at startup
slow or
Rail pressure rise time greater than 2s.
p y
o
Timed engine stop c

Codes P0087, P0088, P1166, P11AC, P11AD only :
e 10
c
n /20
a
d v 09
A 9/
0
Codes P0087, P0088, P1166, P11AD only :
Codes P0087, P0088, P11AC only :
Codes P1166, P11AC, P11AD only :
Codes P1166, P11AD only :
Code P1166 only :
CTR shut off
Code P11AC only :
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-59

I DIAGNOSTICS
DETECTABLE FAULTS
RAIL PRESSURE REGULATION

Fast idle
Code P11AD only :
ASR deactivated
DCU
3 - 5v IMC 13 - 5V
2 - 0V
p y
c o
e 10
DCU
c
n /20
a
1 positive batt IMC 29
v 09
IMV
2 EMC D4
d
A 9/
0
© Delphi
2-60 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
8000rpm
100%
2200bar
2200bar
100mg/st
Requested rail pressure
Requested fuel
OCR IMV
Engine speed
Measured rail pressure

1800bar
1800bar
y
0mg/st
0rpm
0%
op Time
c
e 10
c
Fault chart (Code P0087 - P0088 - P1166 - P11AC - P11AD - P2291)
n /20
1
a
v 09
Carry out the electrical diagnosis of the IMV. Carry out required repairs.
d
Is there an electrical problem?
A 9/
2 Carry out the diagnosis of the HP sensor. Carry out required repairs.
0
HP sensor problem?
3 Check low pressure circuit Carry out required repairs.
Low pressure circuit problem?
4 Check high pressure circuit Carry out required repairs.
High pressure circuit problem?
5 Check the injectors and the HP pump Carry out required repairs.
Component problem ?
6 Replace or update the DCU
Note:
Check low pressure circuit:

1 Check there is fuel in the fuel tank Fill tank
Tank empty?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-61

I DIAGNOSTICS
DETECTABLE FAULTS

2 Visually inspect the fuel supply and return hosing: Carry out required repairs.
- Look for leaks or air leaks,
- Check connections,
- Priming bulb valve conformance (if present),
- Quick release connections.
Is there a problem with the exhaust system?
3 Check there is no air in low pressure system Bleed the supply circuit
Is there air in the low pressure circuit?
4 Check the transfer pump return flow Low pressure circuit is OK
Flow within tolerance ?
5 Flow too high? Check the transfer pressure regulation
6 Check diesel filter reference Replace filter with original part
y
Incorrect filter reference number?
7 Check fuel filter for clogging
op Replace filter
c
Filter clogged?
e 10
8 Check for foreign bodies around the intake screen or in the supply Carry out required repairs.
c
circuit
Any foreign bodies?
a n /20
v 09
9 Low pressure circuit is OK
Note:
Check high pressure system: d
A 9/
Stage
0
Operation / Decision Result
1 Carry out a hydraulic diagnostic check on the system using the Carry out required repairs.
High pressure problem detected
Note:
IMV electrical diagnosis :

1 Check actuator connection Carry out required repairs.
Connection problem?
2 Check actuator coil for on-line power Carry out required repairs.
Supply problem?
3 Check actuator coil terminal resistance Replace actuator
Incorrect resistance?
© Delphi
2-62 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

Connection problem?
Line problem?
6 Does the problem persist? Replace actuator
Note:
Rail pressure sensor electrical diagnosis :

Supply problem?
p y
o
Connection problem?
c
e 10
c
n /20
a
Wrong features?
4 Check DCU connection
d v 09 Carry out required repairs.
A 9/
Connection problem?
6
Line problem?
Replace sensor / rail assembly 0 Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-63

I DIAGNOSTICS
DETECTABLE FAULTS
INLET METERING VALVE CONTROL (IMV)

trouble code
P0001 Inlet metering valve control - Open circuit IMV control open circuit (OC)
(OC)
P0002 IMV control - IMV current requested - IMV control current Not plausible
Plausibility
P0003 Inlet metering valve control - Short circuit IMV control short circuit to earth (CC-)
to earth (SC-)
P0004 Inlet metering valve control - Short circuit IMV control short circuit to Vbat (CC+)
to Vbat (SC+)
P2295 Inlet metering valve control - Low IMV control line resistance estimate too low.
P2296 Inlet metering valve control - High IMV control line resistance estimate too high.
p y
o
c
e 10
Codes P0001, P0004, P0003, P2296, P2295 only :
c
n /20
a
d v 09
Codes P0001, P0003, P0004, P2296, P2295 only :
A 9/
Codes P0001, P0004, P0003, P0002 only :
0
Codes P0001, P0004, P0003 only :
Code P0002 only :
Timed engine stop
Fast idle
© Delphi
2-64 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU

IMV
2 EMC D4
Pin 1 (YDT246) Pin 2

Pin 1
2V/div -
IMV control voltage -
p y Measurement : IMC -29 Measurement : -
c o Reference: EMC-D4 Reference: -
c e 10
n /20
Time base : 1ms/div
a
F=300Hz OCR=12%
v 09
Conditions : pre-starting
d
A 9/
Pin 1 0 Pin 1 (YDT246) Pin 2
2V/div -
Measurement : IMC -29 Measurement : -
Reference: EMC-D4 Reference: -
Time base : 1ms/div

F=300Hz OCR=40%
Conditions : Warm engine idle

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-65

I DIAGNOSTICS
DETECTABLE FAULTS
Pin 1 Pin 1 (YDT246) Pin 2
2V/div -
Time base : 1ms/div

F=377Hz OCR=40%
Conditions : 2000 rpm
y
p
o
c
e 10
Connection problem?
2 Check actuator coil for on-line power
c
n /20
Carry out required repairs.
a
Supply problem?
3
d v 09
Check actuator coil terminal resistance Replace actuator
A 9/
5
Connection problem?
0
Use terminal box to check line continuity and electrical insulation
Line problem?

© Delphi
2-66 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
VLC STRATEGY
trouble code
P0093 Fuel flow correction too high – VLC strategy Torque correction has reached a very high value (around 70Nm)
P0094 Fuel flow correction too high – VLC strategy Torque correction has reached a high value (around 50Nm)
Timed engine stop
y
Code P0093 only :
p
o
c
e 10
c
n /20
1 Carry out the electrical diagnosis of the IMV. Carry out required repairs.
a
v 09
d
2 Carry out the diagnosis of the HP sensor. Carry out required repairs.
A 9/
HP sensor problem?
0
3 Check low pressure circuit Carry out required repairs.
Low pressure circuit problem?
4 Check high pressure circuit Carry out required repairs.
High pressure circuit problem?
5 Check the injectors and the HP pump Carry out required repairs.
Component problem ?
6 Replace or update the DCU
Note:
Check low pressure circuit:

Tank empty?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-67

I DIAGNOSTICS
DETECTABLE FAULTS

- Look for leaks or air leaks,
- Priming bulb valve conformance (if present),
3 Check there is no air in low pressure system Bleed the supply circuit
Is there air in the low pressure circuit?
4 Check the transfer pump return flow Low pressure circuit is OK
Flow within tolerance ?
5 Flow too high? Check the transfer pressure regulation
y
7 Check fuel filter for clogging
op Replace filter
c
Filter clogged?
e 10
8 Check for foreign bodies around the intake screen or in the supply Carry out required repairs.
c
circuit
Any foreign bodies?
a n /20
v 09
Note:
Check high pressure system: d
A 9/
Stage
0
1 Carry out a hydraulic diagnostic check on the system using the Carry out required repairs.
High pressure problem detected © Delphi
2-68 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
C2I/C3I FAULT
trouble code
P1600 C2I/C3I fault C3I(s) not coded, invalid or corrupt DCU memory
or
C3I(s) corrupted
ASR deactivated
Illumination of the "SAFETY" warning LED
y
p
o
c
e 10
c
a n /20
d v 09
A 9/
0
Cylinder number
Timing side 4 3 2 1
Injector number
3 2 4 1

1 Read the C3Is recorded in the DCU with the diagnostic tool Write the C3Is using the diagnostic tool then check the write process
Do the C3I correspond to the injectors ? has been correctly completed
2 Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-69

I DIAGNOSTICS
DETECTABLE FAULTS
CAMSHAFT REFERENCE SIGNAL

trouble code
P0341 Camshaft reference signal - Incorrect The camshaft signal does not arrive when expected (incorrect synchronisation with
synchronisation the flywheel)
P0342 Camshaft reference signal - Absent The DCU has not detected an event on an engine cycle.
P0343 Camshaft reference signal Engine speed measured at the camshaft has exceeded 8000rpm.
Without
DCU
3 - 0v IMC 39
HALL
2-S EMC E1
CAM sensor CAM
y
1 - 5V EMC F1
op
c
e 10
c
n /20
a
Pin 1 (YDT246) Pin 2 (YDT246)
d v 09
Pin 2
A 9/
1V/div 1V/div
0
Engine speed signal Camshaft signal
Measurement : EMC-G1 Measurement : EMC-E1
Reference: IMC -38 Reference: IMC -38
Pin 1 Time base : 20ms/div
Conditions : Idling
© Delphi
2-70 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

Pin 2
1V/div 1V/div
Pin 1 Time base : 5 ms/div
p y
o
c
Pin 2
e 10
1V/div 1V/div
c
n /20
a
v 09
d
A 9/
Pin 1
0 Time base : 20ms/div
Conditions : Idling

1 Check the supply to the sensor terminals Carry out required repairs.
Supply problem?
Connection problem?
3 Check the sensor condition, mounting and the conformance of the Carry out required repairs.
air gap
Is there a wiring or connection problem?
Connection problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-71

I DIAGNOSTICS
DETECTABLE FAULTS

Line problem?
6 Does the problem persist? Replace sensor
7 Check the target timing Carry out required repairs.
Is there a timing problem?
8 Check target Replace target
Target problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-72 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ENGINE SPEED SIGNAL

trouble code
P0336 Engine speed signal - Absent Too many consecutive teeth not detected.
P0338 Engine speed signal - Additional teeth One or more additional non-consecutive teeth detected in a revolution
P0339 Engine speed signal - Gap not detected Long tooth not detected.
p y DCU
3 - 5v
c o EMC F1
e 10
HALL
2-S EMC G1
CRANK sensor CRANK
c
1 - 0V IMC 38
a n /20
d v 09
A 9/
0 Pin 2
Pin 1 (YDT246)
1V/div
Pin 2 (YDT246)
1V/div
Conditions : Idling
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-73

I DIAGNOSTICS
DETECTABLE FAULTS

Pin 2
1V/div 1V/div
p y
o
c
Pin 2
e 10
1V/div 1V/div
c
n /20
a
v 09
d
A 9/
Pin 1
Conditions : Idling

Supply problem?
Connection problem?
3 Check the sensor condition, mounting and the conformance of the Carry out required repairs.
air gap.
Is there a wiring or connection problem?
Connection problem?
© Delphi
2-74 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

Line problem?
6 Does the problem persist? Replace sensor
7 Check target Replace target
Target problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-75

I DIAGNOSTICS
DETECTABLE FAULTS
DCU FAULT - EEPROM INTEGRITY

trouble code
P0603 DCU fault - EEPROM DCU DCU NVM (Non Volatile Memory) integrity (EEPROM) fault
ASR deactivated
y
p
o
c
e 10
c
a n /20
v 09
d
A 9/
0
Timed engine stop
Immediate engine stop

1 Check that the installation (DCU and/or support) (condition, torque, Carry out required repairs.
orientation...) conforms to specification
installation problem?
2 Check the connections of the DCU(particularly earth and supply) Carry out required repairs.
Connection problem?
3 Check the electrical continuity of the wires (earth and supply) Carry out required repairs.
Line problem?
4 Check battery clamps condition and tightness Carry out required repairs.
Battery connection problem
© Delphi
2-76 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

5 Carry out earthing checks Carry out required repairs.
Earthing problem
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-77

I DIAGNOSTICS
DETECTABLE FAULTS
DCU FAULT - RAM INTEGRITY

trouble code
P0604 DCU fault - RAM integrity
"SAFETY" warning lamp on (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
Immediate engine stop (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)

Connection problem?
p y
o
Line problem?
c
e 10
c
n /20
a
Earthing problem
d v 09
A 9/
0
© Delphi
2-78 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU FAULT
trouble code
P0605 DCU fault - Calibration zone
P0606 DCU FAULT DCU internal fault
P1621 DCU monitoring - Fault detected DCU internal fault
P162A DCU monitoring - Fault detected DCU internal fault
P1631 DCU monitoring - Fault detected DCU internal fault
Codes P0606, P162A only :
y
p
Immediate engine stop (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
o
c
Code P0606 only :
e 10
c
Code P1621 only :
a n /20
v 09
d
A 9/
Code P162A only :
0
Fault chart (Code P0605 - P0606 - P1621 - P162A - P1631)

Connection problem?
Line problem?
Earthing problem
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-79

I DIAGNOSTICS
DETECTABLE FAULTS
FAN DIAGNOSTIC
trouble code
P0481 Fan diagnostic - Control blocked Fan relay fault
P0483 Fan diagnostic – consistency Fan status not determined (may be seized)
P0485 Fan diagnostic - fault detected Fan control short circuit detected
or
Chopper fault
P0493 Fan diagnostics No speed on Twin speed fan
P0494 Fan diagnostics Speed too low with dual-speed fan
P0495 Fan diagnostic - fault detected If dual-speed fan, speed too high
or
If variable speed fan, Short circuit to earth on fan speed circuit
or
y
If variable speed fan, Short circuit to vbat or Open Circuit on the fan
op or
c
If variable speed fan, short circuit detected on power supply line
e 10
c
n /20
a
Codes P0493, P0495, P0483, P0485 only :
v 09
d
A 9/
0
CTR shut off
DPF regeneration forbidden
Code P0495 only :
Engine overheat warning activation thresholds lowered
Dashboard air conditioning request

Fan control
VAN H CAN H
Refrigerant fluid
Air conditioning DCU BSI Injection DCU pressure sensor
(pressostat)
VAN L CAN L
Compressor control Injection parameter

adjustment
© Delphi
2-80 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU
PC 13
FAN1 CONTROL
PCC12
Fan 2 control
PCC26
Fan diagnostics

1 Check the connection of the fan control relay Carry out required repairs.
Connection problem?
y
Connection problem?
p
3 Check line continuity and electrical insulation Repair wiring harness
Line problem?
c o
e 10
4 Replace the relay and start the ISO fan cycle Change DCU
c
5 Problem is resolved
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-81

I DIAGNOSTICS
DETECTABLE FAULTS
FAN1 CONTROL
trouble code
P0691 Fan 1 control - Open circuit (OC) or short Fan 1 control electrical fault (Open circuit)
circuit to earth (SC-) or
Fan 1 control electrical fault (SC-)
P0692 Fan 1 control - Short circuit to Vbat (SC+) Fan 1 control electrical fault (SC+Vbat)
CTR shut off
High fan speed activated
y
p
o
c
e 10
DCU
FAN1 CONTROL
c
n /20
PC 13
Fan 2 control
a
v 09
PCC12
d
A 9/
PCC26
Fan diagnostics

0
1 Check the connection of the fan 1 control relay Carry out required repairs.
Connection problem?
Connection problem?
Line problem?
4 Replace the relay and start the ISO fan 1 cycle Change DCU
© Delphi
2-82 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
FAN2 CONTROL
trouble code
P0693 Fan 2 control - Open circuit (OC) or short Fan 2 control electrical fault (Open circuit)
circuit to earth (SC-) or
Fan 2 control electrical fault (SC-)
P0694 Fan 2 control - Short circuit to Vbat (SC+) Fan 2 control electrical fault (SC+Vbat)
CTR shut off
y
op
c
DCU
c e 10
PC 13
FAN1 CONTROL
n /20
PCC12
a
Fan 2 control
v 09
PCC26
d
Fan diagnostics
A 9/
Stage
0
1 Check the connection of the fan 2 control relay Carry out required repairs.
Connection problem?
Connection problem?
Line problem?
4 Replace the relay and start the ISO fan 2 cycle Change DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-83

I DIAGNOSTICS
DETECTABLE FAULTS
INLET AIR HEATER CONTROL

trouble code
P1403 Additional heating 1 control Additional heating1 control open circuit (OC)
or
Additional heating1 control short circuit to Vbat (SC+)
or
Additional heating1 control short circuit to earth (SC-)
P1404 Additional heating 2 control Additional heating2 control open circuit (OC)
or
Additional heating2 control short circuit to Vbat (SC+)
or
Additional heating2 control short circuit to earth (SC-)
y
Without
op
c
e 10
c
1 Check relay connection Carry out required repairs.
n /20
Connection problem?
2 Check relay coil for on-line power
a
v 09
d
Supply problem?
A 9/
3 Check electrical continuity between relay coil terminals Replace relay
0
Open circuit?
Connection problem?
Line problem?
6 Check the earthing points Carry out repairs required.
Earthing problem?
7 Does the problem persist? Replace relay
© Delphi
2-84 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
PPH diagnostics
trouble code
P1351 PPH diagnostic
Preheating warning lamp lit
12V DCU
0v
PPH unit IMC 47 (diag)
EMC H4 (cde)
p y
c o
e 10
Stage
c
n /20
a
1 Check the pre-postheating unit connections Carry out required repairs.
v 09
Connection problem?
Connection problem? d
A 9/
4
Line problem? 0
Check line continuity and electrical insulation
Replace the pre-post heating unit

Repair wiring harness
Change DCU
Does the problem persist? ?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-85

I DIAGNOSTICS
DETECTABLE FAULTS
PPH CONTROL
trouble code
P1349 PPH relay control - Open circuit (OC) or short PPH relay control electrical fault (OC)
circuit to Vbatt (SC+) or
Preheating plug control electrical fault (OC, SC+)
P1350 PPH relay control - Short circuit to earth (SC-) Short circuit to earth (SC-) the plugs are continuously supplied
Preheating warning lamp lit
Code P1350 only :
p y DCU
12V
c o
e 10
0v
PPH unit IMC 47 (diag)
c
EMC H4 (cde)
a n /20
d v 09
A 9/
0
DCU
PCC 07
heater 1 control Or burner
PC 16
Heater 2 command

1 Check the preheating unit (PPH) connection Carry out required repairs
Is there a connection problem?
2 Check DCU connection Carry out required repairs
Is there a connection problem?
3 Use the terminal box to check control line continuity and electrical Carry out required repairs
insulation
Line problem?
4 Does the problem persist? Replace the preheating unit
© Delphi
2-86 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-87

I DIAGNOSTICS
DETECTABLE FAULTS
INJECTOR UNIT 1 CONTROL DIAGNOSTIC

trouble code
P2147 Bank injector 1 diagnostic - High Internal DCU detection, the HSD voltage is greater than 3V
P2148 Bank injector 1 diagnostic - Low Internal DCU detection, the HSD voltage is less than 1V
Fast idle
y
p
o
c
e 10
c
a n /20
v 09
d
A 9/ DCU
cylinder N° 1 0 EMC M4
EMC L1
EMC M1
cylinder N° 2 EMC L2
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
© Delphi
2-88 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Pin 1 (YDT471 / Ammeter

clamp 100mV/A) Pin 2 (YDT471)
Separate pilot Close pilot Main
5A/div 10V/div
Injector control current Injector control voltage

cylinder 4 cylinder 4
Pin 1
Measurement : - Measurement : EMC-L3
Reference: - Reference: EMC-L4
Pin 2
Time base : 1ms/div
y
Main injection
Pin 2 (YDT471)
p
clamp 100mV/A)
c o
Pin 1 5A/div 10V/div
e 10
c
n /20
a
v 09
d
A 9/
Pin 2
0
Time base : 100µs/div
CAUTION
- Limit number of injector disconnections as far as possible.
- When replacing an injector, the C3I for the new injector should be entered into the DCU.

1 Switch off the ignition and check the injector connection Carry out required repairs.
Connection problem?
2 Disconnect the injectors and switch on the ignition Check the injector harnesses
3 Delete the fault then switch the ignition off. Reconnect only one Replace the injector detected as faulty.
injector and switch the ignition back on
Does the problem reappear ?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-89

I DIAGNOSTICS
DETECTABLE FAULTS

4 Repeat the above operation on each injector one by one Replace the injector(s) concerned.
Do one or more injectors cause the fault to reappear?
5 Check the DCU location, condition and supply
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-90 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INJECTOR UNIT 2 CONTROL DIAGNOSTIC

trouble code
P2150 Bank injector 2 diagnostic - High Injector control SC+ or SC-
P2151 Bank injector 2 diagnostic - Low Injector control SC+ or SC-
Fast idle
y
p
o
c
e 10
c
a n /20
v 09
d
A 9/ DCU
EMC L1
EMC M1
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-91

I DIAGNOSTICS
DETECTABLE FAULTS

5A/div 10V/div

Pin 1
Pin 2
Time base : 1ms/div
y
Main injection
Pin 2 (YDT471)
p
clamp 100mV/A)
c o
e 10
c
n /20
a
v 09
d
A 9/
Pin 2
0
CAUTION

1 Switch off the ignition and check the injector connection Carry out required repairs.
Connection problem?
2 Disconnect the injectors and switch on the ignition Check the injector harnesses
3 Delete the fault then switch the ignition off. Reconnect only one Replace the injector detected as faulty.
injector and switch the ignition back on
Does the problem reappear ?
© Delphi
2-92 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

4 Repeat the above operation on each injector one by one Replace the injector(s) concerned.
Do one or more injectors cause the fault to reappear?
5 Check the DCU location, condition and supply
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-93

I DIAGNOSTICS
DETECTABLE FAULTS
INJECTOR - COMBUSTION TOO WEAK

trouble code
P12A2 Injector - Combustion too weak - Cylinder 1 The instantaneous engine speed at the instant of injection on cylinder 1 is too low
compared with the average engine speed over one cycle.
P12AB Injector - Combustion too weak - Cylinder 4 The instantaneous engine speed at the instant of injection on cylinder 4 is too low
ASR deactivated
Fast idle
p y
o
c
e 10
c
n /20
a
d v 09
A 9/ DCU
EMC L1
EMC M1
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
Cylinder number
Timing side 4 3 2 1
Injector number
3 2 4 1
© Delphi
2-94 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

5A/div 10V/div

Pin 1
Pin 2
Time base : 1ms/div
y
Main injection
p
clamp 100mV/A)
Pin 2 (YDT471)
Pin 1
c o 5A/div 10V/div
e 10
c
a n /20 Measurement : - Measurement : EMC-L3
d v 09 Reference: - Reference: EMC-L4
A 9/ Pin 2
0
First check there is no fault code present relating to the electrical diagnosis of the injectors.
Fault chart (Code P12A2 - P12A5 - P12A8 - P12AB)
1 Check fuel conformance Drain, clean and conform to specification (filter...).
Fuel does not conform to specification?
2 Check cylinder seal-tightness (check for internal and external leaks). Carry out required repairs.
Cylinder sealing problem?
3 Check the compression status Carry out required repairs.
Compression problem?
4 Check air inlet system Clean inlet circuit
Inlet circuit blocked?
5 Check EGR operation. Temporarily neutralize EGR for the test as Carry out required repairs.
needed.
EGR problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-95

I DIAGNOSTICS
DETECTABLE FAULTS
Fault chart (Code P12A2 - P12A5 - P12A8 - P12AB)

6 Carry out hydraulic test on injector using external and bench tests Replace injector.
Injector faulty?
7 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-96 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INJECTOR - MDP CORRECTION DRIFT

trouble code
P0263 Injector - MDP drift - Cylinder 1 MDP correction value outside tolerance
or
Post correction MDP value outside tolerance
or
or
or
y
op
c
e 10
Fast idle
c
Code P0263 only :
a n /20
v 09
Code P0266 only :
d
A 9/
Code P0269 only :
0
Code P0272 only :
Cylinder number
Timing side 4 3 2 1
Injector number
3 2 4 1
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-97

I DIAGNOSTICS
DETECTABLE FAULTS
DCU
3 - 5v EMC F1
HALL
2-S EMC G1
CRANK sensor CRANK
1 - 0V IMC 38

5A/div 10V/div

Pin 1
p y
c o Reference: - Reference: EMC-L4
e 10
Pin 2
c
Time base : 1ms/div
a n /20 Conditions : Warm engine idle
d v 09
A 9/
Main injection
0

Pin 2

1 Use diagnostic tool to read out MDP corrections for all injectors. Check fuel conformance
All the injectors show significant drift given the vehicle km
© Delphi
2-98 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

2 If only the injector concerned shows significant drift, use diagnostic Rewrite the C3I, erase fault codes and check if fault has disappeared
tool to check its C3I compliance following a road test by using diagnostic tool to check MDP up-
C3I non compliance dating.
3 Check fuel conformance Drain, clean and conform to specification (filter...).
Fuel does not conform to specification?
4 Check cylinder seal-tightness (check for internal and external leaks). Carry out required repairs.
Cylinder sealing problem?
5 Check the compression status Carry out required repairs.
Compression problem?
6 Does the problem persist? Replace injector concerned.
7 Does the problem persist? Replace the injector control harness.
8 Does the problem persist? Consult the vehicle manufacturer network
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-99

I DIAGNOSTICS
DETECTABLE FAULTS
INJECTOR RESET ABSENT

trouble code
P0611 Absence of injector reset MDP reset conditions not satisfied
P1163 MDP UPDATE The system can no longer reset one or several reset zones.
p y Cylinder number
o
Timing side 4 3 2 1
c
e 10
3
c
n /20
2 4 1
Injector number
a
v 09
d
A 9/
0
DCU
3 - 5v EMC F1
HALL
2-S EMC G1
CRANK sensor CRANK
1 - 0V IMC 38

1 Drive the vehicle, preferably on a fast road, until the MDP corrections
are updated.
© Delphi
2-100 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INJECTOR - OPEN CIRCUIT

trouble code
P0201 Injector - Open circuit - Cylinder 1 Current rise time too long
Fast idle
y
p
o
c
Code P0201 only :
e 10
c
Code P0202 only :
a n /20
v 09
Code P0203 only :
d
A 9/
Code P0204 only :
0
DCU
EMC M4
cylinder N° 1
EMC L1
EMC M1
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-101

I DIAGNOSTICS
DETECTABLE FAULTS
Cylinder number
Timing side 4 3 2 1
Injector number
3 2 4 1
CAUTION
y
p
1 Check the IMV connection
c o Carry out required repairs.
e 10
Connection problem?
c
2 Use multimeter to check electrical continuity between the two Replace injector.
n /20
injector terminals
Open circuit?
a
v 09
d
A 9/
Connection problem?
0
Line problem?
© Delphi
2-102 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INJECTOR CONTROL - HARNESS RESISTANCE

trouble code
P1366 Cylinder 1 injector control - harness The line resistance calculated from the control current is less than 195mOhm
resistance - Low
resistance - Low
resistance - Low
resistance - Low
P1372 Cylinder 1 injector control - harness The line resistance calculated from the control current is greater than 580mOhm
resistance - High
resistance - High
y
resistance - High
op
c
e 10
resistance - High
c
a n /20
v 09
d
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-103

I DIAGNOSTICS
DETECTABLE FAULTS
DCU
EMC M4
cylinder N° 1
EMC L1
EMC M1
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
Cylinder number
Timing side 4 3 2 1
p y
3
c o2 4 1
Injector number
c e 10
a n /20
d v 09 Pin 1 (YDT471 / Ammeter
Pin 2 (YDT471)
A 9/
clamp 100mV/A)
0
5A/div 10V/div

Pin 1
Pin 2
Time base : 1ms/div

© Delphi
2-104 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Main injection

Pin 2
Note:
y
p
c o
e 10
Fault chart (Code P1366 - P1367 - P1368 - P1369 - P1372 - P1373 - P1374 - P1375)
c
1 Check the IMV connection
a n /20 Carry out required repairs.
v 09
Connection problem?
d
Connection problem?
A 9/
0
3 Replace injector. Replace the injector wiring harness
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-105

I DIAGNOSTICS
DETECTABLE FAULTS
INJECTOR - SHORT CIRCUIT

trouble code
P0262 Injector - Short circuit - Cylinder 1 Current rise time too short
Fast idle
y
p
o
c
e 10
Code P0262 only :
c
a n /20
v 09
Code P0265 only :
d
A 9/
0
Code P0268 only :
Code P0271 only :
DCU
EMC M4
cylinder N° 1
EMC L1
EMC M1
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
© Delphi
2-106 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Cylinder number
Timing side 4 3 2 1
Injector number
3 2 4 1
Note:

Stage
p
Operation / Decision
y Result
o
1 Check the IMV connection Carry out required repairs.
Connection problem?
c
e 10
c
2 Use multimeter to check electrical insulation between coil terminal Replace injector.
n /20
and injector body
a
Short circuit?
A 9/
Connection problem?
5
Line problem?
Replace injector.
0 Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-107

I DIAGNOSTICS
DETECTABLE FAULTS
MANIFOLD AIR TEMPERATURE SIGNAL

trouble code
P0096 Manifold air temperature signal - Variation greater than 99 /s
Plausibility
P0097 Manifold air temperature signal - Low The raw temperature value is less than 20 (Temperature > 200 approx.)
P0098 Manifold air temperature signal - High The raw temperature value is greater than 1000 (Temperature < -40 approx.)
y
ECU
op
c
t° 4 – S press CMI 32
Turbo air 3 – 0V CMI 52
e 10
P
temperature & 2 – 5V CME F2
c
pressure sensor CMI 08
1 – S temp
a n /20
d v 09
A 9/
0
Connection problem?
2 Measure the resistance at the sensor terminals (sensor Replace sensor
disconnected) (See section Reference values) and compare the
reading value with the expected value
Connection problem?
Line problem?
5 Replace DCU
© Delphi
2-108 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
AIR FLOWMETER SIGNAL

trouble code
P0101 Air flowmeter signal - Variation rate The variation in flow is greater than 2000 g/s/s
P0102 Air flowmeter signal - High Air flowmeter signal above maximum threshold
or
Flowmeter supply fault
P0103 Air flowmeter signal - Low Air flowmeter signal below minimum threshold
P2710 Air flowmeter signal - plausibility - Low The DCU checks the consistency of the flowmeter High drift in the functional range
(threshold stricter than EOBD)
P2710 Air flowmeter signal - plausibility- EOBD Measured airflow too high compared to calculated flow (EOBD threshold)
or
Measured airflow too low compared to calculated flow (EOBD threshold)
P2710 Air flowmeter signal - plausibility - High The DCU checks the consistency of the flowmeter Low drift in the functional range
y
p
P3007 Air flowmeter signal - plausibility- EOBD Measured airflow too high compared to calculated flow (EOBD threshold)
P3008
c o
Air flowmeter signal - plausibility- EOBD Measured airflow too low compared to calculated flow (EOBD threshold)
e 10
P3026 Air flowmeter signal - plausibility - High The DCU checks the consistency of the flowmeter Low drift in the functional range
c
n /20
P3027 Air flowmeter signal - plausibility - Low The DCU checks the consistency of the flowmeter High drift in the functional range
a
d v 09
A 9/
Codes P0101, P3007, P2710, P3008, P0103, P0102 only :
0
Change to calculated flow mode.
Codes P0101, P3007, P2710, P3008 only :
Codes P0101, P0103, P0102 only :
Codes P3007, P2710, P3008 only :
CTR shut off
Code P0101 only :
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-109

I DIAGNOSTICS
DETECTABLE FAULTS
DCU
4-S EMC F3
t° 2 - 0V EMC A4
Flowmeter with air
temperature sensor 1-S EMC C3
Q 3
L
IMC 17
+ Batt ERU
Turbocharging pressure sensor

Inlet air flap
Boost air temperature sensor
Air filter Flowmeter Compressor Exchanger
EGR valve
Inlet air temperature sensor
y
Inlet air heater bypass flap
p
valve
Particle filter differential
Exchanger
o
pressure
c
Cooling circuit
EGR cooler
e 10
bypass valve
c
converter
Particule
Catalytic
filter
CTR
n /20
Precatalyser Turbine
exchanger
Pre-DPF sensor
a
v 09
Oxygen probe
Note: d
A 9/
0
Process the turbo pressure plausibility defects first.
Fault chart (Code P0101 - P0102 - P0103 - P2710 - P2710 - P2710 - P3007 - P3008 - P3026 - P3027)
1 Check the condition of the air line Carry out required repairs.
(Tightness of clips, contamination, incorrect fitting, presence of
water,...)
Air line problem?
Supply problem?
3 Check the connection of the DCU Carry out required repairs.
Connection problem?
4 Check the electrical features (See Reference values Chapter) and Replace the flowmeter
Wrong features?
Connection problem?
© Delphi
2-110 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Fault chart (Code P0101 - P0102 - P0103 - P2710 - P2710 - P2710 - P3007 - P3008 - P3026 - P3027)
Line problem?
7 Replace the flowmeter Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-111

I DIAGNOSTICS
DETECTABLE FAULTS
FUEL TEMPERATURE SIGNAL

trouble code
P0181 Fuel temperature signal - Variation rate Variation greater than 99 /s
P0182 Fuel temperature signal - Low The raw temperature value is less than 35 (Temperature > 140 approx.)
P0183 Fuel temperature signal - High The raw temperature value is greater than 1000 (Temperature < -30 approx.)
CTR shut off
CTR pump prevented
p y
o
DCU
t° 1-S
c
e 10
EMC J3
c
Fuel temperature sensor 2 - 0V EMC A4
a n /20
d v 09
A 9/
Stage
1 Check sensor connection
0
Result
Connection problem?
Connection problem?
Line problem?
5 Replace DCU
© Delphi
2-112 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
COOLANT TEMPERATURE SIGNAL

trouble code
P0115 Coolant temperature signal - Plausibility The engine is hot after running for a certain time, but the sensor indicates a low
temperature
P0116 Coolant temperature signal - Variation rate Variation greater than 99 /s
P0117 Coolant temperature signal - Low The raw temperature value is less than 30 (Temperature > 140 approx.)
P0118 Coolant temperature signal - High The raw temperature value is greater than 1000 (Temperature < -40° approx.)
CTR shut off
y
CTR pump prevented
p
Fan high speed activation at engine stop
c
o
e 10
c
n /20
a
v 09
d
A 9/ DCU
Coolant temperature sensor

0
t° 2 - 0V
1-S
EMC B2
EMC H3

Connection problem?
Connection problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-113

I DIAGNOSTICS
DETECTABLE FAULTS

Line problem?
5 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-114 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INLET AIR TEMPERATURE SIGNAL

trouble code
P0111 Inlet air temperature signal - Plausibility Variation greater than 99 /s
P0112 Inlet air temperature signal - Low The raw temperature value is less than 40 (Temperature > 130 approx.)
P0113 Inlet air temperature signal - High The raw temperature value is greater than 950 (Temperature < -40° approx.)
CTR shut off
DCU
y
4-S EMC F3
t°
p
2 - 0V EMC A4
Flowmeter with air
o
temperature sensor 1-S EMC C3
c
Q 3
L
e 10
IMC 17
+ Batt ERU
c
n /20
a
v 09
Stage
1 d
A 9/
Check if the sensor value is consistent Correct temperature sensor
Result
2
(Dynamic parameters)
Is the value consistent? 0
Check the 12V supplies to the flowmeter
Reproduce the appearance of the fault with the environment data

Supply problem?
Connection problem?
4 Measure the characteristics at the sensor terminals Change sensor
(Voltage or resistance)
Is there a characteristic problem?
Connection problem?
6 Check the continuity and the electrical insulation of the line Repair wiring harness
Line problem?
7 Change DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-115

I DIAGNOSTICS
DETECTABLE FAULTS
PRE-DPF TEMPERATURE SIGNAL

trouble code
P1412 Pre-DPF temperature signal - Reduced flow
mode
P2031 Pre-DPF temperature signal - Plausibility Consistency fault
P2032 Pre-DPF temperature signal - High The raw temperature value after the catalyser is greater than 1010 (Temperature
< 100 approx.)
P2033 Pre-DPF temperature signal - Low The raw temperature value after the catalyser is less than 70 (Temperature above
700 )
P2084 Pre-DPF temperature signal - Variation rate The variation in the temperature after the catalyser is greater than 200 (converter
raw value)/s
Codes P2033, P2032, P2031, P2084 only :
p y
o
Code P1412 only :
c
e 10
c
n /20
a
EOBD LED on
d v 09
A 9/
0 DCU
2 EMC B3
t°
Diesel temp. Pre-DPF EMC J1
1-S
Fault chart (Code P1412 - P2031 - P2032 - P2033 - P2084)

Connection problem?
© Delphi
2-116 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Fault chart (Code P1412 - P2031 - P2032 - P2033 - P2084)

Connection problem?
Line problem?
5 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-117

I DIAGNOSTICS
DETECTABLE FAULTS
TURBOCHARGING PRESSURE SIGNAL

trouble code
P006D Manifold pressure signal - Plausibility The DCU checks the consistency between the manifold pressure and the
atmospheric pressure
P0235 Manifold pressure signal - Drift The manifold pressure is outside tolerance at key on.
P0236 Manifold pressure signal - Variation rate Air pressure variation too quick
P0237 Manifold pressure signal - Low Detection of open circuits, short circuits to earth.
P0238 Manifold pressure signal - High Detection of short circuits to +Vbat
y
p
CTR shut off
c o
e 10
c
a n /20
v 09
d
A 9/
0
Codes P0237, P0238, P0236, P0235 only :
Codes P0237, P0238, P0236 only :
© Delphi
2-118 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ECU
Turbo air P 3 – 0V CMI 52
1 – S temp
Note:
Plausibility and/or variation rate fault
Fault chart (Code P006D - P0235 - P0236 - P0237 - P0238)

1 Compare the boost pressure with the atmospheric pressure with Replace the boost pressure sensor
the engine stopped.
p y
o
Is the boost pressure value inconsistent ?
c
2 Is the atmospheric pressure value inconsistent ? Replace DCU
e 10
3 Is the atmospheric pressure value inconsistent ? Replace DCU
4 Replace DCU
c
n /20
a
v 09
Fault chart (Code P006D - P0235 - P0236 - P0237 - P0238)
Stage
1 d
A 9/
Check the supply to the sensor terminals Carry out required repairs.
Result
0
Supply problem?
Connection problem?
3 Check the electrical features (See Reference values Chapter) and Replace sensor
Wrong features?
Connection problem?
Line problem?
6 Replace sensor Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-119

I DIAGNOSTICS
DETECTABLE FAULTS
ATMOSPHERIC PRESSURE SIGNAL

trouble code
P2227 Atmospheric Pressure Signal Variation too fast (> or < at 1000 mb/s)
P2228 Atmospheric pressure signal - Low Atmospheric pressure less than 99 mbar.
P2229 Atmospheric pressure signal - High Atmospheric pressure less than 1074 mbar.
y
op
c
c e 10
n /20
1
a
v 09
Check that the installation (DCU and/or support) (condition, torque, Carry out required repairs.
d
A 9/
0
Connection problem?
Line problem?
Earthing problem
© Delphi
2-120 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
TURBO BOOST PRESSURE REGULATION

trouble code
P0100 Manifold pressure regulation The air flow is too high in relation to the operating conditions
P0234 Boost pressure regulation - Negative error The measured boost pressure is higher than the demand.
P0299 Boost pressure regulation - Positive error The measured boost pressure is lower than the demand.
P107A Boost pressure regulation - Positive error The measured boost pressure is lower than the demand.
P11AA Manifold pressure signal - Value too high Excessive boost / Incoherence between the VGT control and the measured boost
pressure
P11AB Manifold pressure signal - Value too low Insufficient boost / Incoherence between the VGT control and the measured boost
pressure
Codes P0100, P0234, P0299, P11AA, P11AB only :
y
p
CTR shut off
o
c
e 10
Codes P0100, P0234, P0299, P11AA only :
c
n /20
Codes P0100, P0234, P0299, P11AB only :
a
v 09
d
A 9/
Codes P0100, P0234, P11AB only :
0
Codes P0100, P11AA, P11AB only :
Codes P0100, P11AB only :
Codes P0234, P11AA only :
Code P0234 only :
Code P11AA only :
Code P11AABonly :
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-121

I DIAGNOSTICS
DETECTABLE FAULTS
ECU
Turbo air P 3 – 0V CMI 52
1 – S temp

Inlet air flap
EGR valve
y
p
valve
Exchanger
o
pressure
c
Cooling circuit
EGR cooler
e 10
bypass valve
c
converter
Particule
Catalytic
filter
CTR
n /20
exchanger
Pre-DPF sensor
a
v 09
Oxygen probe
Fault chart (Code P0100 - P0234 - P0299 - P107A - P11AA - P11AB) d

A 9/
0
1 Check condition of turbo actuator and its control system Carry out required repairs.
Actuator or control system problem?
2 Check air line Carry out required repairs.
Line problem?
3 Check the manifold pressure sensor Replace the manifold pressure sensor
Sensor problem?
4 Replace DCU
© Delphi
2-122 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
VGT CONTROL
trouble code
P0243 Turbo actuator control - Open circuit (OC) Electrical fault - Open circuit (OC)
P0245 Turbo actuator control - Short circuit to earth Electrical fault detected - short circuit to earth
(SC-)
P0246 Turbo actuator control - Short circuit to Vbat Electrical fault - Short circuit to Vbat (SC+)
(SC+)
y
p
c o
e 10
c
n /20
a
v 09
d
A 9/
0 DCU
VGT solenoid
valve 2 IMC 04
IMC 15
VGT position IMC 51
sensor IMC 35

Connection problem?
Supply problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-123

I DIAGNOSTICS
DETECTABLE FAULTS

Connection problem?
Line problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-124 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
VGT SIGNAL POSITION

trouble code
P2564 Turbo actuator position signal - Low Electrical fault - opening voltage very low
P2565 Turbo actuator position signal - High Electrical fault - opening voltage very high
y
p
c o
e 10
c
n /20
a
d v 09
A 9/
DCU
VGT position sensor 0 IMC 15

IMC 51
IMC 35

Connection problem?
Connection problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-125

I DIAGNOSTICS
DETECTABLE FAULTS

Line problem?
5 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-126 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
VGT CONTROL
trouble code
P1496 Boost pressure regulation - Negative error Negative error between the setting and the requested position
- Closed position
P1497 Boost pressure regulation - Positive error - Positive error between the setting and the requested position
Open position
P2562 Boost pressure regulation - Positive error - Positive error between the setting and the requested position
Open position
P2563 Boost pressure regulation - Negative error Negative error between the setting and the requested position
- Closed position
p y
o
c
e 10
c
DCU
a n /20
v 09
IMC 29
d
1 positive batt
VGT solenoid valve
A 9/
2 IMC 04
0
1 Check the position sensor connection Carry out required repairs.
Connection problem?
2 Measure the resistance at the position sensor terminals (sensor Replace the position sensor
Connection problem?
Line problem?
5 Launch the actuator test routine using the diagnostic tool. Carry out required repairs.
Component fouled or seized ?
6 Consult the vehicle manufacturer network
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-127

I DIAGNOSTICS
DETECTABLE FAULTS
VGT PROGRAMMING
trouble code
P149C VGT programming - Closed position Lower stop programming value outside tolerance
P2566 VGT programming - Open position Upper stop programming value outside tolerance
Without
Fault chart (Code P149C - P2566)

Connection problem?
p y
o
Connection problem?
c
e 10
c
n /20
Line problem?
5
a
v 09
Launch the actuator test routine using the diagnostic tool. Carry out required repairs.
d
A 9/
0
© Delphi
2-128 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
OXYGEN PROBE SIGNAL

trouble code
P0130 Oxygen probe signal - Open circuit (OC) Electrical fault : Open circuit
P0131 Oxygen probe signal - Heater - Short circuit Oxygen probe electrical fault SC Earth
to earth (SC-)
P0132 Oxygen probe signal - Heater - Short circuit Oxygen probe electrical fault SC Vbatt
to Vbat (SC+)
P0133 Oxygen probe signal - Value outside range Electrical thresholds exceeded High & Low
P0134 Oxygen probe signal - Heating Heater circuit fault
P2231 Oxygen probe signal - DCU fault Electrical fault - Short circuit (SC-, SC+)
Without
y
DCU
6-S
op IMC 34
c
2 - 0V IMC 24
e 10
O2 probe 5 IMC 22
4 – +batt IMC 17
c
3 IMC 53
n /20
1 IMC 23
a
v 09
d
A 9/ Turbocharging pressure sensor
0
Inlet air flap
EGR valve

valve
pressure Exchanger
Cooling circuit
EGR cooler
bypass valve
converter
Particule
Catalytic
filter
CTR
exchanger
Pre-DPF sensor Oxygen probe
Note:
Fault P0134 only
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-129

I DIAGNOSTICS
DETECTABLE FAULTS

1 Check the connection for the sensor Carry out required repairs.
Connection problem?
2 Check the supply to the heater terminals Carry out required repairs.
Supply problem?
3 Check heater terminal resistance value Replace the sensor
Connection problem?
Line problem?
6 Does the problem persist? Replace the sensor
p y
Stage Operation / Decision
c o Result
e 10
c
Connection problem?
2
a n /20
Carry out a visual inspection of the oxygen probe Replace the sensor
v 09
The probe is damaged (body damaged, contacts corroded, damp...)
d
Connection problem?
A 9/
0
4 Check the oxygen probe heater element resistance value (See Replace the sensor
section Reference values) .
Resistance value wrong ?
5 Carry out the probe dynamic operation test Replace the sensor
Operational problem
Line problem?
7 Replace DCU
© Delphi
2-130 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
RICHNESS CONTROL
trouble code
P0171 Richness control - Plausibility Richness not plausible with the calculated value
P2191 System too lean - Full load Oxygen concentration too high under full load
P2245 Richness control Richness outside tolerance (too high or too low)
P2297 Richness control - Deceleration Richness drift when foot lifted
Without

Inlet air flap
EGR valve
p y
o
valve
c
pressure Exchanger
e 10
Cooling circuit
c
EGR cooler
bypass valve
n /20
converter
Particule
Catalytic
filter
CTR
a
exchanger
Pre-DPF sensor
d v 09 Oxygen probe
A 9/
6-S
0 IMC 34
DCU
2 - 0V IMC 24
O2 probe 5 IMC 22
4 – +batt IMC 17
3 IMC 53
1 IMC 23
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-131

I DIAGNOSTICS
DETECTABLE FAULTS
EGR VALVE CONTROL

trouble code
P2143 EGR valve control - Open circuit (OC) Open circuit on positive request of the EGR valve H bridge Valve physically closed
P2144 EGR valve control - Short circuit to earth SC earth on positive request of the H bridge Valve physically closed
(SC-)
P2145 EGR valve control - Short circuit to Vbat (SC SC earth on positive request of the H bridge Valve physically closed
+)
y
op
c
DCU
c e 10
4 IMC 52
EGR doser +
n /20
5 IMC 14
valve position 3 IMC 25
a
sensor 1 IMC 18
v 09
2 IMC 06
d
A 9/
Stage
0
Connection problem?
Supply problem?
Connection problem?
Line problem?
© Delphi
2-132 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
EGR POSITION SIGNAL

trouble code
P0405 EGR valve position signal - Low The raw value for the EGR valve position is very high
P0406 EGR valve position signal - High The raw value for the EGR valve position is very low
y
p
c o
c e 10 DCU
a n /20
v 09
4 IMC 52
EGR doser +
d
5 IMC 14
A 9/
sensor 1 IMC 18
2 IMC 06
0
Connection problem?
Connection problem?
Line problem?
5 Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-133

I DIAGNOSTICS
DETECTABLE FAULTS
EGR CONTROL
trouble code
P0409 EGR flap valve control - Component stuck EGR cleaning at power latch, valve stuck closed
or
EGR cleaning at power latch, valve stuck open
P0489 EGR regulation - Error too large - Open Gap between setting and measured position too large, the valve is open too far
position
P0490 EGR regulation - Error too large - Closed Gap between setting and measured position too large, the valve is closed too far
position
P12B3 EGR regulation - Error too large - Open Gap between setting and measured position too large, the valve is open too far
position
P12B4 EGR regulation - Error too large - Closed Gap between setting and measured position too large, the valve is closed too far
position
p y
o
c
e 10
c
n /20
a
d v 09
A 9/
Code P0489 only :
ASR deactivated
0
CTR shut off
Code P0490 only :
© Delphi
2-134 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU
4 IMC 52
EGR doser + 5 IMC 14
sensor 1 IMC 18
2 IMC 06
Fault chart (Code P0409 - P0489 - P0490 - P12B3 - P12B4)

Connection problem?
y
p
c o
e 10
c
Connection problem?
n /20
Line problem?
a
v 09
d
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-135

I DIAGNOSTICS
DETECTABLE FAULTS
EGR REGULATION
trouble code
P0401 EGR regulation - EOBD - Negative error Measured air flow higher than setting
P0402 EGR regulation - EOBD - Positive error Measured air flow lower than setting
P129F EGR regulation - Error too large - Closed Insufficient EGR
position
P12A0 EGR regulation - Error too large - Open Excessive EGR
position
y
p
c o
Code P0401 only :
e 10
c
Code P0402 only :
n /20
CTR shut off
a
v 09
d
A 9/
0

Inlet air flap
EGR valve

valve
pressure Exchanger
Cooling circuit
EGR cooler
bypass valve
converter
Particule
Catalytic
filter
CTR
exchanger

© Delphi
2-136 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU
4 IMC 52
sensor 1 IMC 18
2 IMC 06
Fault chart (Code P0401 - P0402 - P129F - P12A0)

1 Check condition of EGR valve and its control system for blocks, Carry out required repairs.
contamination, leaks, etc.
Is there a valve or control problem?
y
2 Check air and exhaust lines Carry out required repairs.
p
(Tightness of clips, contamination, incorrect fitting, presence of
o
water,...)
Line problem?
c
e 10
c
3 Carry out flowmeter diagnosis Carry out required repairs.
n /20
Flowmeter problem?
4
a
v 09
Carry out the electrical diagnosis of the EGR valve. Carry out required repairs.
d
EGR problem?
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-137

I DIAGNOSTICS
DETECTABLE FAULTS
EGR PROGRAMMING
trouble code
P1461 EGR programming - Closed position Lower stop programming value outside tolerance
P1462 EGR programming - Open position Upper stop programming value outside tolerance
Without
DCU
4 IMC 52
sensor 1 IMC 18
2 IMC 06
p y
c o
e 10
1
c
n /20
Check the condition of the actuator, its control and the environment Carry out required repairs.
a
(seizure, dirt, leaks....)
v 09
2
d
A 9/
Carry out the electrical diagnosis of the actuator according to the
associated faults.
0
Problem with the actuator?
3 Carry out the electrical diagnosis of the actuator position sensor. Carry out required repairs.
Position sensor problem ?
4 Does the problem persist? Replace the position sensor
6 Does the problem persist? Replace DCU © Delphi
2-138 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
EGR COOLER SOLENOID VALVE CONTROL

trouble code
P2425 EGR cooler bypass valve control - Open EGR bypass valve control circuit electrical fault (OC)
circuit (OC)
P2426 EGR cooler bypass flap control - Short circuit EGR bypass valve control circuit electrical fault (SC -Vbat)
to earth (SC-)
P2427 EGR cooler bypass flap control - Short circuit EGR bypass valve control circuit electrical fault (SC +Vbat)
to Vbat (SC+)
EGR "moving off" strategy prevented
y
DCU
op
EGR By-pass
solenoid valve
c
positive batt
e 10
IMC 17
IMC 03
c
n /20
a
v 09
d
A 9/
0
Connection problem?
Supply problem?
Connection problem?
Line problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-139

I DIAGNOSTICS
DETECTABLE FAULTS
EGR COOLER FLAP VALVE POSITION SIGNAL

trouble code
P11B2 EGR cooler valve position signal - High Voltage too high
or
Voltage in the switch intermediate zone (not plausible)
P11B3 EGR cooler valve position signal - Low EGR bypass switch electrical fault: SC earth
Without
DCU
EGR by-pass 1 IMC 16

2 EMC A2
position sensor
y
3 IMC 43
op
c
e 10
Fault chart (Code P11B2 - P11B3)
c
n /20
a
1 Check sensor connection
A 9/
Connection problem?

0

Connection problem?
Line problem?
5 Replace DCU
© Delphi
2-140 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
EGR COOLER FLAP VALVE CONTROL

trouble code
P14A3 EGR cooler valve position signal EGR bypass confirmed blocked open: hot side (operational diagnostic: On/Off valve)
P14A4 EGR cooler valve position signal EGR bypass confirmed blocked closed: cold side (operational diagnostic: On/Off
valve)
Code P14A3 only :
DCU
EGR By-pass
p
positive batt
y IMC 17
o
solenoid valve IMC 03
c
e 10
c
n /20
a
v 09
d
Inlet air flap
A 9/
0
valve
EGR valve

pressure Exchanger
Cooling circuit
EGR cooler
bypass valve
converter
Particule
Catalytic
filter
CTR
exchanger
Fault chart (Code P14A3 - P14A4)

1 Check the condition of the actuator, its control and the environment Carry out required repairs.
(seizure, dirt, leaks....)
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-141

I DIAGNOSTICS
DETECTABLE FAULTS
Fault chart (Code P14A3 - P14A4)

2 Carry out the electrical diagnosis of the actuator according to the Carry out required repairs.
associated faults.
Problem with the actuator?
3 Carry out the electrical diagnosis of the actuator position sensor. Carry out required repairs.
Position sensor problem ?
4 Does the problem persist? Replace the position sensor
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-142 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INLET AIR FLAP CONTROL

trouble code
P1471 Air flap control - Open circuit (OC) Electrical fault - Butterfly open (OC)
P2141 Air flap control - Short circuit to earth (SC-) Electrical fault : Air flap circuit SC earth - Doser closed
P2142 Air flap control - Short circuit to Vbat (SC+) Doser open (Internal SC = SC Vbatt)
y
Air flap valve "moving off" strategy prevented
p
o
c
e 10
c
a
Code P2141 only :
n /20
v 09
d
A 9/
0
DCU
1 IMC 14
3 IMC 52
2 IMC 26
Inlet air dose position
sensor + solenoid valve 2 – Ctrl IMC 02
1 – +Batt IMC 17

Connection problem?
Supply problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-143

I DIAGNOSTICS
DETECTABLE FAULTS

Connection problem?
Line problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-144 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

trouble code
P2127 Air flap position signal - Low Electrical fault - Short circuit Earth (SC-)
P2128 Air flap position signal - High Electrical fault - Short circuit Vbat (SC+)
y
Air flap valve control deactivated
p
o
c
e 10
c
n /20
a
v 09
d
A 9/
0
DCU
1 IMC 14
3 IMC 52
2 IMC 26
1 – +Batt IMC 17

Connection problem?
Connection problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-145

I DIAGNOSTICS
DETECTABLE FAULTS

Line problem?
5 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-146 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

trouble code
P0487 Air flap control - Positive error Positive error between the setting and the measurement exceeds the first
threshold.
P0488 Air flap control - Negative error Negative error between the setting and the measurement exceeds the first
threshold.
P1498 Air flap control - Negative error max Positive error between the setting and the measurement exceeds the second
threshold.
P1499 Air flap control - Positive error max Positive error between the setting and the measurement exceeds the second
threshold.
Code P0488 only :
p y
o
c
e 10
c
n /20
DCU
a
v 09
IMC 14
d
3 IMC 52
2 IMC 26
A 9/
1 – +Batt IMC 17
0
Inlet air flap
EGR valve

valve
pressure Exchanger
Cooling circuit
EGR cooler
bypass valve
converter
Particule
Catalytic
filter
CTR
exchanger

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-147

I DIAGNOSTICS
DETECTABLE FAULTS

Connection problem?
Connection problem?
Line problem?
y
op
c
e 10
c
n /20
a
v 09
d
A 9/
0
© Delphi
2-148 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
INLET AIR FLAP PROGRAMMING

trouble code
P2125 Air flap programming - Closed position Lower stop programming value outside tolerance
P2126 Air flap programming - Open position Upper stop programming value outside tolerance
Without
DCU
1 IMC 14
3 IMC 52
2 IMC 26
1 – +Batt IMC 17
p y
c o
e 10
Stage
c
n /20
a
v 09
Connection problem?
2
d
A 9/
Measure the resistance at the position sensor terminals (sensor
Replace the position sensor
0
Connection problem?
Line problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-149

I DIAGNOSTICS
DETECTABLE FAULTS
AIR HEATER BYPASS FLAP VALVE CONTROL

trouble code
P022A Inlet air heater bypass flap control - Open Electrical fault - Open circuit (OC)
circuit (OC)
P022B Inlet air heater bypass flap control - Short Electrical fault : SC earth
circuit to earth (SC-)
P022C Inlet air heater bypass flap control - Short Electrical fault - Short circuit Vbat (SC+)
circuit to Vbat (SC+)
Flowmeter plausibility strategy deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
ASR in recovery mode (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
EGR control dectivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
CTR cut (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
p y
o
Manual only) c
Speed limiter deactivated until next DCU reset (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308
e 10
c
n /20
C/C deactivated until next DCU reset (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual
a
only)
v 09
Code P022B only :
d
A 9/
Fault warning lamp on (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual only)
1
3
0 EMC E2
IMC 52
DCU
Inlet air bypass dose 2 IMC 21

position sensor + IMC 01
2 – Ctrl
solenoid valve
1 – +Batt IMC 17
Fault chart (Code P022A - P022B - P022C)

Connection problem?
Supply problem?
© Delphi
2-150 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Fault chart (Code P022A - P022B - P022C)

Connection problem?
Line problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-151

I DIAGNOSTICS
DETECTABLE FAULTS
AIR HEATER BYPASS FLAP VALVE POSITION SIGNAL

trouble code
P024E Inlet air heater bypass flap valve position Electrical fault - Short circuit Earth (SC-)
signal - Low
P024F Inlet air heater bypass flap valve position Electrical fault : Inlet air heater bypass flap short circuit Vbatt
signal - High
Boost pressure regulation deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual
only)
Forced regeneration (A-S) forbidden (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual only)
EGR programming strategy deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual
only)
p y
EGR diagnostic deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual only)
o
Air valve programming strategy deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308
c
Manual only)
e 10
c
a n /20
v 09
VGT programming strategy deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual
d
only)
A 9/
1
3
0 EMC E2
IMC 52
DCU

2 – Ctrl
solenoid valve
1 – +Batt IMC 17
Fault chart (Code P024E - P024F)

Connection problem?
© Delphi
2-152 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
Fault chart (Code P024E - P024F)

Connection problem?
Line problem?
5 Replace DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-153

I DIAGNOSTICS
DETECTABLE FAULTS
INLET AIR HEATER BYPASS CONTROL

trouble code
P024A Inlet air heater bypass flap control - Positive Positive error between the setting and the measurement exceeds the first
error threshold.
P024B Inlet air heater bypass flap control - Negative error between the setting and the measurement exceeds the first
Negative error threshold.
P149A Inlet air heater bypass flap control - Positive error between the setting and the measurement exceeds the second
Negative error max threshold.
P149B Inlet air heater bypass flap control - Positive Positive error between the setting and the measurement exceeds the second
error max threshold.
Codes P024B, P024A only :
y
Code P024A only :
op
c
e 10
Code P024B only :
c
n /20
a
EGR control deactivated (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
v 09
CTR cut (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual only)
d
A 9/
Fault warning lamp on (C4 Picasso Auto, 407/C5 Auto, 407/C5 Manual, C4 Picasso Manual, 308 Manual only)
1
0 EMC E2
DCU
3 IMC 52
2 – Ctrl
solenoid valve
1 – +Batt IMC 17
© Delphi
2-154 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

Inlet air flap
EGR valve

valve
pressure Exchanger
Cooling circuit
EGR cooler
bypass valve
converter
Particule
Catalytic
filter
CTR
exchanger
Fault chart (Code P024A - P024B - P149A - P149B)

Stage Operation / Decision
p y Result
o
Connection problem?
c
e 10
c
n /20
a
d v 09
A 9/
Connection problem?
4
0
Use terminal box to check line continuity and electrical insulation
Line problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-155

I DIAGNOSTICS
DETECTABLE FAULTS
AIR HEATER BYPASS FLAP VALVE PROGRAMMING

trouble code
P024C Air heater bypass flap programming - Closed Lower stop programming value outside tolerance
position
P024D Air heater bypass flap programming - Open Upper stop programming value outside tolerance
position
Without
DCU
1 EMC E2
3 IMC 52
2 – Ctrl
y
solenoid valve
1 – +Batt IMC 17
op
c
e 10
c
Fault chart (Code P024C - P024D)
Stage
a
n /20 Result
v 09
2
Connection problem?
d
A 9/
Measure the resistance at the position sensor terminals (sensor Replace the position sensor
0
Connection problem?
Line problem?
© Delphi
2-156 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
PARTICLE FILTER (DPF)

trouble code
P1445 Diesel Particulates Filter - Wear DPF clogging calculation linked to natural wear exceeds a certain threshold.
P1447 Particle filter - Clogged The differential pressure has exceeded a certain threshold (depending on the
estimated exhaust air flow) indicating DPF clogging.
P1457 Diesel Particulate Filter - Absent The differential pressure is too low indicating a leak or a missing DPF.
P1490 Particle filter - Overloaded The differential pressure has exceeded a certain threshold (depending on the
estimated exhaust air flow) indicating DPF overload. Although the differential
pressure is below the threshold for DPF clogging detection.
Code P1447 only :
p y
o
c
e 10
c
n /20
a
v 09
d
A 9/
Code P1457 only :
0
DCU
EMC C4
DPF delta P sensor 3 - 5V EMC A4
2 - 0V EMC D2
1-S

1 Check the filter service history. Replace the DPF.
End of service life ?
2 Check the condition and mounting of the differential pressure sensor Carry out repairs required.
Sensor problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-157

I DIAGNOSTICS
DETECTABLE FAULTS

3 Check the conformance of the tubing, the condition of the connectors Carry out repairs required.
and the sense in which they are fitted.
Is there a problem with the tubing or the connectors?
4 Carry out the differential pressure electrical diagnosis Carry out repairs required.
5 Using the diagnostic tool, start a "manual" regeneration and note Consult the vehicle manufacturer network.
the effect
Does the fault persist?
Note:
"Wear" or "Cogged" fault only
y
1
o
Replace the DPF, then reset the DPF programming
p
Note:
c
e 10
c
"Overload" fault only

a n /20
Stage
d v 09
A 9/
1 Launch manual regeneration using the diagnostic tool or drive on
the motorway or fast road for 10 to 15 minutes, then check to see
if the fault has disappeared.
0
© Delphi
2-158 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DPF DIFFERENTIAL PRESSURE SIGNAL

trouble code
P0470 DPF differential pressure signal - Plausibility Pressure not plausible stationary.
P0471 DPF differential pressure signal - Variation The variation in pressure is greater than 750 mbar/s
rate
P0472 DPF differential pressure signal - Low The raw value for differential pressure is less than 41
P0473 DPF differential pressure signal - High The raw value for differential pressure is greater than 982
Code P0470 only :
y
p
EOBD LED on
c o
e 10
c
n /20
a
d v 09
A 9/
DCU
0
EMC C4
DPF delta P sensor 3 - 5V EMC A4
2 - 0V EMC D2
1-S

1 Check the conformance of the tubing, the condition of the connectors Carry out required repairs.
and the sense in which they are fitted.
Is there a problem with the tubing or the connectors?
Supply problem?
Connection problem?
Wrong features?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-159

I DIAGNOSTICS
DETECTABLE FAULTS

Connection problem?
Line problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-160 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ADDITIVE MANAGEMENT SYSTEM

trouble code
P1434 DPF additive pump control Fault on "multiplexed" pump, but no BSI - Additive pump communication problem
P1435 DPF additive pump control Fault on "multiplexed" pump, or BSI - Additive pump communication problem
P1442 DPF additive pump control - Open circuit (OC)
P1443 DPF additive pump control - Short circuit to
earth (SC-)
P1444 DPF additive pump control - Short circuit to
Vbatt (SC+)
P1446 DPF additive level signal - Low level - Below Minimum level of additive in the tank reached.
the minimum threshold
p y
Codes P1434, P1442, P1443, P1444, P1435 only :
o
c
e 10
c
DCU
a n /20 3
v 09
DPF additive pump 12V ERU PCC 08
4
d
A 9/
0
Note:
Fault P1446

1 Replace the additive tank (see the tank replacement procedure) Consult the vehicle manufacturer network
Note:
Other faults :

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-161

I DIAGNOSTICS
DETECTABLE FAULTS
ACCELERATOR PEDAL - TRACK 1 & 2 CORRELATION

trouble code
P0220 Accelerator pedal – Correlation tracks 1& 2
P2137 Accelerator pedal – Correlation tracks 1& 2
Code P2137 only :
ASR deactivated
y
p
o
c
e 10
DCU
6 - 5V
c
n /20
PC 46
a
5 – S2 PC 34
Accelerator pedal
v 09
4 – 0V n°2 PC 44
(tracks 1 & 2) 3 - kick-down PC 36
d
(LVS/CC ) 2 – 0V n°1 PC 47
A 9/
1 – S1 PC 35

0
1 Check the connection of the accelerator pedal sensor Carry out required repairs.
Connection problem?
2 Check the accelerator pedal sensor electrical characteristics for Replace the accelerator pedal sensor
each track (See section Reference values) and compare the value
read with the expected value
Wrong features?
Connection problem?
Line problem?
© Delphi
2-162 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ACCELERATOR PEDAL BLOCKED

trouble code
P2299 Accelerator pedal - Component stuck Accelerator / brake pedal correlation fault
Engine speed set to 1300 rpm (limp home mode)
DCU
6 - 5V PC 46
5 – S2 PC 34
Accelerator pedal
y
4 – 0V n°2 PC 44
p
(LVS/CC ) 2 – 0V n°1 PC 47
o
1 – S1 PC 35
c
e 10
c
n /20
a
Stage
d v 09
A 9/
1 Check the accelerator pedal moves freely Replace the accelerator pedal
Is the pedal stuck?
2
3
Connection problem? 0
Check the connection of the accelerator pedal sensor
Check the accelerator pedal sensor electrical characteristics for

Replace the accelerator pedal sensor

each track (See section Reference values) and compare the value
read with the expected value
Wrong features?
4 Operate the brake pedal switch several times in succession and Delete the fault code and carry out a test under the same conditions
check the change in status in the diagnostic tool (presence, delay as the appearance of the fault.
etc...)
Change in status correct?
5 Perform a visual check on the switch and its mountings. Replace the switch
Is there a switch problem?
6 Check the connection of the switch Carry out required repairs.
Connection problem?
7 Check the operation of the switch with a multimeter. Replace the switch
8 Check the switch connector voltage with a voltmeter Carry out required repairs.
Voltage problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-163

I DIAGNOSTICS
DETECTABLE FAULTS

9 Check the brake switch and accelerator pedal sensor DCU Carry out required repairs.
connections
Connection problem?
Line problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-164 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ACCELERATOR PEDAL SENSOR TRACK 1 SIGNAL

trouble code
P0222 Accelerator pedal sensor track 1 signal - Track 1 electrical fault Short Circuit Earth
Low
P0223 Accelerator pedal sensor track 1 signal - Track 1 electrical fault Short Circuit Vbat
High
y
p
c o
e 10
DCU
6 - 5V
5 – S2
c
n /20
PC 46
a
PC 34
Accelerator pedal PC 44
4 – 0V n°2
v 09
d
(LVS/CC ) 2 – 0V n°1 PC 47
A 9/
1 – S1 PC 35

0
Connection problem?
Connection problem?
Line problem?
5 Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-165

I DIAGNOSTICS
DETECTABLE FAULTS
ACCELERATOR PEDAL SENSOR TRACK 2 SIGNAL

trouble code
P0227 Accelerator pedal sensor track 2 signal - Track 2 electrical fault Short Circuit Earth
Low
P0228 Accelerator pedal sensor track 2 signal - Track 2 electrical fault Short Circuit Vbat
High
y
p
c o
e 10
DCU
6 - 5V
5 – S2
c
n /20
PC 46
a
PC 34
Accelerator pedal PC 44
4 – 0V n°2
v 09
d
(LVS/CC ) 2 – 0V n°1 PC 47
A 9/
1 – S1 PC 35

0
Connection problem?
Connection problem?
Line problem?
5 Replace DCU
© Delphi
2-166 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ACCELERATOR PEDAL KICKDOWN SIGNAL

trouble code
P2132 Accelerator pedal sensor kick-down signal Electrical fault : Short circuit to Vbat (SC+)
- High
P2133 Accelerator pedal sensor kick-down signal Electrical fault : Short circuit to earth
- Low
P2134 Accelerator pedal sensor kick-down signal Signal in the wrong zone: invalid signal
- Invalid
P2140 Accelerator pedal sensor kick-down signal Inconsistent with the pedal position from the pedal sensor
- Plausibility
p y
c o
e 10
DCU
c
6 - 5V PC 46
n /20
5 – S2 PC 34
Accelerator pedal
a
4 – 0V n°2 PC 44
(tracks 1 & 2)
v 09
3 - kick-down PC 36
(LVS/CC ) 2 – 0V n°1 PC 47
d
1 – S1 PC 35
A 9/
0
1 Check the accelerator pedal moves freely Replace the accelerator pedal
Is the pedal stuck?
2 Check brake contactor connection Carry out required repairs.
Connection problem?
Connection problem?
4 Check the continuity and the electrical insulation of the brake switch Line problem?
line
Line problem?
5 Replace brake switch Replace DCU
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-167

I DIAGNOSTICS
DETECTABLE FAULTS
BRAKE PEDAL SWITCH SIGNAL

trouble code
P0504 Brake switches - Plausibility - Acceleration Inconsistency between the main brake (CAN) and the secondary brake when
acceleration is valid
P1536 Brake switches - Plausibility Inconsistency between the main brake (CAN) and the secondary brake during
deceleration
or
Inconsistency between the main brake (CAN) and the secondary brake when
acceleration is invalid
Code P0504 only :
p y
c o
c e 10 DCU
a n /20
v 09
PC 22
d
Dual brake pedal switch positive IGN
A 9/
Rear lamp via BSI
0
1 Check the mobility of the pedal Carry out required repairs.
Pedal stroke problem ?
2 Operate the switch several times in succession and check the Delete the fault code and carry out a test under the same conditions
change in status in the diagnostic tool (presence, delay etc...) as the appearance of the fault.
Connection problem?
6 Check the connector voltage with a voltmeter Carry out required repairs.
Voltage problem?
© Delphi
2-168 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS

Connection problem?
Line problem?
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-169

I DIAGNOSTICS
DETECTABLE FAULTS
CLUTCH PEDAL SWITCH SIGNAL

trouble code
P0704 Clutch pedal switch signal - Plausibility No action on the clutch pedal for a certain time.
P0831 Clutch pedal switch signal Clutch switch fault: No clutch pedal depression detected on a speed range from 0
to 120 kph
C/C deactivated (407/C5 Auto, C4 Picasso Auto, Jumpy/Expert, 308 Manual, 807/C8 Manual only)
DCU
y
PC 22
p
Dual brake pedal switch positive IGN
o
Rear lamp via BSI
c
e 10
c
n /20
a
v 09
d
A 9/
1 Check the mobility of the pedal Carry out required repairs.
0
Pedal stroke problem ?
2 Operate the switch several times in succession and check the Delete the fault code and carry out a test under the same conditions
change in status in the diagnostic tool (presence, delay etc...) as the appearance of the fault.
Connection problem?
6 Check the connector voltage with a voltmeter Carry out required repairs.
Voltage problem?
Connection problem?
Line problem?
© Delphi
2-170 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
AC pressure signal
trouble code
P0532 AC pressure signal - Low The air conditioning pressure is less than 1 bar.
P0533 AC pressure signal - High The air conditioning pressure is greater than 40 bar.
Dashboard air conditioning request

Fan control
VAN H CAN H
Refrigerant fluid
y
Air conditioning DCU BSI Injection DCU pressure sensor
p
(pressostat)
VAN L CAN L
Compressor control
c o
e 10
Injection parameter
adjustment
c
n /20
a
v 09
d
1
A 9/
Check the supply to the sensor terminals Carry out required repairs.
0
Supply problem?
Connection problem?
Wrong features?
Connection problem?
Line problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-171

I DIAGNOSTICS
DETECTABLE FAULTS
COOLANT TEMPERATURE REHEAT SOLENOID VALVE CONTROL

trouble code
P2418 Coolant temperature reheat (CTR) solenoid CTR SV control open circuit
valve control - open circuit (OC)
P2419 Coolant temperature reheat (CTR) solenoid CTR SV control short circuit to earth
valve control - Short circuit to earth (SC-)
P2420 Coolant temperature reheat (CTR) solenoid CTR SV control short circuit to Vbat
valve control - Short circuit to Vbat (SC+)
CTR shut off
CTR pump prevented
y
p
Inlet air flap
o
c
e 10
EGR valve
c
n /20
valve
a
Exchanger
v 09
pressure
d
Cooling circuit
A 9/
EGR cooler
bypass valve
converter
Particule
Catalytic
filter
CTR
0
exchanger

Connection problem?
Supply problem?
Connection problem?
Line problem?
© Delphi
2-172 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
CTR PUMP CONTROL

trouble code
P2400 CTR pump control - open circuit (OC)
P2401 CTR pump control - Line in short circuit (SC)
CTR shut off
CTR pump prevented

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-173

I DIAGNOSTICS
DETECTABLE FAULTS
CRUISE CONTROL / SPEED LIMITER

trouble code
P0565 Cruise control - Plausibility BSI is sending incoherent data
P0568 Cruise control - Plausibility The speed setting has undergone excessive variation.
or
The speed setting is outside tolerance.
P0575 Speed limiter - Plausibility The speed setting has undergone excessive variation.
or
The speed setting is outside tolerance.
P1671 Cruise control - Plausibility BSI is sending incoherent data
or
The speed setting is wrong
or
y
BSI fault
op
c
e 10
c
a n /20
d v 09
A 9/
0
© Delphi
2-174 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
CERTIFICATION NUMBER
trouble code
P160A Certification number - Invalid The certification number has not been correctly configured.
ECU
p y
c o
Fault chart (Code P160A)
c e 10
Stage
a n /20
v 09
1 Read the certification number using the scan tool. Enter the certification number using the diagnostic tool.
d
Is the certification number is blank ?
2 Replace DCU
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-175

I DIAGNOSTICS
DETECTABLE FAULTS
ENGINE START IMPOSSIBLE

trouble code
P0017 Starting - Too long Engine starting time too long (the unacceptable time depends on engine
temperature)
P050B Starting - Camshaft - crankshaft Synchronisation time above 2s.
synchronisation
P0513 Starting - Immobiliser unlock - Too long Immobiliser unlock time above 2s.
Without
Fault chart (Code P0017 - P050B - P0513)

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-176 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ENGINE OIL LEVEL SIGNAL

trouble code
P250B Engine oil level signal - Plausibility The oil level variation is too high compared with the following cycle
P250C Engine oil level signal - Short circuit to earth Measured voltage less than 500mV.
(SC-)
P250D Engine oil level signal - Open circuit (OC) or Measured voltage greater than 3600mV
short circuit to Vbatt (SC+)
P250E Engine oil level signal - Wake up Oil level invalid at key on
Without
ECU
p y
o
1 signal EMC D1
Oil level
c
sensor 2 SENSOR EARTH EMC A3
c e 10
a n /20
d v 09
A 9/
Fault chart (Code P250B - P250C - P250D - P250E)
0
Supply problem?
Connection problem?
Connection problem?
Line problem?
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-177

I DIAGNOSTICS
DETECTABLE FAULTS
OIL COMBUSTION
trouble code
P16A0 Oil combustion Oil combustion detection is based on engine rpm (>6000rpm), boost pressure and
richness (lambda < 1.001) monitoring at foot off.
ASR deactivated
EGR valve close request
Immediate engine stop
Air flap valve closure request
y
p
VGT SV close request
c o
e 10
c
n /20
a
v 09
CTR shut off
d
Engine shut off in case of over revving
A 9/
0
Fault chart (Code P16A0)

1 Check the engine oil level Correct the level
Level incorrect (too low or too high)?
2 Check the engine oil service history Carry out the maintenance
End of service life ?
3 Check the quality of the oil used Carry out the maintenance
Poor oil quality ?
© Delphi
2-178 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
IMMOBILISER
trouble code
P1612 Immobiliser - Invalid Matching not done, invalid or corrupt DCU memory
Transponder
aerial Injection DCU
CAN L CAN H
VAN H
Control panel BSI
VAN L
CAN L CAN H
p y ESP ECU
o
Door switch
c
e 10
c
Stage
a n /20
v 09
1 Using the diagnostic tool ADC3 immobilisation program, read the Consult the vehicle manufacturer network
d
immobilisation configuration, then follow the steps given by the
A 9/
tool.
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-179

I DIAGNOSTICS
DETECTABLE FAULTS
VEHICLE NETWORKS
trouble code
U0019 CAN LS - fault VAN Bodywork network 1 fault. Loss of communication between BSI and the ERU
or
CAN fault Low Speed detected by the BSI.
U0028 Comfort VAN VAN network fault Comfort or Instrument panel (Dashboard).
U0055 CAN Comfort - fault CAN Comfort fault. Loss of communication between the BSI and the instrument
panel.
U0350 CAN Comfort - fault CAN Comfort fault. Loss of communication between the BSI and the instrument
panel.
U0350 CAN LS - fault VAN Bodywork network 1 fault. Loss of communication between BSI and the ERU
or
CAN fault Low Speed detected by the BSI.
y
U0350 Comfort VAN VAN network fault Comfort or Instrument panel (Dashboard).
p
c o
e 10
Codes U0028, U0350, U0055 only :
c
a n /20
d v 09 Air conditioning
management
Fan control
A 9/ VAN L VAN H
0
Control panel
VAN H
VAN L
BSI
CAN H
CAN L
Injection DCU
Injection parameter
Temperature
adjustment
LED
Fault chart (Code U0019 - U0028 - U0055 - U0350 - U0350 - U0350)

© Delphi
2-180 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
ALTERNATOR
trouble code
P0620 Alternator - Electrical fault The alternator has detected an electrical fault.
P065A Alternator - Mechanical fault The alternator has detected a mechanical fault.
P0A1A Alternator - Communication - Fault The alternator has detected a communication fault.
Without
Fault chart (Code P0620 - P065A - P0A1A)

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-181

I DIAGNOSTICS
DETECTABLE FAULTS
LIN - ALTERNATOR
trouble code
U0350 LIN - Alternator - Absent No response or no frame received on the alternator LIN.
U0350 LIN - Alternator - Blocked The DCU cannot transmit on the LIN line.
U1400 LIN - Alternator - Blocked The DCU cannot transmit on the LIN line.
U1401 LIN - Alternator - Absent No response or no frame received on the alternator LIN.
Without
Alternator control EMC A1

LIN
p y
c o
c e 10
n /20
Fault chart (Code U0350 - U0350 - U1400 - U1401)
a
1
d v 09
Consult the vehicle manufacturer network
A 9/
0
© Delphi
2-182 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU WAKE-UP
trouble code
U2000 DCU wake-up - Invalid The frame received is invalid.
U2003 DCU wake-up - Plausibility A wake-up frame is received when the main supply is not active or no frame received
when conditions were satisfied.
U2118 DCU wake-up - Value invalid Post-fan wake-up invalid
or
Immobiliser anticipation wake-up invalid
U2A60 DCU wake-up - Invalid The frame received is invalid.
U2A60 DCU wake-up - Plausibility A wake-up frame is received when the main supply is not active or no frame received
U2A60 DCU wake-up - Value invalid The frame received is invalid.
or
y
A wake-up frame is received when the main supply is not active or no frame received
p
c o
or
e 10
Post-fan wake-up invalid
c
or
n /20
Immobiliser anticipation wake-up invalid
a
v 09
d
A 9/
Codes U2000, U2A60, U2003 only :
0
Fault chart (Code U2000 - U2003 - U2118 - U2A60 - U2A60 - U2A60)

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-183

I DIAGNOSTICS
DETECTABLE FAULTS
VEHICLE SPEED SIGNAL

trouble code
P0500 Vehicle speed signal Vehicle speed data received invalid

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-184 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
REVERSING SIGNAL
trouble code
P0812 Reversing signal The speed / rpm comparison indicates that reverse has been selected although the
reversing switch has not been activated.
Without

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-185

I DIAGNOSTICS
DETECTABLE FAULTS
STARTER
trouble code
P1693 Starter status DAMP frames communication fault
P1694 Starter status Starter control line cut fault
P1695 Starter status Engine blocked or starter US
Without

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-186 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
"SILENT" CAN
trouble code
U0350 CAN silent CAN silent
U1000 CAN silent CAN silent
Note:
When the ignition is switched off, the network enters a variable duration standby phase which may be interrupted by an
event on the vehicle (door opening, remote control...).
Fault chart (Code U0350 - U1000)

y
1 Ignition off and system in standby, Measure the CAN impedance Open circuit on one of the two lines or one of the two end-of-line
p
taken between the CAN high and low lines with all Control Units DCUs is disconnected or faulty
o
connected (directly on the CAN, not via the diagnostic socket).
Impedance = ~120 Ohms
c
e 10
c
2 Impedance = ~0 Ohms The two lines are in short circuit or one of the DCUs on the CAN
n /20
network is faulty
a
3 Impedance = ~60 Ohms CAN conforms electrically ; problem on another vehicle function,
d v 09 consult the Vehicle Manufacturer network
A 9/
4 Disconnect injection DCU from CAN network and measure Replace DCU
resistance between CAN-H and CAN-L pins connected to CAN
0
network.
Resistance <> ~120 Ohms
5 Look for short circuits on the CAN network Carry out repairs required.
Is there a short-circuit problem ?
6 Consult the vehicle manufacturer network.
Locating short circuits on the CAN network

1 With ignition on, use multimeter to measure CAN-H voltage, then CAN-H line is short circuited to +Batt. Carry out required repairs.
CAN-L voltage to earth (directly on CAN, not via diagnostic socket)
VCAN-H = Battery voltage
2 VCAN-H = ~0 V CAN-H line short circuited to earth. Carry out required repairs.
3 VCAN-L = Battery voltage CAN-L line short circuited to +Batt. Carry out required repairs.
4 VCAN-L = ~0 V CAN-L line short circuited to earth. Carry out required repairs.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-187

I DIAGNOSTICS
DETECTABLE FAULTS

network.
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-188 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
CAN "BUS OFF"

trouble code
U0350 CAN "Bus OFF" CAN bus Off
U1003 CAN "Bus OFF" CAN bus Off
Note:
When the ignition is switched off, the network enters a variable duration standby phase which may be interrupted by an
y
event on the vehicle (door opening, remote control...).
op
c
e 10
c
1 Ignition off and system in standby, Measure the CAN impedance Open circuit on one of the two lines or one of the two end-of-line
n /20
taken between the CAN high and low lines with all Control Units DCUs is disconnected or faulty
a
v 09
connected (directly on the CAN, not via the diagnostic socket).
d
Impedance = ~120 Ohms
A 9/
2 Impedance = ~0 Ohms The two lines are in short circuit or one of the DCUs on the CAN
0
network is faulty
3 Impedance = ~60 Ohms CAN conforms electrically ; problem on another vehicle function,
consult the Vehicle Manufacturer network
network.
5 Look for short circuits on the CAN network Carry out repairs required.
Is there a short-circuit problem ?
6 Consult the vehicle manufacturer network.
Locating short circuits on the CAN network

1 With ignition on, use multimeter to measure CAN-H voltage, then CAN-H line is short circuited to +Batt. Carry out required repairs.
CAN-L voltage to earth (directly on CAN, not via diagnostic socket)
VCAN-H = Battery voltage
2 VCAN-H = ~0 V CAN-H line short circuited to earth. Carry out required repairs.
3 VCAN-L = Battery voltage CAN-L line short circuited to +Batt. Carry out required repairs.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-189

I DIAGNOSTICS
DETECTABLE FAULTS

4 VCAN-L = ~0 V CAN-L line short circuited to earth. Carry out required repairs.
network.
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-190 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
CAN - BSI
trouble code
U0350 CAN - BSI - Absent One or more frames sent by the BSI/BCU are corrupted.
or
One or more data packets received by the CAN from BSI/BCU are invalid.
or
one or more frames sent by the BSI/BCU have not been received.
U0350 CAN - BSI - Invalid data One or more frames sent by the BSI/BCU are corrupted.
or
One or more data packets received by the CAN from BSI/BCU are invalid.
or
one or more frames sent by the BSI/BCU have not been received.
U0350 CAN - BSI - Value invalid One or more frames sent by the BSI/BCU are corrupted.
y
or
op One or more data packets received by the CAN from BSI/BCU are invalid.
c
U1118 CAN - BSI - Absent one or more frames sent by the BSI/BCU have not been received.
e 10
U1218 CAN - BSI - Value invalid One or more data packets received by the CAN from BSI/BCU are invalid.
U1318 CAN - BSI - Invalid data
c
n /20
One or more frames sent by the BSI/BCU are corrupted.
a
v 09
d
A 9/
0
Codes U1318, U0350, U1118 only :
Codes U1118, U0350 only :
CTR shut off
Fault chart (Code U0350 - U0350 - U0350 - U1118 - U1218 - U1318)

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-191

I DIAGNOSTICS
DETECTABLE FAULTS
CAN - ABS/ESP
trouble code
U0122 CAN - ESP - Invalid No communication with the braking control unit (BCU)
or
Data received from the braking control unit is invalid.
U0350 CAN - ABS/ESP - Invalid data No communication with the braking control unit (BCU)
or
One or more frames sent by the braking control unit are corrupted.
U0350 CAN - ABS/ESP - Value invalid No communication with the braking control unit (BCU)
or
or
One or more data packets received by the CAN from the control unit are invalid.
y
U0350 CAN - ESP - Absent No communication with the braking control unit (BCU)
op or
c
e 10
or
c
n /20
a
or
v 09
One or more frames sent by the braking control unit have not been received.
U0350 CAN - ESP - Invalid
d
A 9/
No communication with the braking control unit (BCU)
or
0 One or more frames sent by the braking control unit are corrupted.
or
or
One or more frames sent by the braking control unit have not been received.
or
Data received from the braking control unit is invalid.
U0350 CAN - ESP - Plausibility Data received from the braking control unit is inconsistent.
U0416 CAN - ESP - Plausibility Data received from the braking control unit is inconsistent.
U1113 CAN - ESP - Absent One or more frames sent by the braking control unit have not been received.
U1213 CAN - ABS/ESP - Value invalid One or more data packets received by the CAN from the control unit are invalid.
U1313 CAN - ABS/ESP - Invalid data One or more frames sent by the braking control unit are corrupted.
Codes U0122, U0350, U1313, U1213, U1113 only :
© Delphi
2-192 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
CAN - ABS/ESP
Codes U1313, U0350, U1213, U1113, U0416 only :
Codes U0122, U0350, U1313, U1113 only :
Codes U1313, U0350, U1213, U1113 only :
Codes U1313, U0350, U1113 only :
A/C verve deactivation prevented
Vehicle speed info prevented
y
Fault chart (Code U0122 - U0350 - U0350 - U0350 - U0350 - U0350 - U0416 - U1113 - U1213 - U1313)
p
1
c o
Consult the vehicle manufacturer network
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-193

I DIAGNOSTICS
DETECTABLE FAULTS
CAN - TCU
trouble code
U0103 CAN - TCU - Absent No communication with the transmission control unit (TCU)
U0350 CAN - TCU - Absent One or more frames sent by the transmission control unit are corrupted.
or
One or more data packets received by the CAN from the transmission control unit
are invalid.
or
One or more frames sent by the transmission control unit have not been received.
or
No communication with the transmission control unit (TCU)
U0350 CAN - TCU - Invalid data One or more frames sent by the transmission control unit are corrupted.
U0350 CAN - TCU - Value invalid One or more frames sent by the transmission control unit are corrupted.
y
or
op One or more data packets received by the CAN from the transmission control unit
c
are invalid.
e 10
or
c
One or more frames sent by the transmission control unit have not been received.
a n /20 or
v 09
No communication with the transmission control unit (TCU)
d
U1109 CAN - TCU - Absent One or more frames sent by the transmission control unit have not been received.
U1209 CAN - TCU - Value invalid
A 9/ One or more data packets received by the CAN from the transmission control unit
0
are invalid.
U1309 CAN - TCU - Invalid data One or more frames sent by the transmission control unit are corrupted.
Codes U1309, U1109, U0103 only :
"SAFETY" warning lamp on (C4 Picasso Auto, 407/C5 Auto, 807/C8 Auto only)
Cruise Control deactivated (C4 Picasso Auto, 407/C5 Auto, 807/C8 Auto only)
Code U0103 only :
Speed Limiter deactivated (C4 Picasso Auto, 407/C5 Auto, 807/C8 Auto only)
Cruise Control / Speed Limiter deactivated (C4 Picasso Auto, 407/C5 Auto, 807/C8 Auto only)
Fault chart (Code U0103 - U0350 - U0350 - U0350 - U1109 - U1209 - U1309)
© Delphi
2-194 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
DETECTABLE FAULTS
DCU CONFIGURATION
trouble code
P0610 DCU programming - Invalid The DCU configuration has not been done correctly.

p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 2-195

I DIAGNOSTICS
DETECTABLE FAULTS
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
2-196 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
NON DETECTABLE FAULTS
3.1 LIST OF FAULTS / SYMPTOMS

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

1 Pedal sensor fault Check:
- Sensor mounting
- Sensor movement
- Consistency of the pedal signal (0 to 100%)
2 CC/SL button fault Check:
- Mechanical button operation (movement, mobility)
- The voltage levels from the buttons depending on which
button is pressed
3 Rail pressure sensor offset not detected - Read the rail pressure value when cranking
y
4 Engine oil conformance Check:
p
- Oil quality conformance
o
- Oil level correct
c
e 10
- Oil diluted by fuel (post inj. DPF).
c
- Condition of oil vapour recycling circuit
n /20
- Condition of the VGT bearings (cleanliness inside the
a
v 09
circuit)
d
5 Fuel problem Conformance of the fuel
A 9/
6 Exhaust circuit conformance Check:
- Exhaust outlet
0 -
-
Catalytic converter is free of debris
DPF clogged
- Catalytic converter clogged
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-197

I DIAGNOSTICS

3.1.2 Engine hesitation / instability
CAUTION
Apply the procedures relating to cleanliness for all operations

1 Tank empty? Check:
- Presence of fuel in tank / fuel level indicator / primer
bulb
- Sender unit operation
- Conformance of the fuel (petrol, water...) take a sample
2 Check:
- Condition (cut, blocked, ...) of the injector return circuit
Check the fuel supply circuit - Pump supply hose cut or blocked
- Sealing / clogging of the fuel filter
y
- LP connection inverted
op - Fuel filter clogged
c
- Incorrect fuel filter (reference)
e 10
- LP fuel circuit blocked
c
n /20
- Air leak in LP circuit
a
- Pump return circuit blocked
d v 09 - Tank sealing / breather
A 9/
- IMV function
3 Engine mounting Check:
4 0
Check the mechanical and electrical systems
-
Check:
-
Condition of the engine and transmission mountings
Alternator charging
- Battery voltage
- Air conditioning compressor
- Automatic Transmission
- Power assisted steering
5 C3I conformance Check:
- Cylinder to cylinder conformance
6 Sensor drift Check:
- Read the flowmeter value
- Turbo pressure value reading
- Coolant temperature reading
- Read the clutch pedal switch status
- Read the accelerator pedal setting
© Delphi
3-198 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

- Exhaust outlet
- Catalytic converter is free of debris
- DPF - catalytic converter blocked
8 EGR valve - Valve seized or broken
- EGR flap valve position sensor problem
9 Heater plugs - Conformance of the plugs/harness/unit
10 Engine compression - Known method
11 Check:
- Injector contaminated
Injector problem - Needle stuck
- Sealing washer (missing, double or incorrect)
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-199

I DIAGNOSTICS

3.1.3 Engine stop - stalling
CAUTION

1 DCU supply US? Check:
- Fuses
- Relay
- ECU earth
- Harness connections
- Battery and charging circuit
2 Check:
Check fuel conformance bulb
y
op - Conformance of the fuel (petrol, water...) take a sample
c
3 Air intake circuit conformance Check:
e 10
- Altitude
c
- Obstruction
a n /20 - Condition of the VGT
v 09
- Filter downstream from the VGT (exchanger, pipes...)
d
A 9/
-
-
Air filter (clogged & conformance)
Conformance of the line
4 0 -
Check:
-
Air flap functioning (if present) or position sensor
Condition (cut, blocked, ...) of the injector return circuit

- Tank sealing / breather
5 Check:
- Visual
Is there an HP leak? - Smell
- Exhaust outlet
- DPF clogged
© Delphi
3-200 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

7 Check:
(using the plugging the rail method)
HP circuit - The pump
- The injectors (if stuck open)
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-201

I DIAGNOSTICS

3.1.4 Rushing noise
CAUTION

3 Undetected coolant temperature sensor drift - Measurement of the ambient value read
4 Check:
- OCR control
IMV - Verification of requested rail pressure/measured rail
pressure
- Presence of pollution
y
5 Check:
p
- Conformance of the injector / engine
Unsuitable injector
c o
e 10
6 Fuel problem Check:
c
- Conformance of the fuel
a n /20
d v 09
A 9/
0
© Delphi
3-202 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.5 Noise interference
CAUTION

1 Noise on injector Check:
- Injector "buzzing" noise
(Discharge via the injectors)
- Compare with the actuator test
- Incorrect injector clamp fitting
2 HP pipe noise Check:
- the clips are correct
- Condition of the clips
3 Noise from mechanical and electrical equipment Check:
y
- Alternator
op - Clutch
c
e 10
c
n /20
a
- VGT
d v 09 - Other
A 9/
4 Air noise Check:
- Air filter (3 parts)
0 -
-
Conformance of the air line
(Flowmeter, exchanger...)
VGT
5 Exhaust noise Check:
- Exhaust outlet
- Catalytic converter
- DPF
- EGR
6 Accessory noise Check:
- Auxiliary heating
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-203

I DIAGNOSTICS

3.1.6 Engine noise
CAUTION

4 Airflow sensor drift - Air flow reading compared with a nominal value
5 EGR valve stuck open or closed Check:
- Vacuum circuit connection correct
- Solenoid valve breather
- EGR flap valve position sensor
p y - Valve seized or broken
o
6 Injector return circuit Check the conformance of the return circuit:
c
- Clip on the injector
e 10
- Condition of the hoses
c
n /20
- Condition of the venturi
a
7 Heater plugs Check:
v 09
- PPH harness condition
d
A 9/
-
-
PPH unit logic
Condition of the plugs
0
9 Check:
Unsuitable injector - Sealing washer on the cylinder head
10 Check:
© Delphi
3-204 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.7 Excessive consumption
CAUTION

1 Vehicle conformance Check:
- Conformance of the tyres
- Accessories (roof rack...)
- Parking brake
- Equipment...
3 Check the mechanical and electrical systems Check:
- Alternator charging
y
- Battery voltage
op - Air conditioning compressor
c
e 10
4
c
n /20
Check:
a
- Injector return pipes cut
v 09
Check the fuel supply circuit - Pump return circuit cut
5
d
A 9/
Check the fuel quality Check:
- Conformance of the fuel (presence of petrol, water...)
0
- Taking a sample
6 Check:
- Visual
Is there a fuel leak? - Smell
7 EGR valve stuck open Check:
- Valve seized or broken
- Altitude
- Obstruction
- Condition of the VGT
- Filter downstream from the VGT (exchanger, pipes...)
- Conformance of the line
- Functionality of choke (if present)
9 Oil level correct Check:
- Oil level too high
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-205

I DIAGNOSTICS

- Exhaust outlet
- DPF / Catalytic converter clogged
12 Injector problem Check:
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
3-206 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.8 Engine difficult to start when hot
CAUTION

1 Check fuel conformance Check:
bulb
2 Check the battery/starter Check:
- Charging/ battery voltage
3 Starter US ? - Check the engine rpm under cranking
4 Check:
y
p
Check the fuel supply circuit - Pump supply hoses cut or leaking
c o - Sealing / clogging of the fuel filter
e 10
c
a n /20 - Pump return circuit blocked
v 09
5
d
A 9/
Check:
- Visual
0
Is there a major HP leak? - Smell
- Fuses
- Relay
- ECU earth
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-207

I DIAGNOSTICS

- Flowmeter
- Obstruction
- Air filter
- Inlet air flap valve control routine
- Air heater bypass flap valve control routine
- EGR cooler bypass flap valve routine
- EGR control routine
- Air flow control routine
- EGR flow control routine
- Boost pressure control routine
y
- Exhaust outlet
op - Catalytic converter is free of debris
c
e 10
- Particle filter - Clogged
9 C3I conformance
c
n /20
Check:
a
v 09
11 EGR valve stuck open
d
A 9/
Check:
0
12 Check:
- Rail pressure on starting
IMV partially blocked - IMV
14 Check:
© Delphi
3-208 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.9 Engine starts then stalls
CAUTION

bulb
2 Check:
Check the fuel supply circuit - Pump supply hoses cut or leaking
y
- LP connection inverted
op - Incorrect fuel filter (reference)
c
e 10
c
n /20
a
3 DCU supply US?
d v 09 Check:
A 9/
- Fuses
- Relay
0 -
-
-
ECU earth
Harness connections
Battery and charging circuit
- Exhaust outlet
- DPF and/or Catalyser clogged
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-209

I DIAGNOSTICS

9 Check:
- Rail pressure on starting
Pump problem - IMV
10 Heater plugs - Conformance of the plugs/harness/unit
- Needle stuck or blocked open
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
3-210 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.10 Smoke on acceleration
CAUTION

1 Driving conditions Ask:
- Driving conditions during the phenomenon (town,
altitude, speed, towing...)
3 Airflow sensor drift - Air flow control
5 Turbo pressure sensor drift not detected - Boost pressure control
6 Atmospheric pressure sensor offset not detected - Read the atmospheric pressure value in comparison with
y
a nominal value
p
7 Undetected coolant temperature sensor drift • Measurement of the ambient value read
8 EGR circuit conformance
c o Check:
e 10
c
n /20
a
v 09
- Condition of the valve (seized or broken)
d
A 9/ - Cooler bypass flap valve status
0
- Vacuum pump vacuum value
- Bypass flap valve solenoid valve breather
- Air flap valve and its position sensor operation
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-211

I DIAGNOSTICS

- Flowmeter
- Obstruction
- Air filter (clogging and conformance)
10 Engine conformance Check:
- Engine coolant consumption
- Oil level (too high)
y
- Oil vapour circuit
op - Turbo bearings(VGT)
c
- Injector clamp fitting
e 10
- Cylinder compression
c
n /20
- Cylinder head/injector sealing washer
a
11 Check:
v 09
- Presence of water in filter
Conformance of the fuel
d
A 9/
-
-
Conformance of the fuel (mix, quality)
Inappropriate additive
12 Exhaust circuit conformance
0 Check:
-
-
DPF holed or regenerating
Catalytic converter clogged
13 Check:
Unsuitable injector - Sealing washer on the cylinder head
14 Check:
© Delphi
3-212 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.11 Blue & white smoke
CAUTION

1 Conformance of the fuel Check:
- Presence of water in filter
- Conformance of the fuel (mix, quality)
- Inappropriate additive
2 Engine conformance Check:
- Oil level (too high)
- Turbo bearings(VGT)
p y - Injector clamp fitting
o
3 c
e 10
Air intake circuit conformance
-
Check:
Cylinder head/injector sealing washer
c
n /20
- Flowmeter
a
- Air filter
d v 09 - Line sealing
A 9/
- Operation of the air throttle (if present)
5 0
PPH circuit conformance
-
Check:
-
Catalytic converter clogged
Control unit
- plugs
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-213

I DIAGNOSTICS

3.1.12 Lack of power
CAUTION

1 Vehicle conformance Check:
- Conformance of the tyres
- Accessories (roof rack)
- Parking brake
- Equipment...
- Sensor mounting
y
- State of the accelerator cable
op - Sensor movement
c
e 10
c
a n /20 - Battery voltage
v 09
d
A 9/
-
-
Automatic Transmission
Power assisted steering
5 Sensor drift
0 Check:
-
-
Read the flowmeter value
Read the turbocharging pressure
- Read the accelerator pedal setting
- Read the catalytic converter - DPF temperature
6 Check:
- Pump supply hoses pinched or leaking
Check the fuel supply circuit - Sealing / clogging of the fuel filter
- Fuel reheating
7 Check:
- Visual
© Delphi
3-214 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

8 EGR circuit conformance Check:
- Cooler bypass flap valve status
p y - Air flow control routine
o
9 Air intake circuit conformance
c
e 10
Check:
- Altitude
c
n /20
- Flowmeter
a
- Obstruction
d v 09 - Air filter (clogging and conformance)
A 9/
0 -
-
Inlet air flap valve control routine
Air flow control routine
• Oil level too high
- Exhaust outlet
- DPF - catalytic converter blocked
- Needle stuck or blocked open
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-215

I DIAGNOSTICS

3.1.13 Engine does not start
CAUTION

1 DCU locked - Check immobiliser operation
bulb
- Conformance of the fuel (petrol, water...)
3 Starter US ? - Check the engine rpm under cranking
4 Check:
- Pump supply hose cut
y
Check the fuel supply circuit - Sealing / clogging of the fuel filter
op - LP connection inverted
c
e 10
c
n /20
a
d v 09 - Tank sealing / breather
A 9/
5 Check:
- Visual
0
- Fuses
- Relay
- ECU earth
7 Ignition key problem Check the ignition key operation
- Flowmeter
- Obstruction
- Air filter
- Exhaust outlet
© Delphi
3-216 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

13 Cam and CRANK signals missing at the same time Check:
(when cranking)
- CAM signal conformance
- CRANK signal conformance
14 Check:
- IMV
IMV stuck closed
15 - Take a fuel sample from the tank
y
Fuel quality (presence of water)
p
16 Intermittent connection fault - Known method (test the connector, wire...)
o
17 Heater plugs - PPH unit logic
18 Engine compression
c
e 10
- Known method
c
19 Transfer pump US - Pump return flow measurement (nominal value when
n /20
cranking)
a
20 HP pump US - Read the consistent rail pressure (nominal value when
d v 09 cranking)
A 9/
21 Injector valve leak - Return flow measurement (nominal value when
cranking)
22
Injector stuck open

0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-217

I DIAGNOSTICS

3.1.14 Engine does not stop
CAUTION

1 Check:
- Oil quality
Engine oil conformance - Oil level correct
- Oil diluted by fuel (post inj.- DPF)
- Condition of oil vapour recycling circuit
- Condition of the VGT bearings (cleanliness inside the
circuit)
2 Ignition key problem Check that the ignition key data is correctly transferred to the
DCU
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
3-218 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.15 Engine dies when moving off
CAUTION

- Sensor mounting
- Sensor movement
2 Rail pressure sensor offset not detected - Rail pressure reading
3 Turbo pressure sensor drift not detected - Check the value of the turbocharging pressure
- Battery voltage
p y - Air conditioning compressor
o
c
e 10
-
-
Power assisted steering
Brakes stuck...
5
c
n /20
Check:
a
v 09
Check the fuel supply circuit
d
- Pump supply hoses cut or leaking
A 9/
6
0
Air intake circuit conformance
-
-
Check:
Air leak in LP circuit
Tank sealing / breather
- Air filter
- Conformance of the air line (flowmeter; exchanger...)
- Exhaust outlet
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-219

I DIAGNOSTICS

8 Check:
Engine conformance - Oil level (too high)
- Turbo bearings(VGT)
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
3-220 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.16 Smell of fuel
CAUTION

1 Check:
- Condition of the tank (filler neck; breather connections...)
Condition of the LP fuel circuit - Condition of the fuel filter (type; quick release
connections; heater...)
- Condition of the pump (quick release connections)
- Condition of the venturi / fuel temperature sensor (type;
quick release connections; sensor clamp fitting...)
- Primer bulb condition
- Condition of the injector return circuit
y
- Condition of the auxiliary heating (if present)
2
op Check:
c
- Condition of the pump (IMV; limiter; HP pipes...)
e 10
Conformance of the HP fuel circuit - Condition of the rail / pressure sensor (type; thread...)
c
n /20
- Condition of the injector (clamp fitting; connections...)
a
3 Exhaust injector blocked open Check:
v 09
- The exhaust injector operation
d
A 9/
- The operation of the exhaust injector shut off valve (flap
mobility, vacuum value, vacuum circuit conformance, air
0
breather etc...)
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-221

I DIAGNOSTICS

3.1.17 Exhaust smells
CAUTION

- EGR valve position sensor
- Oil level too high
3 VGT problem Check:
- Condition of the VGT bearings
- Exhaust outlet
y
op - DPF and/or Catalyser clogged
c
- Exhaust line sealing
e 10
- EGR circuit sealing
c
5 Check:
a n /20 - Conformance of the injector / engine
v 09
Injector problem - Injector clamp fitting
d
- Sealing washers (conformance, double or missing)
6 Software bug
A 9/ - DCU download then change DCU if problem persists
0
© Delphi
3-222 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

3.1.18 Idle speed stuck
CAUTION

1 Undetected coolant temperature sensor drift Check:
- Consistency of the ambient value
- Check the sensor circuit (resistance; connector;
continuity)
- Bleed the cooling circuit
2 Offset for fuel injected at idle speed Check:
- Consistency of the fuel injected (high residual torque)
y
- Battery voltage
op - Air conditioning compressor
c
e 10
c
n /20
a
v 09
d
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-223

I DIAGNOSTICS

3.1.19 Idle unstable - Hunting
CAUTION

bulb
- Battery voltage
y
op - Power assisted steering
c
3 Check:
e 10
- Condition (cut, blocked...)
c
a n /20 - Sealing / clogging of the fuel filter
v 09
d
A 9/
-
-
Air leak in LP circuit
Pump return circuit blocked
4 0 -
Check:
-
Tank sealing / breather
Visual
- Air filter
- Operation of the air throttle (if present)
- DPF: IAH flap (if present)
- Exhaust outlet
7 C3I conformance - Cylinder to cylinder conformance
8 Preheater plug circuit - Conformance of the plugs (post heating)
© Delphi
3-224 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

11 Check:
- Verification of requested rail pressure/measured rail
IMV pressure + IMV parameters (current loop...)
- HP pump US
12 Intermittent connection fault Known method (test the connector, wire...)
y
14
op Check:
c
e 10
Injector problem - Injector contaminated
c
- Needle stuck
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-225

I DIAGNOSTICS

3.1.20 Engine overheat
CAUTION

- Fuel quality
- Conformance of the fuel (petrol, water...)
- Take a sample
3
p y
Undetected coolant temperature sensor drift Check:
o
- Consistency of the ambient value
c
- Check the sensor circuit (resistance; connector;
e 10
continuity)
c
- Bleed the cooling circuit
4
a n /20
Conformance of the DCU configuration Check:
v 09
- Cooling configuration
5 d
A 9/
Condition of the cooling system
-
Check:
Equipment configuration
0
- Fans
- Harness
- Fan supply (fuses; relays...)
- Exhaust outlet
7 Preheater plug circuit Check:
- Conformance of the plug supply
© Delphi
3-226 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

9 Coolant Temperature Reheat solenoid valve conformance Check:
10 Check:
Engine conformance - Oil level (too high)
11 Software bug - ECU download then change ECU if problem persists
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-227

I DIAGNOSTICS

3.1.21 Acceleration flat spots
CAUTION

- Sealing of the air line (all components)
2 Turbocharging pressure problem - Comparison of the setting value and measured value
- Sensor mounting
- State of the accelerator cable
- Sensor movement
y
op - EGR flap valve position sensor
c
e 10
c
n /20
a
d v 09 - Air flap valve and its position sensor operation
A 9/
5 Check:
- Low pressure circuit
0
Check the fuel supply circuit conformance - Clogging of the fuel filter
- Battery voltage
7 Engine compression Check:
- Compression at each cylinder
8 Check:
- Visual
Is there an HP leak in transitory phase? - Smell
© Delphi
3-228 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I

9 Check:
- OCR control
IMV - Verification of requested rail pressure/measured rail
pressure
- Presence of pollution
- Condition of the exhaust system (catalytic converter and
DPF)
11 Check:
- Cylinder by cylinder fuel gaps
Injector problem
12 Fuel problem Check:
- Conformance of the fuel
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 3-229

I DIAGNOSTICS
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
3-230 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
CHECKS
4.1 DESCRIPTION OF THE CHECKS
4.1.1 Earthing Checks
Fault chart (Code

1 Check condition and tightness of battery earth terminal Carry out required repairs.
Battery terminal problem?
2 Check condition and tightness of battery/chassis earthing point Carry out required repairs.
Is there a problem with the battery/chassis earthing point?
3 Check battery/chassis earth connection continuity Carry out required repairs.
Line problem?
4 Check condition and tightness of battery/engine earthing point Carry out required repairs.
Is there a problem with the battery/chassis earthing point?
5 Check battery/engine earth connection continuity Carry out required repairs.
Line problem?
p y
o
6 Check condition and tightness of DCU/chassis earthing point Carry out required repairs.
c
Is there a problem with the DCU/chassis earthing point?
e 10
c
n /20
Connection problem?
a
8 Check continuity of each DCU earth line Carry out required repairs.
d v 09
Continuity problem in one or more lines?
A 9/
4.1.2 Checking the electrical supply circuits.
Stage
1
0
Monitoring electrical supply: Check level of battery charge and Carry out required repairs.
Result
that alternator is working

Is there a charging circuit problem?
2 Check the fuses Carry out required repairs.
Is there a fuse problem?
3 Check the correct operation of the supply relay Replace supply relay
Is there a supply relay problem?
4 Check the DCU earth Carry out required repairs.
Is there a DCU earth problem?
5 Electrical supply circuit OK
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 4-231

I DIAGNOSTICS
CHECKS
4.1.3 Line insulation and continuity checks
Checking continuity
• Visually check for any signs of stress or damage and that cabling is securely fastened.
• Switch off ignition and wait for power latch phase completion.
• Disconnect battery beginning with negative terminal.
• Disconnect DCU and fit terminal box without re-connecting DCU.
• Disconnect any components connected to the line to be tested.
• Use a multimeter in Ohmmeter mode to check resistance between the component-side connector terminal
and the corresponding terminal box exit.
Result Diagnostics
Value measured very low (near 0 Ohms) Line is continuous
Measured value very large (infinity) Line is cut
y
Sensor or Actuator Mini B.O.B. Vehicle harness DCU terminal box DCU
op
c
B
c e 10
n /20
Ω
0.1 Ω
a
OL
d v 09
A 9/
Note: 0
After completing intervention reconnect battery starting with positive terminal.
© Delphi
4-232 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
CHECKS
Check for any short-circuits between lines
• Disconnect any components connected to the two lines to be tested.
• Use a multimeter in Ohmmeter mode to check resistance between the two terminal box outputs
corresponding to the two lines being tested.
Result Diagnostics
Value measured very low (near 0 Ohms) Short-circuit between lines being monitored
Measured value very large (infinity) No short-circuit between lines being monitored
Sensors or
Vehicle harness DCU terminal box DCU
Actuators
p y
c o
c e 10
n /20
0.1 Ω OL Ω
a
v 09
d
A 9/
Note:
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 4-233

I DIAGNOSTICS
CHECKS
Check for any short-circuits to earth
• Disconnect any components connected to the line to be tested.
• Use a multimeter in Ohmmeter mode to check resistance between the terminal box output corresponding
to the line being tested and to earth.
Result Diagnostics
Value measured very low (near 0 Ohms) Line is short-circuited to earth
Measured value very large (infinity) Line is not short-circuited to earth
Sensor or Actuator Mini B.O.B. Vehicle harness DCU
y
A
p
B
c o
e 10
Ω Ω
c
0.1 OL
a n /20
d v 09
A 9/
Note:
0
Note:
After completing intervention, remove terminal box having previously made sure that contact is cut, and having
disconnected the battery beginning with negative terminal. Then re-connect battery beginning with positive
terminal. © Delphi
4-234 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
CHECKS
4.1.4 Checking a component connection
Step Procedure
1 Switch off ignition and wait for power latch phase completion.
2 Disconnect component connector and visually check terminals.
3 Check for any traces of oxidation that might create bad contact conditions.
4 Visually check connection.
5 Check that connector pins and terminals are intact and correctly inserted in their respective connectors.
6 Make sure terminals and pins are perfectly crimped or soldered to the conductor and that there is no mix-up of terminals
or pins when connecting.
7 After completing the above checks, reconnect the component and ensure connectors are correctly clipped in place.
4.1.5 DCU connections check
y
Step Procedure
1
p
Switch off ignition and wait for power latch phase completion.
o
c
2 Unplug component connector and do a visual check on terminals.
e 10
3 Check for any traces of oxidation, dust or silicon particles that might create bad contact conditions.
4
c
n /20
Visually check connection.
a
5 On DCU and harness check fool-proofing device compliance, body condition and connector fastenings.
6
d v 09
Check that connector pins and terminals are intact and correctly inserted in their respective connectors.
A 9/
7 Make sure terminals and pins are perfectly crimped or soldered to the conductor and that there is no mix-up of terminals
0
or pins when connecting.
8 After completing the above checks, reconnect the component and ensure connectors are correctly clipped in place.
4.1.6 Checking the low pressure circuit
Fault chart (Code

Tank empty?
- Check for leaks or air leaks (if non-immersed external
pump)
3 Check high pressure pump flow and pressure at entry Low pressure circuit is OK
Are flow and pressure values within tolerance?
4 Pressure too low Charge pump problem
5 Pressure and flow values too high or within tolerance Check high pressure pump transfer pressure valve
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 4-235

I DIAGNOSTICS
CHECKS
Fault chart (Code

6 Check charge pump flow at exit Check reservoir gauge well for foreign bodies and replace
Flow value outside tolerance charge pump if necessary
8 Check fuel filter for clogging Replace filter
Filter clogged?
9 Check there are no foreign bodies in supply circuit Carry out required repairs.
Any foreign bodies?
4.1.7 Checking the injectors and the high pressure circuit

Use hydraulic diagnostic tools and refer to the user manual included with the kits (CD DDRX113).
4.1.8 Checking engine parameters
p y
Stage
c o
e 10
1 Use diagnostic tool to check consistency of dynamic Carry out required repairs.
parameters:
c
n /20
a
- Parameters within tolerance (see the list of dynamic
v 09
parameters)
d
- Consistency of parameter values (check there is no drift)
-
A 9/
Stability of the values
0
Are the parameters incorrect?
2 End
© Delphi
4-236 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
CHECKS
4.1.9 C3I conformance check

1 Read the C3I stored in the DCU Use diagnostic tool to write C3I to memory.
Does the C3I stored in the memory correspond to that set in the Take care to ensure the cylinder number is correct.
injectors?
2 End
4.1.10 Checking the air inlet circuit

1 Check air inlet circuit: Check there are no air leaks Carry out required repairs.
Are there any leaks?
2 Check air filter condition Replace the air filter with a new component
y
Is there an air filter problem?
3
p
Ensure the inlet manifold is not blocked (with deposits)
o
Inlet air circuit OK
c
Inlet manifold blocked?
e 10
4 Clean inlet manifold
c
n /20
4.2 REFERENCE CURVES
a
v 09
4.2.1 RPM signal engine and camshaft d
A 9/
Idle
0
Pin 2
1V/div 1V/div
Conditions : Idling
2000rpm
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 4-237

I DIAGNOSTICS
CHECKS

Pin 2
1V/div 1V/div
Long tooth
p y
c o Pin 1 (YDT246) Pin 2 (YDT246)
e 10
Pin 2
c
1V/div 1V/div
a n /20 Engine speed signal Camshaft signal
d v 09 Measurement : EMC-G1 Measurement : EMC-E1
A 9/ Reference: IMC -38 Reference: IMC -38
Pin 1
Conditions : Idling
© Delphi
4-238 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
CHECKS
4.2.2 Injector control
Pilot and main injections at idle

5A/div 10V/div

Pin 1
Pin 2
Time base : 1ms/div
p y
o
Main injection at idle
c
e 10
Main injection
c
clamp 100mV/A)
Pin 2 (YDT471)
a n /20
v 09
Injector control voltage
d
Injector control current
A 9/ Measurement : - Measurement : EMC-L3
0 Pin 2

© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 4-239

I DIAGNOSTICS
CHECKS
4.2.3 IMV control
Note:
The IMV drive frequency is variable.
Pre-starting

Pin 1
2V/div -
p y Time base : 1ms/div
o
F=300Hz OCR=12%
c
Conditions : pre-starting
c e 10
Idle
a n /20
d v 09
A 9/
Pin 1 Pin 1 (YDT246) Pin 2
0
2V/div -
Time base : 1ms/div

F=377Hz OCR=40%
2000 rpm
© Delphi
4-240 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTICS I
CHECKS

Pin 1
2V/div -
Time base : 1ms/div

F=300Hz OCR=40%
4.2.4 Rail pressure and flow control

Hot start
p y
c o
c e 10
n /20
100%
100mg/st
8000rpm
2200bar
2200bar
a
v 09
d
A 9/ Requested rail pressure
0 Requested fuel
OCR IMV
Engine speed
Measured rail pressure

1800bar
1800bar
0mg/st
0rpm
0%
Time
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 4-241

I DIAGNOSTICS
CHECKS
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
4-242 DDNX340A(EN) - Issue 1 of 06/2010

TECHNICAL INFORMATION
5.1 TIGHTENING TORQUES

Components to tighten Torque
PPH plugs/engine block 10 to 15 N.m
DCU metal panel nut 2 Nm
PPH plug terminal nut 0.8 to 1.5 N.m
PWM SV fixing nut 10 N.m max
Water detector 2.5 Nm ± 10% after plastic diaphragm pierced
HP union on pump 18 Nm then 27 ± 2 Nm
HP union on injector 18 Nm then 27 ± 2 Nm
HP connector on rail (chamfer and black nut) 18 Nm then 27 ± 2 Nm
Pump/rail HP pipe vibration damper bolt 15 ± 1 N.m
Fixing bolt under harness 8 N.m max
On/Off SV fixing bolt 10 N.m max
Injector clamp bolt 7 N.m then 75° ± 5°
Pump/block mounting bolt
p y 22 ± 2 N.m
o
DCU / plastic base bolt Tighten by hand.
c
Rail/block mounting bolt 22 ± 2 N.m
e 10
IMV bolt on pump (staged tightening at the same time) 5.5 Nm
CRANK and CAM sensor bolt
c
n /20
10 N.m max
a
v 09
d
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-243

5.2 REFERENCE VALUES
Terminals
Components Measuring tolerance
Sensor or DCU
Pedal sensor YDT280 YDT484
(Connector 4 or 6 way - black error proofing) "signal 1" : 1 and earth : 2 "1" : PCC35 and PCC47
Hall effect
YDT280 YDT484
"signal 2" : 5 and earth : 4 "2" : PCC34 and PCC44
Rail pressure sensor YDT246 YDT483 Voltage depends on the pressure
(Connector, 3 way - red error proofing) Between 1 and 2 IMC 20 and IMC40
CRANK sensor YDT246 YDT482 Hall effect
(Connector, 3 way - blue error proofing) "raw " signal : 2 and earth : 1 EMC G1 and EMC138
CAM sensor YDT246 YDT483 Hall effect
y
(Connector, 3 way - white error proofing) "raw " signal : 2 and earth : 3 IMC E1 and IMC39
Catalytic converter temperature sensor
p
YDT246
o
Pre: Voltage depends on the temperature
c
(ditto on pre- and post) Between 1 and 2 • YDT482
e 10
(Connector, 2 way - brown error proofing) • EMC G2
c
Post:
n /20
• YDT482
a
v 09
• EMC H2
d
DPF differential pressure sensor YDT246 YDT482 Voltage is a function of pressure difference
(Connector, 3 way - black error proofing)
A 9/ Between 1 and 2 EMC D2 and A4
0
Manifold pressure sensor YDT246 YDT483 Voltage depends on the pressure
(Connector, 4 way - grey error proofing) Between 4 and 3 IMC 32 and 52
AC pressure sensor YDT246 YDT484 Voltage depends on the pressure
(Connector, 3 way - black error proofing) Between 2 and 3 PCC 33 and 45
Inlet air temperature sensor (in AMF) YDT280 YDT482 Voltage depends on the temperature
(Connector, 4 way - grey error proofing) Between 2 and 4 EMC F3 and A4
Inlet air temperature sensor YDT280 YDT483 Voltage depends on the temperature
(Connector, 4 way - grey error proofing) Between 1 and 3 IMC 08 and 52
Coolant temperature sensor YDT246 YDT483 Resistance depends on the temperature
(Connector, 2 way - green error proofing) Between 1 and 2 IMC H3 and B2
Fuel temperature sensor YDT246 YDT483 Resistance depends on the temperature
(Connector, 2 way - green error proofing) Between 1 and 2 IMC J3 and A4
Clutch pedal "On/Off" switch YDT484
Between 2 and 3 Voltage depends on pedal position
(Connector, 2 way - grey error proofing) PC 39
"Proportional" clutch pedal sensor 3V & 4V:
3V : Between 2 and 3
(Connector 3 or 4 way - black error proofing) • YDT484 Voltage depends on pedal position
4V : Between 2 and 4
• PCC 51 and 43
© Delphi
5-244 DDNX340A(EN) - Issue 1 of 06/2010

Terminals
Sensor or DCU
EGR valve - control/motor +:
(Connector, 5 way - blue error proofing) • YDT483
YDT521D • IMC 06 pwm signal
Between 1 and 2 -: Engine: 3.5 Ω at 20 .
• YDT483
• IMC 18
EGR valve - position sensor YDT521D YDT483
Voltage depends on the position
(Connector, 5 way - blue error proofing) Between 3 and 4 IMC 25 and 52
EGR exchanger by-pass - position sensor YDT482
(Connector, 3 way - blue error proofing) EMC A2
YDT246
and Voltage depends on the position
Between 2 and 3
YDT483
p y IMC 43
o
Filter water sensor YDT246 YDT482
c
Voltage depends on the presence of water
e 10
(Connector, 3 way - blue error proofing) Between 2 and 3 EMC D3
c
VGT position sensor YDT246 YDT483
n /20
Voltage depends on the position
(Connector, 3 way - black error proofing) Between 1 and 3 IMC 35 and 51
Brake pedal main switch
a
v 09
d
Between 1 and 2 (to BSI) Not closed at rest
(connector, 4 way, green)
Brake pedal duplicate switch
A 9/ YDT484
0
Between 3 and 4 Closed at rest
(connector, 4 way, green) PC 22
EGR cooler by-pass SV on/off YDT483
Supply from the ERU
(Connector, 2 way - black error proofing) YDT246 IMC 03
(+12V on pin 1)
Coolant temperature heater SV on/off Between 1 and 2 YDT484
20Ω at 20°C
(Connector, 2 way - black error proofing) PC 41
VGT pwm SV YDT483
Supply via the DCU IMC 17
(Connector, 2 way - black error proofing) IMC 04
(+12V on pin 1)
TAR flap pwm SV YDT246 YDT483
16.5Ω at 20°C.
(Connector 2 way) Between 1 and 2 IMC 02
2 A max
TAR by-pass flap valve pwm SV. YDT483
0.9 at 99% pwm
(Connector, 2 way - black error proofing) IMC 01
O2 probe YDT529D YDT483 Voltage depends on oxygen level
(Connector, 6 way, black) Between 2 and 6 IMC 24 and 34 Heating - Supply 12V/DCU IMC17 on pin 4
Supply 12V/DCU IMC 29 on pin 1
IMV YDT246 YDT482
5.3 Ω ± 10% at 20°C
(Connector, 2 way - brown error proofing) Between 1 and 2 EMC D4
1.2 A max
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-245

Terminals
Sensor or DCU
Injector n°1 to n°4 YDT482
(Connector, 2 way, grey on each injector) EMC:
(2 intermediate 4 pin connectors located on YDT471 • Injector n°1 : M3
the top of the engine for cylinder 1/2 and 3/4) and M4
Between 1 and 2
• Injector n°2 : L1
or 180 mΩ
and M1
YDT330
on secondary harness and M2
and L4
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
5-246 DDNX340A(EN) - Issue 1 of 06/2010

Variable solenoid valve

(Check with YDT246)
OCR/PWM(%) Vacuum(mbar / min-max)
0 0 - 70
20 15 - 120
40 120 - 240
60 290 - 390
80 490 - 560
95 570 - 760
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-247


(Check with YDT246)
Temperature(°C) Resistance (Ω)
- 40 167834
- 35 121097
- 30 88341
- 25 65121
- 20 48127
- 15 38427
- 10 27649
-5 21157
0 16138
y
5 12898
p
10 9551
c o
15 7857
e 10
20 5245
c
n /20
25 5068
a
30 4326
d v 09 35 3266
A 9/
40 2862
0
45 2163
50 1928
55 1432
60 1249
70 875
80 628
90 456
100 340
110 255
120 194
130 150
© Delphi
5-248 DDNX340A(EN) - Issue 1 of 06/2010

Air temperature sensor (integral in air flowmeter)

(Check with YDT280)
Temperature(°C) Nominal resistance(kΩ)
- 40 43,32
- 30 24,71
- 20 14,65
- 10 8,96
0 5,65
10 3,66
20 2,43
30 1,65
40 1,14
y
50 0,81
p
60 0,58
Fuel temperature sensor

c o
(Check with YDT246)
c e 10
n /20
Temperature(°C) Nominal resistance(Ω)
a
v 09
- 40 75780
d
- 10 12462
A 9/ 25 2252
0 50
80
811
283
110 115
120 88
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-249

Inlet air flowmeter

(Check with YDT280)
Air flow (kg/h) Frequency(Hz ) Max frequency(Hz )
550 8966 9077
500 8702 8811
450 8424 8530
400 8118 8221
350 7783 7884
300 7405 7502
250 6981 7072
200 6501 6574
150 5903 5991
y
100 5040 5128
p
80 4569 4648
c o 50 3804 3865
e 10
35 3315 3366
c
n /20
18 2582 2625
a
8 1816 1852
d v 09
A 9/
Manifold pressure sensor (combined with temperature)
(Check with YDT280)
0 Pressure (mbar)
500
Voltage(V)
1,58
1000 2,3
(Atmospheric pressure approx. 1020 mbar)
1500 3,2
2000 3,95
2500 4,75
© Delphi
5-250 DDNX340A(EN) - Issue 1 of 06/2010

Manifold inlet temperature sensor (combined with pressure)

(Check with YDT280)
Temperature(°C) Voltage(V)
- 40 4,88
- 16 4,6
08 4
32 3,04
56 2,02
80 1,24
104 0,74
128 0,45
152 0,28
y
176 0,18
p
184 0,15
c o 200 0,13
AC pressure sensor
c e 10
n /20
(Check with YDT246)
a
v 09
Pressure (bar) Voltage(V)
d
0 0,2
A 9/ 4 0,95
0 8
12
1,7
2,44
16 3,2
20 3,85
24 4,67
25 4,86
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-251

Rail pressure sensor

(Check with YDT246)
Pressure (bar) Voltage(V)
0 0,5
250 0,95
500 1,4
750 1,86
1000 2,32
1250 2,77
1500 3;2
1750 3,7
2000 4,1
y
2025 4,2
p
2200 4,5
c o
Catalyser temperature sensor (identical pre- and post characteristics)
(Check with YDT246)
c e 10
n /20
Temperature(°C) Voltage(V)
a
v 09
100 4,9
d
160 4,67
A 9/ 220 4,2
0 280
340
3,46
2,6
400 1,83
460 1,3
520 0,94
580 0,68
640 0,5
700 0,37
© Delphi
5-252 DDNX340A(EN) - Issue 1 of 06/2010

VGT position sensor (rod displacement for control diaphragm)

(Check with YDT246)
(%) Voltage(V)
0 0
15 0,73
30 1,5
45 2,2
60 2,95
75 3,7
90 4,4
100 5
Inlet air flap valve position sensor (normal flow & by-pass)
y
(Check with YDT246)
op (%) Voltage(V)
0
c
e 10
4,67
c
10 4,25
n /20
20 3,83
By-pass
a
v 09
30 3,42
d
RAS
RAS
40 3
A 9/ 50 2,58
0 60
70
2,17
1,75
80 1,33
90 0,92
100 0,5
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-253

EGR exchanger by-pass position sensor

(Check with YDT246)
(%) Voltage(V)
0 4,67
10 4,25
20 3,83
30 3,42
40 3
50 2,58
60 2,17
70 1,75
80 1,33
y
90 0,92
p
100 0,5
EGR position sensor (integral with the valve)

c o
(Check with YDT521 - Cable D)
c e 10
n /20
Opening (%) Min/max voltage(V)
a
v 09
0 0
d
15 0,73
A 9/ 30 1,46
0 44
58
2,2
2,93
74 3,66
88 4,4
100 5
DPF delta P sensor

(Check with YDT246)
Pressure (mbar) Voltage(V)
0 0,5
200 1,3
400 2,1
600 2,9
800 3,7
1000 4,5
© Delphi
5-254 DDNX340A(EN) - Issue 1 of 06/2010

5.3 TOOLING REQUIRED
5.3.1 Changes in diagnostic cables.
Note:
(*) Change from "SICMA2" to "SICMA3" type
connectors required removal of the external lug on YDT246 &
the male connectors in kits YDT246 and YDT280
YDT280.
A separate Technical Bulletin describes this
modification in detail.
This modification has been applied to kits
YDT246 and YDT280 : See DT444 .
p y
o
5.3.2 Changes to "SICMA" connectors.
Change from "SICMA2" to "SICMA3" type

c
e 10
c
connectors required a different locking system.
n /20
Unlocking is by simultaneous application of :
a
v 09
• light pressure on lug [1] with a small
d
screwdriver. Warning: Push =
A 9/
• a light extraction effort on the connector body Unlocked Pull =
[2] in line with the sensor or actuator axis. Broken !!!
0
This modification is described in a special
bulletin : See DT444 .
5.3.3 Special tooling summary.
Special tooling Part number

Plug dispenser YDT480
Vacuum cleaner YDT205
Peugeot Citroën CR kit YDT250
Upgrade kit YDT474
"Click" clip pliers YDT390
HP socket 17mm "long" YDT339
HP socket 17mm "short" YDT512
Injector extractor YDT522
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-255

Special tooling Part number

Hydraulic diagnostic Part number
H3PI - Hydraulic diagnostics kit YDT278
DFI1.5 connectors - Hydraulic diagnostics YDT478
500ml container with 8mm quick-fit to measure the pump backleak flow YDT377 (also included in kit YDT465)
Kit HP-T - Hydraulic diagnostics YDT465
Dummy actuator kit YDT410
DCU diagnostic Part number
DIAMAND YDT450 / YDT460
Electrical diagnostic Part number
154 way DCU terminal box harness kit (for the 48 and 53 way CINCH) YDT481 (YDT482 ; YDT483 ; YDT484)
Mini harness kit for sensors and actuators (for SICMA 2 and 3 way) YDT246
y
Mini harness kit for sensors and actuators (for SICMA 4 and 6 way) YDT280
p
Mini harness kit for sensors and actuators (for KOSTAL 4 way) YDT330
c o
Mini harness kit for sensors and actuators (for SICMA 5 way) YDT521
e 10
Mini harness kit for sensors and actuators (for KOSTAL 6 way) YDT529
Injector check harness (for FCI 2 way)
c
n /20
YDT471
5.3.4 General tooling summary

a
v 09
Standard tooling d
A 9/
Part number
0
Adaptor socket Facom R0.235 type
10 mm pipe wrench Facom 76.10 type
13 mm pipe wrench Facom 76.13 type
7 mm allen key Facom 83SH.7 type
Torque wrench, 0-5 Nm Facom R0.301 type
Torque wrench, 10-50 Nm Facom J.305DA type
Ratchet socket Facom S.372V type
10 mm combination wrench Facom 40.10 type
1/4 ratchet Facom R0.161 type
1/2 ratchet Facom S.161 type
Repositioner Facom S.234 type
1/4 8 mm socket Facom R0.8 type
© Delphi
5-256 DDNX340A(EN) - Issue 1 of 06/2010

Standard tooling Part number

Hexagonal socket head long Facom SHP.P6L type
17 mm crowfoot socket Facom 18.17 type
Torx 25 adapter Facom EX.625 type
Torx female socket 6 Facom RTX.6 type
Thin nose pliers Facom 185.20CPY type
1/4 extension Facom R0.209 type
1/4 extension Facom R0.210 type
1/2 extension Facom S.210 type
Reducer Facom S.230 type
y
Angular tightening sector Facom DM.360 type
5.3.5 Consumables summary

op
Parts, consumables and cleaning kit
c
e 10
Part number
"Clean" plugs
c
n /20
9001-870 to 9001-881 from dispenser YDT480
a
Clean brush
Cleaning solution
d v 09 Carclean brand
A 9/
Lint-free cloths
0
Clean container
Grease for injector and pump backleak O-rings. ORAPI "CT 615" type or equivalent.
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-257

5.3.6 Wiring diagrams
EMC M3
EMC M4
cylinder N° 1
EMC L1
EMC M1
Injectors
EMCM2
cylinder N° 3
EMC L3
EMC L4
cylinder N° 4
IMV EMC D4
2
4 IMC 52
EGR doser +
0V
5 IMC 14
valve position
5V
3 IMC 25
sensor
S
1 IMC 18
+ -
2 IMC 06
M
positive batt IMC 17

EGR By-pass
y
solenoid valve IMC 03
p
EGR by-pass 1 IMC 16
o
5V
2 EMC A2
position sensor
0V
c
IMC 43
DCU 3.5
S
Coolant 1
+ Batt ERU
e 10
temperature 2 PC 41
c
solenoid valve
IMC 29
n /20
VGT solenoid 1 positive batt
valve IMC 04 DW10CTED4
a
2
v 09
2 IMC 15
VGT position
5V
IMC 51 DELPHI
d
1
0V
sensor 3 IMC 35
S
A 9/
4-S EMC F3
Flowmeter with t° 2 - 0V EMC A4
0
air temperature
sensor 1-S EMC C3
Q 3
L + Batt ERU
6 - 5V PC 46
Accelerator 5 – S2 PC 34
pedal 4 – 0V n°2 PC 44
(LVS/CC ) 2 – 0V n°1 PC 47
1 – S1 PC 35
6-S IMC 34
2 - 0V IMC 24
O2 probe 5 IMC 22
4 – +batt IMC 17
3 IMC 53
1 IMC 23
1 IMC 14
5V
3 IMC 52
0V
Inlet air dose position 2 IMC 26

S
sensor + solenoid 2 – Ctrl IMC 02

valve
1 – +Batt IMC 17
1 EMC E2
5V
3 IMC 52
0V
2 IMC 21
Inlet air bypass dose
S
position sensor + 2 – Ctrl IMC 01

solenoid valve
1 – +Batt IMC 17
© Delphi
5-258 DDNX340A(EN) - Issue 1 of 06/2010

PC 22
positive
Dual brake pedal
IGN
Rear lamp via BSI switch
Oil pressure switch 12V

IMC 31
0v
0v
IMC 47 (diag) PPH unit
EMC H4 (cde)
PC 39 3 - 0v
PC 51 2-S
Clutch position sensor
PC 46 1 - 5V
IMC 41 1 - 12V Water sensor

EMC D3 0v
3-S on filter
IMC 39 3 - 0v
DCU .3.5 EMC E1
HALL
2-S CAM CAM sensor
DW10CTED4 EMC F1
1 - 5V
DELPHI 3 - 5v
HALL
EMC G1
2 - S CRANK CRANK sensor
IMC 38
y
1 - 0V
p
IMC 13 - 5V 3 - 5v
IMC 40 - 0V 2 - 0V
o
IMC 20 - S 1-S Rail pressure sensor
c
PC 45 3 - 0V
e 10
PC 33 2-S
PC 21
AC fluid pressure sensor.
1 - 5v
c
EMC J3
n /20
1-S t°
EMC A4 2 - 0V Fuel temperature sensor
a
v 09
EMC B2 2 - 0V t°
d
EMC H3 1-S
A 9/
IMC 32 4 – S press
IMC 52
t°
3 - 0V Turbo air temperature &
P
0
EMC F2 2 - 5V pressure sensor
IMC 08 1 – S temp
EMC B3 2 t°
EMC J1 1-S
Diesel temp. Pre-DPF
EMC C4
EMC A4 3 - 5V DPF delta P sensor
EMC D2 2 - 0V
1-S
3
PCC 08 12V ERU DPF additive pump
4
EMC A4 2 t°
EMC G2 1-S Diesel temp. Pre-pre-cata
EMC A4 2 t°
EMC H2 1-S
Diesel temp. Post-pre-cata
PC 40 CAN H 6 4
0v
PC 52 CAN L 14 5
EMC B1 ISO K 7
16 EOBD diagnostic socket
12V
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-259

PC 13
FAN1 CONTROL
PCC12
Fan 2 control
PCC26
Fan diagnostics
PCC 07
heater 1 control Or burner
PC 16
Heater 2 command
PC 27
Starter relay control
DCU 3.5
DW10CTED4
y
Alternator control LIN
EMC A1 DELPHI
op
c
+ batt Main
e 10
supply
c
relay PC 28
n /20
20A PCC02 & PCC05
+ batt
F1
F21
a
v 09
5A
Fan unit
d
ERU
A 9/
Secondary relay
PC 11
0
+ batt 15 A PCC 06
F05
30 A PCC 01
F10
F19
15 A PC 10
F20
10 A PC 30
PCC 03
PCC 04
Power earths.
Remote Control Wake PC 19

(RCW)
PC 10
Engine running data
1 signal EMC D1
Oil level
sensor 2 SENSOR EARTH EMC A3
© Delphi
5-260 DDNX340A(EN) - Issue 1 of 06/2010

5.4 ABBREVIATIONS AND DESCRIPTIONS
+IGN + Ignition on (battery voltage when ignition is on)

+Bat or VBat Battery voltage
ABS Anti Lock Brake System
AC Air Conditioning
Immob Engine immobiliser
ADIN Alternator-starter
AIH Air Heater (preheating resistor)
Supp. Power supply
AMF Air Mass Flow
AOS Anti-Oscillation Strategy
ASR Anti-skid
LP Low pressure
PPH unit Pre-post heating unit
ACCR Air conditioning cooling requirement
y
BSI Built-In Systems Interface
p
ERU Engine Relay Unit
o
LP Low pressure
Automatic
Transmission c
Automatic transmission
e 10
Manual Manual gearbox
c
n /20
a
Transmission
v 09
Sequential Sequential gearbox
d
C3I Individual Injector Correction
A 9/
C.A.N Controller Area Network (communication network)
0
3D Mapping Three dimensional map
SC Short circuit
SC - Short circuit to earth
SC+ Short circuit to a positive potential
Control Control
PCC Passenger Compartment Connector
A/C Air conditioning
EMC External Motor Connector
EMC Effective Average Torque
IMC Internal Motor Connector
PCC Passenger Compartment Connector
CR Common Rail
RHD Right-Hand Drive
LHD Left-Hand Drive
DCU Diesel Control Unit (injection DCU)
DTC Diagnostic Trouble Code (fault code)
EEPROM Electronically Erasable Programmable ROM
EGR Exhaust Gas Recirculation
EOBD European On Board Diagnostic
ESP Electronic Stability Programme
SV Solenoid valve
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-261

DPF Particle filter
Gap Gap representing two teeth missing from flywheel
Fan Fan unit
Fan 1 Fan low speed
Fan 2 Fan high speed
Heater Water heaters
Hexadecimal 16-character digital base from 0 to F
HP High pressure
HPS High Pressure Sensor
US Unserviceable, off
HSD Controlled by positive side of injector control circuit (High Side Drive)
IDE Identification
IMV Inlet Metering Valve
Info. Information
Key off Ignition off
Key on Ignition on
y
Limp home Recovery strategy which sets the engine speed to 1300 rpm regardless of pedal position. Used
p
to drive the vehicle to nearest parking place.
LIN
Linearised
c o
Controller Area Network (communication network)
A linearised value is the conversion of the signal sent to the DCU input into a physical value
LSD
c e 10
Controlled by earth (negative) side of injector control circuit (Low Side Drive).
n /20
VSL Vehicle speed limiter
a
Max Maximum
v 09
MDP Minimum Drive Pulse (minimum pulse required for injection).
d
Min Minimum
A 9/
NVM Non Volatile Memory
0
OBD On Board Diagnostic (diagnostics linked to emissions)
Pedal 1 Data from track 1 of accelerator pedal sensor
Pedal 2 Data from track 2 of accelerator pedal sensor
PICL Pilot Injection Closed Loop(Injector reset strategy)
Power latch Phase when DCU is on standby after ignition is switched off
PPH Pre-Post Heating
Prail Rail pressure
Preheating 1 Resistor control for preheating 1
Preheating 2 Resistor control for preheating 2
PWM Pulse With Modulation (%) See OCR
RAA Inlet air heater
TAR Turbo Air Reheat (TAR)
RAM Random Access Memory
RCW Remote Control Wake
OCR Open Cycle Ratio (%)
PI regulator Proportional Integral Regulator
RN Random Number
CTR Coolant Temperature Reheat
VCC Cruise control
S2RE Electronic heating regulation system
© Delphi
5-262 DDNX340A(EN) - Issue 1 of 06/2010

A-S After Sales Department
Swirl Inlet throttle
T° Temperature
Temp. Temperature
TCU Transmission Control Unit (automatic transmission control unit - TCU)
VGT Variable Geometry Turbo.
Thermo. 1, 2 or 3 Water heater 1, 2 or 3
Digital value It is the output value from the analogue / digital converter
VAN Vehicle Area Network
Vext Sensor supply voltage (approx 5V)
VSD Vehicle Specific Data (vehicle information used to program the codes)
WH Water Heater
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 5-263

FAULT CODE INDEX
Diagnostic trouble code Diagnostic tool title Page number

P0001 Inlet metering valve control - Open circuit (OC) 2-64
P0002 IMV control - IMV current requested - Plausibility 2-64
P0003 Inlet metering valve control - Short circuit to earth (SC-) 2-64
P0004 Inlet metering valve control - Short circuit to Vbat (SC+) 2-64
P0017 Starting - Too long 2-176
P006D Manifold pressure signal - Plausibility 2-118
P0087 Rail pressure regulation - Pressure difference - Negative error 2-59
P0088 Rail pressure regulation - Pressure difference - Positive error 2-59
P0093 Fuel flow correction too high – VLC strategy 2-67
P0094 Fuel flow correction too high – VLC strategy 2-67
P0096 Manifold air temperature signal - Plausibility 2-108
P0097 Manifold air temperature signal - Low 2-108
P0098 Manifold air temperature signal - High 2-108
y
P0100 Manifold pressure regulation 2-121
P0101
op
Air flowmeter signal - Variation rate 2-109
c
P0102 Air flowmeter signal - High 2-109
e 10
P0103 Air flowmeter signal - Low 2-109
P0111
c
n /20
Inlet air temperature signal - Plausibility 2-115
a
P0112 Inlet air temperature signal - Low 2-115
v 09
P0113 Inlet air temperature signal - High 2-115
P0115
P0116 d
A 9/
Coolant temperature signal - Plausibility
Coolant temperature signal - Variation rate
2-113
2-113
P0117
P0118
P0130
0
Coolant temperature signal - Low
Coolant temperature signal - High
Oxygen probe signal - Open circuit (OC)
2-113
2-113
2-129
P0131 Oxygen probe signal - Heater - Short circuit to earth (SC-) 2-129
P0132 Oxygen probe signal - Heater - Short circuit to Vbat (SC+) 2-129
P0133 Oxygen probe signal - Value outside range 2-129
P0134 Oxygen probe signal - Heating 2-129
P0171 Richness control - Plausibility 2-131
P0181 Fuel temperature signal - Variation rate 2-112
P0182 Fuel temperature signal - Low 2-112
P0183 Fuel temperature signal - High 2-112
P0191 Rail pressure signal - Variation rate 2-55
P0192 Rail pressure signal - Low 2-55
P0193 Rail pressure signal - High 2-55
P0201 Injector - Open circuit - Cylinder 1 2-101
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 6-264

FAULT CODE INDEX

P0215 DCU supply relay - Plausibility 2-53
P0220 Accelerator pedal – Correlation tracks 1& 2 2-162
P0222 Accelerator pedal sensor track 1 signal - Low 2-165
P0223 Accelerator pedal sensor track 1 signal - High 2-165
P0227 Accelerator pedal sensor track 2 signal - Low 2-166
P0228 Accelerator pedal sensor track 2 signal - High 2-166
P022A Inlet air heater bypass flap control - Open circuit (OC) 2-150
P022B Inlet air heater bypass flap control - Short circuit to earth (SC-) 2-150
P022C Inlet air heater bypass flap control - Short circuit to Vbat (SC+) 2-150
P0234 Boost pressure regulation - Negative error 2-121
P0235 Manifold pressure signal - Drift 2-118
P0236 Manifold pressure signal - Variation rate 2-118
y
P0237 Manifold pressure signal - Low 2-118
P0238
op
Manifold pressure signal - High 2-118
c
P0243 Turbo actuator control - Open circuit (OC) 2-123
e 10
P0245 Turbo actuator control - Short circuit to earth (SC-) 2-123
P0246
c
n /20
Turbo actuator control - Short circuit to Vbat (SC+) 2-123
a
P024A Inlet air heater bypass flap control - Positive error 2-154
v 09
P024B Inlet air heater bypass flap control - Negative error 2-154
P024C
P024D d
A 9/
Air heater bypass flap programming - Closed position
Air heater bypass flap programming - Open position
2-156
2-156
P024E
P024F
P0262
0
Inlet air heater bypass flap valve position signal - Low
Inlet air heater bypass flap valve position signal - High
Injector - Short circuit - Cylinder 1
2-152
2-152
2-106
P0263 Injector - MDP drift - Cylinder 1 2-97
P0265 Injector - Short circuit - Cylinder 2 2-106
P0299 Boost pressure regulation - Positive error 2-121
P0336 Engine speed signal - Absent 2-73
P0338 Engine speed signal - Additional teeth 2-73
P0339 Engine speed signal - Gap not detected 2-73
P0341 Camshaft reference signal - Incorrect synchronisation 2-70
P0342 Camshaft reference signal - Absent 2-70
P0343 Camshaft reference signal 2-70
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 6-265

FAULT CODE INDEX

P0401 EGR regulation - EOBD - Negative error 2-136
P0402 EGR regulation - EOBD - Positive error 2-136
P0405 EGR valve position signal - Low 2-133
P0406 EGR valve position signal - High 2-133
P0409 EGR flap valve control - Component stuck 2-134
P0470 DPF differential pressure signal - Plausibility 2-159
P0471 DPF differential pressure signal - Variation rate 2-159
P0472 DPF differential pressure signal - Low 2-159
P0473 DPF differential pressure signal - High 2-159
P0481 Fan diagnostic - Control blocked 2-80
P0483 Fan diagnostic – consistency 2-80
P0485 Fan diagnostic - fault detected 2-80
P0487 Air flap control - Positive error 2-147
y
P0488 Air flap control - Negative error 2-147
P0489
op
EGR regulation - Error too large - Open position 2-134
c
P0490 EGR regulation - Error too large - Closed position 2-134
e 10
P0493 Fan diagnostics 2-80
P0494 Fan diagnostics
c
n /20
2-80
a
P0495 Fan diagnostic - fault detected 2-80
v 09
P0500 Vehicle speed signal 2-184
P0504
P050B d
A 9/
Brake switches - Plausibility - Acceleration
Starting - Camshaft - crankshaft synchronisation
2-168
2-176
P0513
P0532
P0533
0
Starting - Immobiliser unlock - Too long
AC pressure signal - Low
AC pressure signal - High
2-176
2-171
2-171
P0562 Battery voltage - Low 2-51
P0563 Battery voltage - High 2-51
P0565 Cruise control - Plausibility 2-174
P0575 Speed limiter - Plausibility 2-174
P0603 DCU fault - EEPROM DCU 2-76
P0604 DCU fault - RAM integrity 2-78
P0605 DCU fault - Calibration zone 2-79
P0606 DCU FAULT 2-79
P0610 DCU programming - Invalid 2-195
P0611 Absence of injector reset 2-100
P0620 Alternator - Electrical fault 2-181
P0658 5V sensor supply (Vext1) - Low 2-47
P0659 5V sensor supply (Vext1) - High 2-47
© Delphi
6-266 DDNX340A(EN) - Issue 1 of 06/2010

FAULT CODE INDEX

P065A Alternator - Mechanical fault 2-181
P0685 Main relay control - Open circuit (OC) 2-53
P0686 Main relay control - Short circuit to earth (SC-) 2-53
P0687 Main relay control - Short circuit to Vbat (SC+) 2-53
P0691 Fan 1 control - Open circuit (OC) or short circuit to earth (SC-) 2-82
P0692 Fan 1 control - Short circuit to Vbat (SC+) 2-82
P0693 Fan 2 control - Open circuit (OC) or short circuit to earth (SC-) 2-83
P0694 Fan 2 control - Short circuit to Vbat (SC+) 2-83
P0704 Clutch pedal switch signal - Plausibility 2-170
P0812 Reversing signal 2-185
P0831 Clutch pedal switch signal 2-170
P0A1A Alternator - Communication - Fault 2-181
P107A Boost pressure regulation - Positive error 2-121
y
P1163 MDP UPDATE 2-100
P1164
op
Rail pressure signal - drift 2-57
c
P1166 Rail pressure regulation - Overpressure 2-59
e 10
P11AA Manifold pressure signal - Value too high 2-121
P11AB
c
n /20
Manifold pressure signal - Value too low 2-121
a
P11AC IMV control - IMV current requested - Blocked open 2-59
v 09
P11AD Rail pressure signal - Pressure drop 2-59
P11B2
P11B3 d
A 9/
EGR cooler valve position signal - High
EGR cooler valve position signal - Low
2-140
2-140
P129F
P12A0
P12A2
0
EGR regulation - Error too large - Closed position
EGR regulation - Error too large - Open position
Injector - Combustion too weak - Cylinder 1
2-136
2-136
2-94
P12A5 Injector - Combustion too weak - Cylinder 2 2-94
P12A8 Injector - Combustion too weak - Cylinder 3 2-94
P12AB Injector - Combustion too weak - Cylinder 4 2-94
P12B3 EGR regulation - Error too large - Open position 2-134
P12B4 EGR regulation - Error too large - Closed position 2-134
P1349 PPH relay control - Open circuit (OC) or short circuit to Vbatt (SC+) 2-86
P1350 PPH relay control - Short circuit to earth (SC-) 2-86
P1351 PPH diagnostic 2-85
P1366 Cylinder 1 injector control - harness resistance - Low 2-103
P1372 Cylinder 1 injector control - harness resistance - High 2-103
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 6-267

FAULT CODE INDEX

P1403 Additional heating 1 control 2-84
P1404 Additional heating 2 control 2-84
P1412 Pre-DPF temperature signal - Reduced flow mode 2-116
P1434 DPF additive pump control 2-161
P1435 DPF additive pump control 2-161
P1442 DPF additive pump control - Open circuit (OC) 2-161
P1443 DPF additive pump control - Short circuit to earth (SC-) 2-161
P1444 DPF additive pump control - Short circuit to Vbatt (SC+) 2-161
P1445 Diesel Particulates Filter - Wear 2-157
P1446 DPF additive level signal - Low level - Below the minimum threshold 2-161
P1447 Particle filter - Clogged 2-157
y
P1457 Diesel Particulate Filter - Absent 2-157
P1461
op
EGR programming - Closed position 2-138
c
P1462 EGR programming - Open position 2-138
e 10
P1471 Air flap control - Open circuit (OC) 2-143
P1490
c
n /20
Particle filter - Overloaded 2-157
a
P1496 Boost pressure regulation - Negative error - Closed position 2-127
v 09
P1497 Boost pressure regulation - Positive error - Open position 2-127
P1498
P1499 d
A 9/
Air flap control - Negative error max
Air flap control - Positive error max
2-147
2-147
P149A
P149B
P149C
0
Inlet air heater bypass flap control - Negative error max
Inlet air heater bypass flap control - Positive error max
VGT programming - Closed position
2-154
2-154
2-128
P14A3 EGR cooler valve position signal 2-141
P14A4 EGR cooler valve position signal 2-141
P1536 Brake switches - Plausibility 2-168
P1600 C2I/C3I fault 2-69
P160A Certification number - Invalid 2-175
P1612 Immobiliser - Invalid 2-179
P1621 DCU monitoring - Fault detected 2-79
P162A DCU monitoring - Fault detected 2-79
P1631 DCU monitoring - Fault detected 2-79
P1693 Starter status 2-186
P16A0 Oil combustion 2-178
© Delphi
6-268 DDNX340A(EN) - Issue 1 of 06/2010

FAULT CODE INDEX

P2031 Pre-DPF temperature signal - Plausibility 2-116
P2032 Pre-DPF temperature signal - High 2-116
P2033 Pre-DPF temperature signal - Low 2-116
P2084 Pre-DPF temperature signal - Variation rate 2-116
P2125 Air flap programming - Closed position 2-149
P2126 Air flap programming - Open position 2-149
P2127 Air flap position signal - Low 2-145
P2128 Air flap position signal - High 2-145
P2132 Accelerator pedal sensor kick-down signal - High 2-167
P2133 Accelerator pedal sensor kick-down signal - Low 2-167
P2134 Accelerator pedal sensor kick-down signal - Invalid 2-167
P2137 Accelerator pedal – Correlation tracks 1& 2 2-162
P2140 Accelerator pedal sensor kick-down signal - Plausibility 2-167
y
P2141 Air flap control - Short circuit to earth (SC-) 2-143
P2142
op
Air flap control - Short circuit to Vbat (SC+) 2-143
c
P2143 EGR valve control - Open circuit (OC) 2-132
e 10
P2144 EGR valve control - Short circuit to earth (SC-) 2-132
P2145
c
n /20
EGR valve control - Short circuit to Vbat (SC+) 2-132
a
P2147 Bank injector 1 diagnostic - High 2-88
v 09
P2148 Bank injector 1 diagnostic - Low 2-88
P2150
P2151 d
A 9/
Bank injector 2 diagnostic - High
Bank injector 2 diagnostic - Low
2-91
2-91
P2191
P2227
P2228
0
System too lean - Full load
Atmospheric Pressure Signal
Atmospheric pressure signal - Low
2-131
2-120
2-120
P2229 Atmospheric pressure signal - High 2-120
P2231 Oxygen probe signal - DCU fault 2-129
P2245 Richness control 2-131
P2291 Rail pressure regulation - Pressure rise - too slow 2-59
P2295 Inlet metering valve control - Low 2-64
P2296 Inlet metering valve control - High 2-64
P2297 Richness control - Deceleration 2-131
P2299 Accelerator pedal - Component stuck 2-163
P2400 CTR pump control - open circuit (OC) 2-173
P2401 CTR pump control - Line in short circuit (SC) 2-173
P2418 Coolant temperature reheat (CTR) solenoid valve control - open circuit (OC) 2-172
P2419 Coolant temperature reheat (CTR) solenoid valve control - Short circuit to earth (SC-) 2-172
P2420 Coolant temperature reheat (CTR) solenoid valve control - Short circuit to Vbat (SC+) 2-172
P2425 EGR cooler bypass valve control - Open circuit (OC) 2-139
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 6-269

FAULT CODE INDEX

P2426 EGR cooler bypass flap control - Short circuit to earth (SC-) 2-139
P2427 EGR cooler bypass flap control - Short circuit to Vbat (SC+) 2-139
P250B Engine oil level signal - Plausibility 2-177
P250C Engine oil level signal - Short circuit to earth (SC-) 2-177
P250D Engine oil level signal - Open circuit (OC) or short circuit to Vbatt (SC+) 2-177
P250E Engine oil level signal - Wake up 2-177
P2562 Boost pressure regulation - Positive error - Open position 2-127
P2563 Boost pressure regulation - Negative error - Closed position 2-127
P2564 Turbo actuator position signal - Low 2-125
P2565 Turbo actuator position signal - High 2-125
P2566 VGT programming - Open position 2-128
P2671 5V sensor supply (Vext2) - High 2-47
y
P2686
op
5V sensor supply (Vext3) - High 2-47
c
P2710 Air flowmeter signal - plausibility - Low 2-109
e 10
P2710 Air flowmeter signal - plausibility- EOBD 2-109
P2710
c
n /20
Air flowmeter signal - plausibility - High 2-109
a
v 09
P3026
P3027 d
A 9/
Air flowmeter signal - plausibility - High
Air flowmeter signal - plausibility - Low
2-109
2-109
U0019
U0028
U0055
CAN LS - fault
Comfort VAN 0
CAN Comfort - fault
2-180
2-180
2-180
U0103 CAN - TCU - Absent 2-194
U0122 CAN - ESP - Invalid 2-192
U0350 CAN Comfort - fault 2-180
U0350 CAN LS - fault 2-180
U0350 Comfort VAN 2-180
U0350 LIN - Alternator - Absent 2-180
U0350 LIN - Alternator - Blocked 2-180
U0350 CAN silent 2-180
U0350 CAN "Bus OFF" 2-180
U0350 CAN - BSI - Absent 2-180
U0350 CAN - BSI - Invalid data 2-180
U0350 CAN - BSI - Value invalid 2-180
U0350 CAN - ABS/ESP - Invalid data 2-180
U0350 CAN - ABS/ESP - Value invalid 2-180
© Delphi
6-270 DDNX340A(EN) - Issue 1 of 06/2010

FAULT CODE INDEX

U0350 CAN - ESP - Absent 2-180
U0350 CAN - ESP - Invalid 2-180
U0350 CAN - ESP - Plausibility 2-180
U0350 CAN - TCU - Invalid data 2-180
U0350 CAN - TCU - Value invalid 2-180
U0416 CAN - ESP - Plausibility 2-192
U1000 CAN silent 2-187
U1003 CAN "Bus OFF" 2-189
U1113 CAN - ESP - Absent 2-192
U1118 CAN - BSI - Absent 2-191
U1209 CAN - TCU - Value invalid 2-194
y
U1213 CAN - ABS/ESP - Value invalid 2-192
U1218
op
CAN - BSI - Value invalid 2-191
c
U1309 CAN - TCU - Invalid data 2-194
e 10
U1313 CAN - ABS/ESP - Invalid data 2-192
U1318
c
n /20
CAN - BSI - Invalid data 2-191
a
U1400 LIN - Alternator - Blocked 2-182
v 09
U1401 LIN - Alternator - Absent 2-182
U2000
U2003 d
A 9/
DCU wake-up - Invalid
DCU wake-up - Plausibility
2-183
2-183
U2118
U2A60
U2A60
0
DCU wake-up - Value invalid
DCU wake-up - Invalid
DCU wake-up - Plausibility
2-183
2-183
2-183
U2A60 DCU wake-up - Value invalid 2-183
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 6-271

NOTES
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 7-272

NOTES
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
DDNX340A(EN) - Issue 1 of 06/2010 7-273

NOTES
p y
c o
c e 10
a n /20
d v 09
A 9/
0
© Delphi
7-274 DDNX340A(EN) - Issue 1 of 06/2010

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TABLE OF CONTENTS

Produced and published by:

DDNX340A(EN) - Issue 1 of 06/2010 i

1. DIAGNOSTIC TOOL FUNCTIONS

ii DDNX340A(EN) - Issue 1 of 06/2010

DDNX340A(EN) - Issue 1 of 06/2010 iii

iv DDNX340A(EN) - Issue 1 of 06/2010

DDNX340A(EN) - Issue 1 of 06/2010 v

vi DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

1.1 DIAGNOSTIC TOOL CONNECTION

1.1.1 Equipment required

YDT460 DIAMAND diagnostic tool

DDNX340A(EN) - Issue 1 of 06/2010 1-1

DIAGNOSTIC TOOL FUNCTIONS

YDT450 DIAMAND diagnostic tool

YDT182 Diagnostic EOBD 16 way cable

1-2 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

YDT233 Auxiliary harness

YDT453 Diagnostic adaptor cable

Terminal box interface for DCU DCM3.5 /

DDNX340A(EN) - Issue 1 of 06/2010 1-3

DIAGNOSTIC TOOL FUNCTIONS

Pins No. of pins available

1.1.3 Diagnostic socket description

Diagnostic socket type: Pin no. Description

1.1.4 Diagnostic socket location

1-4 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

DDNX340A(EN) - Issue 1 of 06/2010 1-5

DIAGNOSTIC TOOL FUNCTIONS

1.1.5 Equipment for electrical diagnosis

1-6 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

YDT330 Mini-harness kit n°3

YDT471 Mini-harness injector FCI

YDT529 Mini-harness kit n°6

DDNX340A(EN) - Issue 1 of 06/2010 1-7

DIAGNOSTIC TOOL FUNCTIONS

1.1.6 Managing diagnostic tool - DCU communication

1-8 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

1.2 READING FAULT CODES

1.2.2 Using the diagnostic tool

Fault code monitoring function

DDNX340A(EN) - Issue 1 of 06/2010 1-9

DIAGNOSTIC TOOL FUNCTIONS

1.2.3 Environmental data

1-10 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX340A(EN) - Issue 1 of 06/2010 1-11

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1-12 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX340A(EN) - Issue 1 of 06/2010 1-13

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1-14 DDNX340A(EN) - Issue 1 of 06/2010

DIAGNOSTIC TOOL FUNCTIONS