Renault

1 Engine and peripherals
DIESEL INJECTION
13B
DDCR INJECTION
Program No.: BE
Vdiag No.: 14
Fault finding – Introduction 13B - 2

Fault finding – System operation 13B - 9
Fault finding – Replacement of components 13B - 15
Fault finding – Configuration and programming 13B - 17
Fault finding – Fault summary table 13B - 18
Fault finding – Interpretation of faults 13B - 20
Fault finding – Conformity check 13B - 74
Fault finding – Status summary table 13B - 79
Fault finding – Interpretation of statuses 13B - 80
Fault finding – Parameter summary table 13B - 83
Fault finding – Interpretation of parameters 13B - 84
Fault finding – Dealing with command modes 13B - 85
Fault finding – Tests 13B - 87
Fault finding – Customer complaints 13B - 112
Fault finding – Fault finding charts 13B - 113
V2 Edition Anglaise
"The repair procedures given by the manufacturer in this document are based on the All rights reserved by Renault s.a.s.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The procedures may be modified as a result of changes introduced by the reference numbering system is forbidden without the prior written authority of
manufacturer in the production of the various component units and accessories from Renault s.a.s.
which his vehicles are constructed."
© Renault s.a.s. 2008

MR-425-X35-13B050$TOC.mif
V2
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Introduction
1. SCOPE OF THIS DOCUMENT
This document presents the fault finding procedure applicable to all computers with the following specifications:
Vehicle(s): THALIA 2/ SYMBOL 2 Computer name: DDCR INJECTION
Engine: K9K 700, 706 Program No.: BE
Function concerned: DIESEL INJECTION

Vdiag No.: 14
DELPHI K9K COMMON RAIL (DDCR)
2. PREREQUISITES FOR FAULT FINDING

Documentation type:
Fault finding procedures (this manual):

– Assisted fault finding (integrated into the CLIP diagnostic tool), Dialogys.
Wiring Diagrams:
– Visu-Schéma (CD-ROM), paper.
Type of diagnostic tools:

– CLIP
Special tooling required:
Special tooling required
Multimeter
Elé. 1590 112-track computer bornier.
Elé. 1681 Universal bornier
Mot.1711 Injector flow measuring kit.

3. REMINDERS
Procedure
To run fault finding on the vehicle computers, switch on the ignition.

Depending on the type of vehicle equipment, proceed as follows:
For vehicles with key/radiofrequency remote control unit,

switch on the ignition with the key.
To cut off + after ignition feed, proceed as follows:
For vehicles with key/radiofrequency remote control unit,

switch off the ignition with the key.
DDCR_V14_PRELI
MR-425-X35-13B050$010.mif
V2
13B-2
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Faults
Faults are declared present or stored (depending on whether they appeared in a certain context and have
disappeared since, or whether they remain present but are not diagnosed within the current context).
The present or stored status of faults should be taken into consideration when the diagnostic tool is used after the
+ after ignition feed (without activating the system components).
For a present fault, apply the procedure described in the Interpretation of faults section.
For a stored fault, note the faults displayed and apply the Notes section.
If the fault is confirmed when the instructions are applied, the fault is present. Deal with the fault.
If the fault is not confirmed, check:

– the electrical lines which correspond to the fault,
– the connectors on these lines (corrosion, bent pins, etc.),
– the resistance of the faulty component,
– the condition of the wires (melted or cut insulation, wear).
– Or use diagnostics to check the circuit of the suspect component.
Conformity check
The aim of the conformity check is to check data which does not produce a fault on the diagnostic tool when the
data is inconsistent. Therefore, this stage is used to:
– carry out fault finding on faults that do not have a fault display, and which may correspond to a customer complaint.
– check that the system is operating correctly and that there is no risk of a fault recurring after repair.
This section gives the fault finding procedures for statuses and parameters and the conditions for checking them.
If a status is not behaving normally or a parameter is outside permitted tolerance values, you should consult the
corresponding fault finding page.
Customer complaints - Fault finding chart
If the test with the diagnostic tool is OK but the customer complaint is still present, the fault should be dealt with by
customer complaints.
A synopsis of the general procedure to follow is provided on the following page in the form of a flow chart.
MR-425-X35-13B050$010.mif
V2
13B-3
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
4. FAULT FINDING PROCEDURE
Perform a pre-diagnostic on the system
Print the system fault finding log (available on

CLIP and in the Workshop Repair Manual or
Technical Note)
Connect CLIP
Dialogue with
NO See ALP no. 1
computer?
YES
Read the faults
Faults present NO
Conformity check
YES
Deal with present faults

The cause is still
present NO
Fault solved
Deal with stored faults Use fault finding charts (ALPs)
The cause is still The cause is still

present NO present NO
Fault solved Fault solved
YES Contact Techline with the completed fault

finding log
MR-425-X35-13B050$010.mif
V2
13B-4
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
4. FAULT FINDING PROCEDURE (continued)

Wiring check
Fault finding problems

Disconnecting the connectors and/or manipulating the wiring may temporarily clear the cause of a fault.
Electrical measurements of voltage, resistance and insulation are generally correct, especially if the fault is not
present when the analysis is made (stored fault).
Visual inspection
Look for damage under the bonnet and in the passenger compartment.
Carefully check the fuses, insulators and wiring harness routing.
Look for signs of oxidation.
Physical inspection
When handling the wiring, use the diagnostic tool to detect any change in the status of the faults from stored to
present.
Make sure that the connectors are firmly secured.
Apply light pressure to the connectors.
Twist the wiring harness.
If there is a change in status, try to locate the source of the fault.
Inspection of each component

Disconnect the connectors and check the appearance of the clips and tabs, as well as the crimping (no crimping on
the insulating section).
Make sure that the clips and tabs are properly locked in the sockets.
Check that the clips or tabs have not been bent back during connection.
Check the clip contact pressure using an appropriate model of tab.
Resistance check
Check the continuity of entire lines, then section by section.
Look for a short circuit to earth, to + 12 V or with another wire.
If a fault is detected, repair or replace the wiring harness.
5. FAULT FINDING LOG
IMPORTANT
All faults involving a complex system call for thorough diagnostics with the appropriate tools. The
FAULT FINDING LOG, which should be completed during the fault finding procedure, ensures a
record is kept of the procedure carried out. It is an essential document when consulting the
IMPORTANT! manufacturer.
IT IS THEREFORE ESSENTIAL THAT THE FAULT FINDING LOG IS FILLED OUT EVERY TIME IT IS
REQUESTED BY TECHLINE OR THE WARRANTY RETURNS DEPARTMENT
You will always be asked for this log:

● when requesting technical assistance from the Techline,
● when requesting approval before replacing parts for which approval is compulsory,
● to be attached to monitored parts for which reimbursement is requested. The log is needed for warranty
reimbursement, and enables better analysis of the parts removed.
MR-425-X35-13B050$010.mif
V2
13B-5
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
6. SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
Safety rules must be observed during any work on a component to prevent any material damage or personal injury:
– check the battery voltage to avoid incorrect operation of computer functions,
– use the proper tools.
7. CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH-

PRESSURE DIRECT INJECTION SYSTEM
1. Risks relating to contamination:
The high pressure direct injection system is highly sensitive to contamination. The risks associated with
contamination are:
– damage to or destruction of the high pressure injection system,
– components jamming,
– a component leaking.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) should enter the system during dismantling.
The cleanliness principle must be applied from the filter to the injectors.
What are the sources of contamination?
– metal or plastic swarf,

– paint,
– fibres:
from cardboard boxes,
from brushes,
from paper,
from clothing,
from cloths.
– foreign bodies such as hair,
– ambient air,
– etc.
IMPORTANT
Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections. In
addition, moisture may collect in the connectors and create electrical connection faults.
2. Instructions to be followed before any work is carried out on the injection system
WARNING
BEFORE CARRYING OUT ANY WORK ON THE INJECTION SYSTEM, CHECK WITH THE DIAGNOSTIC
TOOL:
– that the rail is depressurised,
– that the fuel temperature is not too high.
MR-425-X35-13B050$010.mif
V2
13B-6
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
IMPORTANT
Before any work is carried out on the high pressure injection system, protect:
– the accessories and timing belts,
– the electrical accessories, (starter, alternator, electric power-assisted steering pump),
– the flywheel surface, to prevent any diesel from running onto the clutch friction plate.
Check that you have plugs for the unions to be opened (set of plugs available from the Parts Department). The plugs
are single-use only. After use, they must be discarded (once used they are soiled and cleaning is not sufficient to
make them reusable). Unused plugs must be discarded.
Ensure that you have hermetically resealable plastic bags for storing removed parts. Parts stored in this way will be
less susceptible to the risk of contamination. These are single-use bags; after use they must be discarded.
Use lint-free cleaning cloths (part no. 77 11 211 707). Using normal cloth or paper is prohibited. They are not lint-free
and could contaminate the fuel circuit. Each cloth should only be used once.
Use fresh cleaning agent for each operation (used cleaning agent is contaminated). Pour it into an uncontaminated
container.
For each operation, use a clean brush in good condition (the brush must not shed its bristles).
Use a brush and cleaning agent to clean the unions to be opened.
Blow compressed air over the cleaned parts (tools, workbench, and the parts, unions and injection system sections).
Check that no bristles remain.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves cover them with latex gloves to prevent contamination.
Instructions to be followed during the operation
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Department. They must not be reused under any circumstances.
Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries impurities.
All components removed from the injection system must be stored in a hermetically sealed plastic bag once they
have been plugged.
Using a brush, cleaning agent, air gun, sponge or normal cloth is strictly prohibited once the circuit has been opened.
These items could allow contamination to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
MR-425-X35-13B050$010.mif
V2
13B-7
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
8. KEY TO ABBREVIATIONS
EGR: Exhaust Gas Recirculation.
GMV: Cooling Fan Assembly.
UCH: Passenger Compartment Central Unit.
12 Volts APC: 12 Volts After ignition.
12 Volts AVC: 12 Volts Before ignition.
ABS: Anti-lock Brake System.
ESP: Electronic Stability Program.
BVA: Automatic Gearbox.
CAN: Controller Area Network.
TDC: Top Dead Centre.
VIN: Vehicle Identification Number.
POWER LATCH: Maintained supply phase.
C2I: Individual injector correction.
AC: Air conditioning.
PAS: Power assisted steering.
IMV: Fuel flow actuator.
MR-425-X35-13B050$010.mif
V2
13B-8
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – System operation
System outline
The DDCR injection system used on the K9 engine is an electronically managed high pressure injection system. The
fuel is compressed by a high pressure pump then stored in a rail that feeds the injectors. Injection occurs when a
current pulse is applied to the injector holders. The injected flow is proportional to the rail pressure and to the applied
pulse length, and the start of injection is phased with the start of the pulse.
The circuit comprises two subsystems, which are distinguished by the fuel pressure level:
– the low pressure circuit contains the tank, the diesel fuel filter, the transfer pump and the injector holder return pipes,
– the high pressure circuit contains the High Pressure pump, the rail, the injector holders and the High Pressure
pipes.
There are a certain number of sensors and regulating actuators for controlling and monitoring the entire system.
Functions provided
Management of the fuel supply (advance, flow rate and pressure).
– Quantity of fuel injected and injection timing adjustment
The injection checking parameters are the quantities to be injected and their respective timing. These are calculated
by the processor, from the signals from the following sensors:
– Engine speed (Crankshaft + Cam for synchronisation)

– Accelerator pedal
– Turbocharging air temperature and pressure (Turbocharger pressure)
– Coolant temperature
– Air temperature
– Air load (Flow and Pressure)
– Rail pressure
– Flowmeter
– Turbocharging solenoid valve
The quantities to be injected and their respective timing are converted into:
– a reference tooth
– the time between this tooth and the start of the pulse
– the time during which the injector holder is supplied.
An electrical current (pulse) is sent to each injector holder according to previously calculated data. The system
makes one or two injections (1 pilot injection, 1 main injection). The general principle is to calculate an overall
injected flow which is then divided into a main injection flow and a pilot injection flow, to help the combustion process
work properly and to reduce pollutant emissions.
An accelerometer checks some of the fuel injection deviation. It has several roles:
– Protecting the engine by detecting injection leaks (disabled on the basic vehicle).
– Checking the pilot quantity by measuring deviation and dispersion.
By changing both the duration and timing of the injection, the quantity of fuel injected and the mixture ignition timing
can be adjusted.
MR-425-X35-13B050$020.mif
V2
13B-9
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
– Rail pressure check
The quality of combustion is influenced by the size of the atomised droplets in the cylinder. In the combustion
chamber, smaller fuel droplets will have time to burn fully, and will not produce smoke or unburned particles. To meet
pollution requirements, the droplet size, and therefore the size of the injection holes must be reduced.
When these holes are smaller, less fuel can be introduced at a given pressure, which limits the power. To offset this
disadvantage, the quantity of fuel injected must be increased, which means increased pressure (and the more holes
in the injector nozzles). For the DDCR injection system, the pressure reaches 1600 bar in the rail and must be
constantly regulated. The measuring circuit comprises an active pressure sensor on the rail connected to an
analogue port on the computer.
The High Pressure pump is supplied at low pressure (5 bar) by a built-in transfer pump. This pump supplies the rail.
The rail filling pressure is controlled by the filling valve (IMV) and the discharge pressure is controlled by the injector
valves. This compensates for pressure drops. The filling actuator enables the High Pressure pump to supply just the
exact quantity of diesel fuel required to maintain the rail pressure. This mechanism minimises the heat generated
and improves engine output.
In order to discharge the rail using the injector valves, the valves are actuated by short electrical pulses which are:
– short enough not to open the injector (and pass through the return circuit from the injectors)
– long enough to open the valves and discharge the rail.
The fuel surplus is sent back to the fuel filter or the tank, according to its flow. If there is no IMV control, the rail
pressure is limited by a discharge valve fitted on the pump.
– Idling speed regulation
The computer handles the calculation of idling speed. This has to take account of the instantaneous power level to
be supplied, according to the status of the following factors:
– Engine coolant temperature

– Gear engaged
– Battery charging
– Electrical consumers (Heating elements, Air conditioning, Fan assembly, Heated windscreen, etc.) active or
inactive
– System faults detected
– Individual injector correction (C2I)

The DDCR system injectors must be calibrated with corrective values to adjust their flow precisely. Each injector is
calibrated for different pressures on a test bench, and its specifications are shown on a label attached to the body of
the injector holders. These individual correction values are then written to the computer EEPROM, which can then
actuate the injectors by taking into account their manufacturing variation.
– Measuring the angular position (Cylinder reference sensor)

The angular position is measured using a magneto-inductive sensor triggered by machined teeth on the shaft
flywheel. This flywheel has 60 teeth separated by six degrees, minus 2 missing teeth that form a notch.
A second sensor (Hall effect) activated by a machined tooth on the high pressure pump drive pulley (synchronised
with the camshaft) and which rotates at half the engine speed, supplies an injection cycle running signal.
By comparing the signals from these two sensors, the computer's APS module (Angular Position Subsystem) can
supply the entire system with the synchronisation factors, which are: the angular position of the flywheel, the engine
speed, the number of the active injector and the injection cycle timing.
This module also supplies the system with the engine speed signal.
MR-425-X35-13B050$020.mif
V2
13B-10
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
– Flow capacity function (VLC)
Because of the combination of several parameters such as the diesel fuel temperature, part wear, clogging of the
diesel filter etc., the system limit may be reached during its service life. If this happens, the rail pressure cannot be
maintained because the pump lacks the necessary capacity. If the pump lacks the necessary capacity, this
programming will therefore reduce the requested flow to a value that will enable the pressure monitoring system to
control the pressure again.
Air flow management.

– EGR valve control
The EGR system (Exhaust gas recirculation) comprises a proportional EGR valve, with a built-in valve position
feedback potentiometer. The EGR valve position is controlled by the potentiometer in a closed loop and/or by
changes in the estimated air flow.
– Calculation of the air flow
Certain models are not fitted with air flowmeters. In this case the amount of fresh inlet air must be evaluated, based
on the values supplied by the surrounding systems.
The (theoretical) air volume is calculated using a model with various calculation parameters, which are:
– the inlet air temperature measured by a sensor located after the turbocharger and/or after the exchanger (if fitted),
– the turbocharging pressure,
– the atmospheric pressure (external air),
– the EGR valve position,
– the fuel flow,
– the engine speed.
The atmospheric pressure sensor is optional. If fitted, it sends back an atmospheric pressure signal to an analogue
port on the micro-controller. If not, atmospheric pressure is found from the turbocharger pressure and the engine
field.
– Pre-postheating actuation
Pre-postheating actuation consists of controlling the heater plugs and preheating warning light on the instrument
panel. The heater plugs are activated by relays, and the power is supplied from the battery. After the ignition is
switched on. Preheating is activated for a period of time. The warning light is lit for the activation period which is
dependent on the battery voltage, atmospheric pressure and coolant temperature. If the temperature is below a
certain threshold, a postheating function can be used to improve the combustion stability, and consequently engine
operation. (Reducing unburnt particles and pollutant emissions).
– Turbocharger control solenoid valve actuation

The turbocharger system comprises a solenoid valve that is used to actuate the vanes (or wastegate) to create an
overpressure or a vacuum in the inlet circuit.
– Hosted functions.
MR-425-X35-13B050$020.mif
V2
13B-11
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Air conditioning management assistance.
For models with air conditioning, the DDCR injection system can deactivate the air conditioning under certain
conditions of use:
– when requested by the driver
– when starting the engine
– if the engine overheats (in order to reduce the power the engine has to supply)
– when the engine speed is kept at a very high level (to protect the compressor)
– during transitory phases (such as demands for high acceleration when overtaking, anti-stall and start-up). These
conditions are only taken into account when they do not occur repeatedly, to prevent instability in the system (erratic
deactivations)
– when certain faults appear.
Cold loop air conditioning management.
If the air conditioning is limited to a cold loop, its regulation is handled entirely by the computer. This is responsible
for:
– interfacing the air conditioning control signal from the instrument panel,
– recovering the power signal absorbed by the compressor from the refrigerant pressure and engine speed signal.
So the main functions of this programming are:

– managing demand for cold air according to the passenger compartment commands and the pressure value,
– determining the power absorbed by the compressor from the pressure,
– determining the fan unit commands according to vehicle speed and pressure.
The driver requests operation of the air conditioning system via the fan speed selector linked to a switch. The cold air
request is authorised or denied depending on the pressure measured. If this pressure is outside the operating limits,
the cold loop program is not activated. Otherwise, the computer manages the fan assembly regulation controls.
Electric Power Steering management.
On models equipped with air conditioning, the bulky hydraulic power-assisted steering is replaced with electric
power steering.
The power-assisted steering pump electronic control can:
– actuate the power assisted steering pump as soon as the engine has started,
– cut off the pump's supply during starting,
– prevent the battery discharging when the engine is stationary,
– provide power-assisted steering when the engine has stalled and there is no gear engaged, while the vehicle is still
being driven.
Thermal regulation of the cooling circuit.
In a direct injection engine, fuel is injected directly into the combustion chamber. This leads to heat being lost
through the upper part of the engine and consequently, the cylinder head cooling circuit is smaller in size.
The effect of this is that the temperature of the coolant which flows through this circuit rises more slowly. This coolant
is also used by the passenger compartment heating system. In very cold conditions, it is therefore difficult to achieve
a comfortable passenger compartment temperature quickly.
To limit this time, the cooling circuit has been provided with resistive heating components called thermoplungers.
The heating power is divided between three or four thermoplungers actuated by two or three relays. The computer
has to handle the temperature increase in the cooling circuit by controlling the thermoplungers until they reach a
threshold temperature value.
MR-425-X35-13B050$020.mif
V2
13B-12
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Instrument panel display.
The computer displays certain information on the instrument panel relating to engine operation. This involves 5
functions:
● the MIL (Malfunction Indicator Lamp)
● the EOBD (European On Board Diagnostic),
● pre/postheating,
● the coolant temperature,
● engine faults: Level 1 (non-critical fault) and Level 2 (emergency stop).
These five functions are represented by 3 or 5 warning lights on the instrument panel.
Pre-postheating warning light
This light is used both as an in-operation indicator light and as a system fault indicator:
Continuously lit: normal operation, indicates that the plugs are being heated.
Flashing: after preheating and an automatic 3-second shutdown, flashing indicates a Level 1 fault (leading to
reduced operation and a limited safety level. The driver should have repairs carried out as soon as possible.)
Temperature / emergency stop warning light
This indicator light is used both as an in-operation indicator light and as a system fault warning light. It lights up for
3 seconds when the ignition is switched on (automatic test procedure).
Continuously lit: indicates engine overheating or a Level 2 fault.

If the fault reaches a critical level, the injection cuts off automatically after several seconds. In the event of
overheating, it is up to the driver whether to stop the vehicle or continue driving.
OBD warning light
This warning light is used to alert the driver of any injection faults that could lead to excessive pollution, or if the
EOBD system has been deactivated.
The injection computer requests illumination of the OBD warning light for a present fault only after three consecutive
driving cycles.
The 3-second visual inspection when the ignition is switched on (automatic test procedure managed by the
instrument panel) is carried out by the injection computer.
NOTE: This warning light is only illuminated if the vehicle has been EOBD approved.
OBD warning light activation management
The OBD warning light activation is dependent on a number of cycles. It is only activated if the fault is detected after
3 consecutive driving cycles (start-up + 5 seconds + complete power latch).
The warning light goes out if the fault is not present after 3 consecutive driving cycles.
MR-425-X35-13B050$020.mif
V2
13B-13
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Faults that activate the OBD warning light
Tool fault Title Specification
DF010 EGR position sensor circuit CO.0 - CC.1
DF016 EGR control circuit CO.0 - 4.DEF
DF026 Cylinder 1 injector control circuit CO - CC
DF038 Computer 3.DEF
MR-425-X35-13B050$020.mif
V2
13B-14
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Replacement of components
COMPUTER REPLACEMENT, PROGRAMMING AND REPROGRAMMING OPERATIONS
Before reprogramming or removing the computer in After-Sales operations, save the following data to the
diagnostic tool:
– The C2I parameters (individual injector correction) and the engine adaptives using command SC003 Save
computer data.
The system can be reprogrammed with the diagnostic socket using the RENAULT CLIP diagnostic tool
(Consult Technical Note 3585A, Computer programming and reprogramming procedure, and follow the
instructions given by the diagnostic tool).
IMPORTANT:
– Switch on the diagnostic tool (mains or cigarette lighter supply).
– Connect a battery charger
– Switch off all electrical consumers (lights, interior lights, air conditioning, radio/CD, etc.).
– Wait for the engine to cool (engine coolant temperature: X < 60˚C and air temperature: X < 50˚C).
Any time the computer has been reprogrammed
– Use the diagnostic tool command SC001 Enter saved data to restore the C2I and the engine adaptives.
– Run command AC028 Static test to reinitialise the computer (GMV, etc.).
– When replacin g the pump, refer to the high pressure pump replacement procedure (consult Technical Note 5011A,
Repriming Delphi high pressure pumps on K9K engines).
– Switch the ignition off and then on again.
– Activate the starter without releasing the key until the engine starts (the engine start time can be up to 20
seconds).
– Stop the engine (to initialise the computer) and wait 30 seconds.
– Switch the ignition on again and use the diagnostic tool to carry out the following steps:
– Run command VP010 Enter VIN.
– After injection system programming, stored faults may appear on other computers. Clear the memory of these
computers.
IMPORTANT
AFTER A PROGRAMMING OPERATION, DO NOT CONNECT THE BATTERY FOR AT LEAST 30 minutes (to
carry out other operations on the vehicle).
Note:
If commands SC001 and AC028have been lost or if theyare not operating after programming the computer:
– Enter the C2I for each injector manually, by reading the C2I on each injector (see Replacement of components,
Injector replacement).
– Use command AC028 Static test to reinitialise the computer (fan assembly, etc.).
– Switch the ignition off and then on again.
– Clear the engine management computer faults.
IMPORTANT
It is not possible to try an injection computer from the Parts Department as it will not be possible to fit it on another
vehicle afterwards.
MR-425-X35-13B050$030.mif
V2
13B-15
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Replacement of components
REPLACING THE INJECTORS
Note:
C2I (individual injector correction) is a calibration carried out in the factory on each injector to adjust the flow
of each injector precisely.
These correction values are written on a label on each injector and entered into the computer, which can then
actuate each injector taking account of their manufacturing variations.
The system can be configured via the diagnostic socket using the RENAULT CLIP diagnostic tool.
The C2I parameters must be replaced when replacing an injector/injectors.
It is also possible to enter all four C2I using command SC002 Enter injector codes.
The technician uses the appropriate command to reprogram the new C2I for the replaced injector and erase the
old C2I.
Only after replacing at least 3 injectors simultaneously, reset the injector adaptives using command RZ008 Engine
parameter adaptives.
REPLACING THE HIGH PRESSURE PUMP
IMPORTANT:
When reprogramming the computer, the following procedure should be carried out after having run
command AC028 Static test (see Replacement of components, Computer reprogramming operation).
This reprogramming will install new functions in the computer to enable the injection pump to be reprimed with diesel
without damaging it.
Apply the procedure below before starting the engine.
PROCEDURE
Refer to Technical Note 5011A, Repriming Delphi high pressure pumps on K9K engines.
EGR VALVE REPLACEMENT:
If the EGR valve is replaced, it is essential to program the new valve's offset position. To do this, clear the old offset
using the EGR programming clearing procedure and run command RZ002 EGR adaptive.
IMPORTANT:
Do not use this procedure if the valve is not new.
MR-425-X35-13B050$030.mif
V2
13B-16
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Configuration and programming
Tool
Diagnostic tool title Comments
command
This command permits manual entry of the vehicle's VIN into

VP010 Enter VIN the computer. This command must be used each time the
computer is replaced or (re)programmed.
Deactivation of electrical This command inhibits the major electrical consumers (heater
VP012
consumers plugs, thermoplungers, etc.).
This command disables electrical actuation of the injectors, for

VP022 Injection inhibition
carrying out the compression test.
This command is used to configure the type of gearbox fitted to

CF027 Gearbox type
the vehicle
This command is used to configure the air conditioning

CF028 Air conditioning
according to the vehicle equipment.
Power assisted steering This command is used to configure the power-assisted pump
CF029
pump assembly assembly (WITH if vehicle fitted with air conditioning).
This command is used to configure the number of

CF130 Number of thermoplungers
thermoplungers fitted to the vehicle (WITHOUT, 3 or 4)
This command is used to determine the type of gearbox

LC005 Gearbox type
configured on the vehicle
This command is used to determine the configuration status of

LC009 Air conditioning
the air conditioning
This command is used to determine the configuration status of

Power assisted steering
LC055 the power-assisted steering pump assembly (WITH if vehicle
pump assembly
fitted with air conditioning).
This command is used to configure the number of

LC171 Number of thermoplungers
thermoplungers fitted to the vehicle (WITHOUT, 3 or 4).
MR-425-X35-13B050$040.mif
V2
13B-17
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Fault summary table
Tool fault DTC Diagnostic tool title
DF001 1001 Coolant temperature sensor circuit.
DF002 1002 Air temperature sensor circuit.
DF003 1003 Atmospheric pressure sensor circuit.
DF005 1007 Engine speed sensor circuit.
DF007 1009 Rail pressure sensor circuit.
DF008 100A Pedal potentiometer circuit gang 1.
DF009 100B Pedal potentiometer circuit gang 2.
DF010 100C EGR position sensor circuit.
DF012 1010 Sensor supply voltage no. 2.
DF014 1011 Vehicle speed signal circuit.
DF015 1013 Main relay control circuit.
DF016 1014 EGR control circuit.
DF017 1016 Preheater unit control circuit.
DF018 1017 Low-speed fan assembly control circuit.
DF019 1018 High-speed fan assembly control circuit.
DF024 1023 Low pressure actuator control circuit.
DF025 1026 Preheating unit diagnostic line.
DF026 102E Cylinder 1 injector control circuit.
DF027 102F Cylinder 2 injector control circuit.
DF028 1030 Cylinder 3 injector control circuit.
DF029 1031 Cylinder 4 injector control circuit.
DF038 103F Computer.
DF039 1042 Inlet air temperature sensor circuit.
DF046 1066 Battery voltage.
DF049 106B Refrigerant sensor circuit.
DF050 1078 Brake switch circuit.
DF052 1086 Injector control circuit.
DF053 1088 Rail pressure regulation function.
DF059 105E Combustion misfires on cylinder 1.
DF060 105F Combustion misfires on cylinder 2.
MR-425-X35-13B050$050.mif
V2
13B-18
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Fault summary table
Tool fault DTC Diagnostic tool title
DF061 1060 Combustion misfires on cylinder 3.
DF062 1061 Combustion misfires on cylinder 4.
DF089 1004 Inlet manifold pressure sensor circuit.
DF098 1005 Fuel temperature sensor circuit.
DF107 1074 Computer memory.
DF112 1008 Cylinder reference sensor circuit.
DF113 100F Sensor supply voltage.
DF121 1069 Accelerometer circuit.
DF159 1019 Power assisted steering assembly relay control circuit.
DF179 103D Injection <-> air conditioning connections.
DF238 1036 Thermoplunger no. 3 relay circuit
DF489 101A Air conditioning compressor control.
MR-425-X35-13B050$050.mif
V2
13B-19
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Interpretation of faults
DF001 COOLANT TEMPERATURE SENSOR CIRCUIT

PRESENT CC.0: Short circuit to earth
OR CO.1: Open circuit or short circuit to +12 V
STORED
Special notes:
If DF001 is present, the fan assembly is activated at low speed (fan assembly 1). If fan
NOTES
assembly 1 is faulty, fan assembly 2 is activated for vehicles fitted with air conditioning.
The preheating phase is 15 seconds.
Check the connection and condition of the coolant temperature sensor, component code 244.
Check the connection and condition of the injection computer connector, component code 120.
If the connector or connectors are faulty and if there is a repair procedure (see Technical Note 6015A, Repairing
electrical wiring, Wiring: Precautions for repair), repair the connector, otherwise replace the wiring.
Check the insulation, continuity and the absence of interference resistance on the following connections:
● 3JK between components 244 and 120,
● 3C between components 244 and 120,
● 42A between components 244 and 247,
● N between components 244 and earth.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace it.
Measure the resistance of the coolant temperature sensor, component code 244, between connections 3JK
and 3C.
Replace the coolant temperature sensor, component code 244 if the resistance is not between: 2139.84 Ω < X <
2364.16 Ω at 25˚C.
If the fault is still present, contact the Techline.
Deal with any faults displayed by the diagnostic tool.

AFTER REPAIR Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
DDCR_V14_DF001
MR-425-X35-13B050$061.mif
V2
13B-20
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF002 AIR TEMPERATURE SENSOR CIRCUIT

PRESENT CC.0: Short circuit to earth.
OR CO.1: Open circuit or short circuit to +12 V.
STORED
NOTES None.
Check the condition and connection of the air temperature sensor connector, component code 272.
● 3B between components 272 and 120,
● 3JQ between components 272 and 120.
Measure the resistance between connections 3B and 3JQ on the air temperature sensor, component code 272.
Replace the air temperature sensor, component code 272 if the resistance is not between:
8622 Ω < X < 10454 Ω at - 10˚C,
1931 Ω < X < 2171 Ω at 25˚C,
772 Ω < X < 864 Ω at 50˚C.

DDCR_V14_DF002
MR-425-X35-13B050$061.mif
V2
13B-21
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF003 ATMOSPHERIC PRESSURE SENSOR CIRCUIT

PRESENT CC.1: Short-circuit on +12 volts.
OR CO.0: Open circuit or short circuit to earth.
STORED
NOTES None.
Contact the Techline.

DDCR_V14_DF003
MR-425-X35-13B050$061.mif
V2
13B-22
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ENGINE SPEED SENSOR CIRCUIT

DF005 1.DEF: Consistency.
PRESENT 2.DEF: No tooth signal.
3.DEF: Too many additional teeth.
OR 4.DEF: Teeth missing.
STORED 5.DEF: Additional teeth.
6.DEF: Too many teeth missing.
Special notes:
– If DF005, 1.DEF, 2.DEF, 3.DEF, 6.DEF are present: engine stopped and level 1 and
2 warning lights illuminated.
– If DF005, 4.DEF, 5.DEF, 75% engine performance, warning light not illuminated.
NOTES
Conditions for applying fault finding procedures to stored faults:

– the fault is declared present with the engine under the starter or idling.
Check that the flywheel target is not faulty (missing teeth).
Check the connection and condition of the TDC sensor connector, component code 149.
Ensure the sensor is correctly fitted on the engine.

Repair if necessary.
● 3BG between components 149 and 120,
● 3BL between components 149 and 120.
Measure the resistance at the terminals of the TDC sensor, component code 149.
Replace the TDC sensor, component code 149, if the resistance is not between: 720 Ω < X < 880 Ω at 20˚C

DDCR_V14_DF005
MR-425-X35-13B050$061.mif
V2
13B-23
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
RAIL PRESSURE SENSOR CIRCUIT

DF007 1.DEF: Consistency.
PRESENT 2.DEF: Below minimum threshold.
OR 3.DEF: > maximum threshold.
STORED C0.0: Open circuit or short circuit to earth.
CO.1: Open circuit or short circuit to +12 V.
Priority when dealing with a number of faults:

– Deal with fault DF113 Sensor supply voltage first.
– In the case of DF007 3.DEF, deal first with fault DF113, then DF015 Main relay
control circuit.
NOTES Conditions for applying fault finding procedures to stored faults:

– The fault is declared present after the engine is started.
Special notes: In the case of DF007, the engine stops and starting impossible.
– Level 1 and 2 warning lights lit.
Check the connection and condition of the rail pressure sensor connector, component code 1032.
● 3LY between components 1032 and 120,
● 3LZ between components 1032 and 120,
● 3LX between components 1032 and 120.
If the fault is still present, the rail pressure sensor is faulty, replace the rail.

DDCR_V14_DF007
MR-425-X35-13B050$061.mif
V2
13B-24
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
PEDAL POTENTIOMETER CIRCUIT GANG 1

DF008 1.DEF: consistent.
PRESENT 2.DEF: No signal.
OR 3.DEF: Jammed component.
STORED CO.0: Open circuit or short circuit to earth.
CC.1: Short circuit to +12 volts.
– If DF008: the engine speed is maintained above 1000 rpm, and the level 1 warning
light comes on.
– If DF008 and DF009: the engine speed is fixed at 1300 rpm and the level 1 warning
light comes on.

NOTES – DF113 Sensor supply voltage.
Special note: There is 1 CTS sensor fitted in the engine compartment on non-multiplex
vehicles.
Important:
– The 3.DEF specification may be present after sports style driving, when the brake
pedal and accelerator pedal are depressed at the same time (heel and toe).
CO.0
CC.1 NOTES None.
2.DEF
Check the connection and condition of the accelerator potentiometer connector, component number 921.
Check the insulation, continuity and the absence of interference resistance between the following
connections:
● 3LS between components 921 and 120,
● 3LT between components 921 and 120,
● 3LR between components 921 and 120.
Disconnect the injection computer connector, component code 120 and the connector of the accelerator
potentiometer, component code 921.
Check the insulation on the injection computer connector, component code 120 between connections 3LR and
3LS.

DDCR_V14_DF008
MR-425-X35-13B050$061.mif
V2
13B-25
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF008
CONTINUED
Measure the resistance between connections 3LR and 3LT of the accelerator potentiometer, component code
921.
Replace the accelerator potentiometer, component code 921 if the resistance is not between: 0.8 Ω < X < 2.6 Ω.
1.DEF NOTES None.
Check the insulation on the injection computer connector, component code 120 between connections 3LS and
3LW.
Special notes:
– The 3.DEF specification may be present after sports style
3.DEF NOTES
driving, when the brake pedal and accelerator pedal are
depressed at the same time (heel and toe).
Check that the accelerator pedal is not jammed using parameter PR030 Accelerator pedal position.
Replace the accelerator pedal potentiometer if necessary.
Check that the brake pedal is not jammed using status ET122 Brake switch no.1 signal.
Replace the brake light switch, component code 160 if necessary.
Warn the customer that "heel and toe" sports style driving (brake and accelerator depressed) can cause a fault and
the instrument panel warning lights will come on.

MR-425-X35-13B050$061.mif
V2
13B-26
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF009 PEDAL POTENTIOMETER CIRCUIT GANG 2

PRESENT CO.0: Open circuit or short circuit to earth.
OR CC.1: Short circuit to +12 volts.
STORED
– If DF009: The engine speed is maintained above 1000 rpm, and the level 1 warning
light comes on.
– If DF009 and DF008: the engine speed is fixed at 1300 rpm and the level 1 warning
light comes on.
NOTES Priority when dealing with a number of faults:

– DF113 Sensor supply voltage.
Special note:
– There is 1 CTS sensor fitted in the engine compartment on non-multiplex vehicles.
CO.0 NOTES None.
Check the connection and condition of the accelerator potentiometer connector, component code 921.
Check the insulation to earth on connection 3LW on the injection computer connector, component code 120.
If the connection is faulty and there is a repair procedure (see Technical Note 6015A, Electrical wiring repair,
Wiring: Precautions for repair), repair the wiring, otherwise replace it.
Check the continuity of the following connection:

● 3LW between components 921 and 120.

DDCR_V14_DF009
MR-425-X35-13B050$061.mif
V2
13B-27
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF009
CONTINUED
Measure the resistance between connections 3LU and 3LV of the accelerator potentiometer, component code
921.
Replace the accelerator potentiometer, component code 921 if the resistance is not between: 0.8 KΩ < X <
5.2 KΩ.
CC.1 NOTES None.
Check the connection and condition of the accelerator potentiometer connector, component code 921.
Disconnect the injection computer connector, component code 120 and the accelerator potentiometer
connector, component code 921.
Check the insulation between connections 3LU and 3LW and in relation to 12 V on the injection computer
Check the continuity of the following connections:
● 3LW between components 921 and 120,
● 3LU between components 921 and 120,
● 3LV between components 921 and 120.
Measure the resistance between connections 3LU and 3LV of the accelerator potentiometer, component code
921.
Replace the accelerator potentiometer, component code 921 if the resistance is not between: 0.8 KΩ < X <
5.2 KΩ.

MR-425-X35-13B050$061.mif
V2
13B-28
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF010 EGR POSITION SENSOR CIRCUIT

PRESENT 1. DEF: Below minimum threshold
2. DEF: > maximum threshold
OR CO.0: Open circuit or short circuit to earth.
STORED CC.1: Short circuit to +12 volts.

NOTES
– The fault is declared present after the engine is started.
Check the connection and condition of the EGR valve connector, component code 398.
Check the insulation and continuity of the following connections:

● 3GC between components 398 and 120,
● 3EL between components 398 and 120,
● 3JM between components 398 and 120.
Check for + 5 V on connection 3GC of component 398.

Check for earth on connection 3JM of component 398.
Check the resistance of the EGR valve, component code 398:

with the engine stopped, the EGR valve will be closed (unless there is a fault),
wait for the ambient temperature around the valve to stabilise (approximately 20˚C),
measure the resistance between connections 3FB and 3GB. The resistance should be between 7.54 Ω < X <
8.5 Ω (at 20˚C),
measure the resistance between connections 3GC and 3JM. The resistance must be between 2.4 KW < X <
5.6 KW (at 20˚C),
measure the resistance between connections 3JM and 3EL. The resistance must be between 800 Ω < X < 3.6 KΩ
(at 20˚C).
If the value is not correct, replace the exhaust gas recirculation valve, component code 398.
After replacing the EGR valve, component code 398, use command RZ002 EGR adaptives to reinitialise the EGR
valve offsets.

DDCR_V14_DF010
MR-425-X35-13B050$061.mif
V2
13B-29
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF012 SENSOR SUPPLY VOLTAGE NO. 2

OR C0.1: Open circuit or short circuit to +12 V.
STORED
– If DF012: The engine speed is maintained above 1000 rpm, and the level 1 warning
light comes on.
– If DF012 and DF008: The engine speed is fixed at 1300 rpm and the level 1 warning
light comes on.
NOTES
Special note:
– There is 1 CTS sensor fitted in the engine compartment on non-multiplex vehicles.
CC.0 NOTES None.
On gang 2, check for the presence of + 5V after ignition feed on connection 3LU of the accelerator
potentiometer sensor connector, component code 921.
If the connection is faulty and if there is a repair procedure (see Technical Note 6015A, Electrical wiring repair,
Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
Check the insulation from earth of the following connection:

● 3LU between components 921 and 120.

DDCR_V14_DF012
MR-425-X35-13B050$061.mif
V2
13B-30
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF012
CONTINUED
C0.1 NOTES None.
On gang 2, check for the presence of + 5V after ignition feed on connection 3LU of the accelerator
potentiometer sensor connector, component code 921.
Disconnect the injection computer connector, component code 120 and the accelerator potentiometer
Check the insulation on the injection computer connector, component code 120 between connections 3LU and
3LW.
Check the continuity and insulation of the following connections:

● 3LU between components 921 and 120,
● 3LV between components 921 and 120.

MR-425-X35-13B050$061.mif
V2
13B-31
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF014 VEHICLE SPEED SIGNAL CIRCUIT

PRESENT 1.DEF: Consistency.
OR 2.DEF: No signal.
STORED

NOTES
– The fault is declared present after a road test.
Check the connection and condition of the speed sensor connector, component code 250.
● AP15 between components 250 and 1016,
● M between components 250 and the earth.
Check the insulation to + 12V of the following connection:

● 47F between components 250 and 120.

DDCR_V14_DF014
MR-425-X35-13B050$061.mif
V2
13B-32
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF015 MAIN RELAY CONTRIOL CIRCUIT

PRESENT 1.DEF: Relay cutting out too early.
OR 2.DEF: Relay cutting out too late.
STORED
NOTES None.
Check supply fuse F1 (30 A) of the injection locking relay, component code 1047 in the engine compartment.
Replace the fuse if necessary.
Check the connection and condition of the injection locking relay connectors, component code 1047.
● BP37 between components 1016 and 1047,
● 3FAC between components 1047 and 120,
● 3FB between components 1047 and 120,
If the fault is still present, replace the injection locking relay, component code 1047.

DDCR_V14_DF015
MR-425-X35-13B050$061.mif
V2
13B-33
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
EGR VALVE CONTROL CIRCUIT

DF016 CC.1: Short circuit to +12 volts
PRESENT CO.0: Open circuit or short circuit to earth
1.DEF: At minimum limit
OR 2.DEF: At maximum limit
STORED 3.DEF: > maximum threshold
4.DEF: Component seized.

– The fault is declared present at idle speed.
NOTES
Special notes:
– If DF016, CC.0, the level 1 warning light comes on.
Check the connection and condition of the exhaust gas recirculation valve connector, component code 398.

● 3GB between components 398 and 120,
● 3FB between components 398 and 784.
Check for the supply 13 V < X < 14 V (with the engine running), 11.5 V < X < 12.5 V (with the ignition on and
the engine stopped) on connection 3FB of component 398.
Measure the resistance of the EGR valve, component code 398:

with the engine stopped, the EGR valve will be closed (unless there is a fault),
wait for the ambient temperature around the valve to stabilise (approximately 20˚C),
measure the resistance between connections 3FB and 3GB of component 398. The resistance should be
between 7.5 Ω < X < 8.5 Ω (at 20˚C),
measure the resistance between connections 3GC and 3JM of component 398. The resistance must be between
2.4 KΩ < X < 5.6 KΩ (at 20˚C),
measure the resistance between connections 3JM and 3EL of component 398. The resistance must be between
800 Ω < X < 3.6 KΩ (at 20˚C),
if the value is not correct, replace the exhaust gas recirculation valve, component code 398.
After replacing the EGR valve, component code 398, use command RZ002 EGR adaptives to reinitialise the EGR
valve offsets.

DDCR_V14_DF016
MR-425-X35-13B050$061.mif
V2
13B-34
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF017 PRE-POSTHEATING UNIT CONTROL CIRCUIT

STORED
Special notes:
– If DF017 is present, the engine is difficult to start (and even impossible when cold). If
NOTES
CO.0: the plugs are permanently switched on with risk of damage or even engine
failure.
Check the connection and condition of the preheating unit connector, component code 257.
● 3FY between components 257 and 120,
● 3FF between components 257 and 120.
If the connections are correct, check that the relay is operating correctly using command AC037 Preheating relay.
If the fault is still present, replace the preheating unit, component code 257.

DDCR_V14_DF017
MR-425-X35-13B050$061.mif
V2
13B-35
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF018 LOW SPEED FAN ASSEMBLY CONTROL CIRCUIT

STORED

– CC.1: The fault is declared present after running command AC038 Low speed fan
NOTES
assembly relay.
– CO.0: Fault finding procedure to be applied only if fault is present.
Check the connection and condition of the low speed fan assembly relay connector, component code 700.
Check the insulation, continuity and the absence of interference resistance on the following connection:
● 3JN between components 120 and 700.
Check for + after ignition on connections BP7.

If the fault is still present, replace the low speed fan assembly relay, component code 700.

DDCR_V14_DF018
MR-425-X35-13B050$061.mif
V2
13B-36
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF019 HIGH SPEED FAN ASSEMBLY CONTROL CIRCUIT

STORED

– CC.1: The fault is declared present after running command AC039 High speed fan
NOTES
assembly relay.
– CO.0: Fault finding procedure to be applied only if the fault is present.
Check the connection and condition of the high speed fan assembly relay connector, component code 336.
● 3JP (or 3JN) between components 120 and 336.
Check for + after ignition on connections BP7.

If the fault is still present, replace the high speed fan assembly relay, component code 336.

DDCR_V14_DF019
MR-425-X35-13B050$061.mif
V2
13B-37
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF024 LOW-PRESSURE ACTUATOR CONTROL CIRCUIT

STORED
Special notes:
– If DF024 with CO.0 or CC.1, the level 1 and 2 warning lights are illuminated.
NOTES
The fuel flow actuator is fully open, there is a clicking, and the engine is stopped to
prevent it from racing.
Check the connection and condition of the flow actuator connector, component code 864.
● 3FP between components 120 and 864.
Measure the resistance between connections 3FP and 3FB of the flow actuator, component code 864.
Replace the flow actuator if the resistance is not between: 4.8 Ω < X < 5.8Ω at 20˚C.

DDCR_V14_DF024
MR-425-X35-13B050$061.mif
V2
13B-38
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF025 PRE-POSTHEATING UNIT DIAGNOSTIC LINE

PRESENT CO: Open circuit.
OR
STORED
Special notes:
NOTES
– This fault only directs fault finding with an open circuit.
Check the connection and condition of the preheating unit connector, component code 257.
Check the connection and condition of the heater plug connectors, component codes 680, 681, 682, and 683.
● 3FF between components 120 and 257.
Measure the resistance of each heater plug. The resistance should be: X < 2Ω.
Replace the faulty plug(s), component codes 680, 681, 682 or 683.
If the fault is still present, replace the preheating unit, component code 257.

DDCR_V14_DF025
MR-425-X35-13B050$061.mif
V2
13B-39
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF026 CYLINDER 1 INJECTOR CONTROL CIRCUIT

OR CC: Short circuit.
1. DEF: At minimum stop
STORED

NOTES – The fault is present with the engine idling.
– The level 1 warning light is illuminated.
CO
NOTES None.
CC
Switch off the ignition and wait 15 seconds.

Check the connection and condition of the injector connector, component code 193.
Run command AC005 Cylinder 1 injector.

If a cycle of 5 actuations of injector 1 cannot be heard working, connect the cylinder 2 injector wire to cylinder
1 injector and run command AC006 Cylinder 2 injector.
Does this injector actuation cycle work?
Note:
If the wires cannot be swapped, continue the procedure by replying YES to the previous question.
YES Injector 1 is not faulty, the fault is on the injector 1 control circuit.

● 3L between components 120 and 193,
● 3KW between components 120 and 193.
If the connection or connections are faulty and there is a repair procedure (see
Technical Note 6015A, Electrical wiring repair, Wiring: Precautions for repair),
repair the wiring. Otherwise replace the wiring.

DDCR_V14_DF026
MR-425-X35-13B050$061.mif
V2
13B-40
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF026
CONTINUED
NO Injector 1 is faulty, replace the cylinder 1 injector, component code 193.
1.DEF NOTES None.
Check the conformity of the injectors fitted to the vehicle in relation to the type of vehicle and engine number (low,
high or very high pressure injector).
Check that the C2I is correctly entered on the computer.

Check the accelerometer shielding on connection TB1 of the injection computer connector, component code 120.
Check that the accelerometer is secured on the engine.
After retightening the accelerometer, it is essential to clear the engine adaptives using command RZ008
Engine parameter adaptives.
Disconnect and reconnect the accelerometer sensor to accomplish fast programming.
Carry out a road test to check if the fault is still present.
If the fault is still present, replace the cylinder 1 injector, component code 193.

MR-425-X35-13B050$061.mif
V2
13B-41
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF027 INJECTOR CYLINDER 2 CONTROL CIRCUIT

STORED

NOTES – The fault is declared present with the engine at idle speed.
– Level 1 warning light illuminated
CO
NOTES None.
CC


If a cycle of 5 actuations of injector 2 cannot be heard working, connect the cylinder 3 injector wire to the cylinder
Note:
YES Injector 2 is not faulty, the fault is in the injector 2 control circuit.

● 3LA between components 120 and 194,
● 3KX between components 120 and 194.
repair the wiring, otherwise replace it.

DDCR_V14_DF027
MR-425-X35-13B050$061.mif
V2
13B-42
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF027
CONTINUED
1.DEF NOTES None.


MR-425-X35-13B050$061.mif
V2
13B-43
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14

STORED

CO
NOTES None.
CC


Note:
YES Injector 3 is not faulty, the fault is on the injector 3 control circuit.

● 3LB between components 120 and 195,
● 3KY between components 120 and 195.

DDCR_V14_DF028
MR-425-X35-13B050$061.mif
V2
13B-44
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF028
CONTINUED
1.DEF NOTES None.


MR-425-X35-13B050$061.mif
V2
13B-45
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14

STORED

CO
NOTES None.
CC


Note:
YES Injector 4 is not faulty, the fault is in the injector 4 control circuit.

● 3LC between components 120 and 196,
● 3KZ between components 120 and 196.

DDCR_V14_DF029
MR-425-X35-13B050$061.mif
V2
13B-46
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF029
CONTINUED
1.DEF NOTES None.


MR-425-X35-13B050$061.mif
V2
13B-47
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
COMPUTER
1.DEF: Analogue - digital converter.
DF038 2.DEF: Enter EEPROM memory.
PRESENT 3.DEF: Read EEPROM memory.
4.DEF: Injector calibration data.
OR 5.DEF: Memory self-test.
STORED 6.DEF: Watchdog not refreshed.
7.DEF: Interference on the injector control line.
8.DEF: Watchdog activation.
1.DEF
5.DEF
NOTES Apply the fault finding procedure even if the fault is stored.
6.DEF
8.DEF
Contact the Techline
2.DEF
NOTES Apply the fault finding procedure even if the fault is stored.
3.DEF

Clear the computer memory.
Switch the ignition back on, carry out another check using the diagnostic tool and, if the fault is still present, clear
the computer memory again.
4.DEF NOTES Apply the fault finding procedure even if the fault is stored.
Check that the individual injector correction (C2I) correctly corresponds to the injectors (see the identification
screen on the diagnostic tool) otherwise write the C2I using command SC002 Enter injector codes.
If the C2I does correspond to the injectors, contact the Techline.

DDCR_V14_DF038
MR-425-X35-13B050$061.mif
V2
13B-48
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF038
CONTINUED
7.DEF NOTES Apply the fault finding procedure even if the fault is stored.
If the connector is faulty and there is a repair method (see Technical Note 6015A, Repairing electrical wiring,
Wiring: Precautions for repair), repair the connector, otherwise replace the wiring.
● 3KW between components 120 and 193,
● 3KX between components 120 and 194,
● 3KY between components 120 and 195,

MR-425-X35-13B050$061.mif
V2
13B-49
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF039 INLET AIR TEMPERATURE SENSOR CIRCUIT

STORED
NOTES None
Check the connection and condition of the injection air temperature sensor connector component code 272.
● 3B between components 272 and 120,
● 3JQ between components 272 and 120.
Measure the resistance between connections 3B and 3JQ on the injection air temperature sensor, component
code 272.
Replace the injection air temperature sensor, component code 272 if the resistance is not between: 1931 Ω < X <
2171 Ω at 25˚C.

DDCR_V14_DF039
MR-425-X35-13B050$061.mif
V2
13B-50
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF046 BATTERY VOLTAGE

PRESENT 1. DEF: Below minimum threshold
OR 2. DEF: > maximum threshold
STORED
Conditions for applying the fault finding procedure to a stored fault:

NOTES
– The fault is declared present with the engine running at over 1000 rpm
Measure the battery voltage when the ignition is switched on.

If the battery voltage is: X < 10 V, recharge the battery.
Check the condition and connection of the battery terminals.

Check the vehicle's charging circuit.


DDCR_V14_DF046
MR-425-X35-13B050$061.mif
V2
13B-51
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF049 REFRIGERANT SENSOR CIRCUIT

PRESENT CO.1: Open circuit or short circuit to +12 V.
OR CC.0: Short circuit to earth.
STORED

The fault is declared present with the engine idling and air conditioning operating
on vehicles fitted with cold loop.
NOTES
Priority when dealing with several faults: DF113 Sensor supply voltage.
Check the connection and condition of the refrigerant pressure sensor connector, component code 1202.
● 38U between components 120 and 1202,
● 38X between components 120 and 1202,
● 38Y between components 120 and 1202.
If the fault is still present, replace the refrigerant pressure sensor, component code 1202.

DDCR_V14_DF049
MR-425-X35-13B050$061.mif
V2
13B-52
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF050 BRAKE SWITCH CIRCUIT

PRESENT 1. DEF: Consistency with redundant brakes
OR 2. DEF: No signal.
3. DEF: Inconsistent signal.
STORED

– The fault is declared present when the ignition is switched on, when decelerating or
NOTES
when the brake pedal is depressed.
– Deal with the fault even if it is stored.
Check the connection and condition of the brake switch connector, component code 160.
Check the connection and condition of the injection computer connectors, component code 120.
Check for + 12 V on the brake switch supply, component code 160 on connection AP10.
Check the operation of the brake light switch, component code 160.
● 65A between components 160 and 120.

DDCR_V14_DF050
MR-425-X35-13B050$061.mif
V2
13B-53
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF052 INJECTORS CONTROL CIRCUIT

PRESENT CC.1: Short circuit to +12 volts.
CC.0: Short circuit to earth.
OR 1. DEF: Below minimum threshold.
STORED 2. DEF: > maximum threshold.

– If there is a combination of faults DF052 and DF026, DF027, DF028 or DF029, the fault
finding procedure remains the same, but the faulty injector(s) is(are) identified.
NOTES
Special notes:
– The engine stalls when the fault appears. Level 1 warning light illuminated.
Switch off the ignition, check the condition and connection of the injector connectors, component codes 193,
194, 195, and 196.
Switch off the ignition, disconnect the injectors (or the injector identified by DF026, DF027, DF028, DF029)
and switch the ignition back on.
Using the diagnostic tool, check for changes to DF052.
Is DF052 present or stored?
DF052 The injectors are not defective.

present
Check the insulation, continuity and the absence of interference resistance on
the following connections:
● 3KW between components 120 and 193,
● 3KX between components 120 and 194,
● 3KY between components 120 and 195,

DDCR_V14_DF052
MR-425-X35-13B050$061.mif
V2
13B-54
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF052
CONTINUED
DF052 Injector(s) defective.

stored
Replace the injector identified by DF026 to DF029 if present.
If none of the faults identifying the defective injector circuit are present:
– Switch off the ignition.
– Reconnect one of the four injectors.
– Switch the ignition back on and, if the fault reappears as present, replace the
reconnected injector.
Carry out the same procedure for the remaining injectors.

MR-425-X35-13B050$061.mif
V2
13B-55
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
RAIL PRESSURE REGULATION FUNCTION

1.DEF: Pressure < minimum.
DF053 2.DEF: Pressure > maximum.
PRESENT 3.DEF: Below minimum threshold.
4.DEF: > maximum threshold.
OR 5.DEF: High flow current < minimum.
STORED 6.DEF: High flow current > maximum.
7.DEF: Low flow current < minimum.
8.DEF: Low flow current > maximum.
Special notes:
– If DF053, the engine may stop, with level 1 and 2 warning lights illuminated.

NOTES DF098 Fuel temperature sensor circuit,
DF007 Rail pressure sensor circuit

– The fault is declared present with the engine running.
4.DEF
6.DEF NOTES None.
8.DEF
Check the connection and condition of the flow actuator (IMV) connector, component code 864.
● 3FP between components 120 and 864.

DDCR_V14_DF053
MR-425-X35-13B050$061.mif
V2
13B-56
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF053
CONTINUED
Measure the resistance between connections 3FP and 3FB of the flow actuator, component code 864.
Replace the flow actuator if the resistance is not between: 4.8 Ω < X < 5.8Ω at 20˚C.
Check for fuel in the tank.

Check the conformity of the fuel, run TEST 13 Diesel fuel conformity check.
Apply TEST 1 Low pressure circuit check.
Apply TEST 6 High pressure system check.
Apply TEST 8 Injector return flow.
1.DEF
2.DEF
3.DEF NOTES None.
5.DEF
7.DEF
Check for fuel in the tank

Check the conformity of the fuel, run TEST 13 Diesel fuel conformity check.
Apply TEST 1 Low pressure circuit check.
Apply TEST 6 High pressure system check.
Apply TEST 8 Injector return flow.

MR-425-X35-13B050$061.mif
V2
13B-57
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF059 COMBUSTION MISFIRES ON CYLINDER 1

PRESENT
OR
STORED
Special notes: If DF059, engine speed maintained at 1000 rpm with level 1 warning
light illuminated and engine performance reduced to 75%.

NOTES
The fault is declared present with the engine at idle speed.

– DF026 Cylinder 1 injector control circuit (CC or CO).
– DF053 Pressure regulation function (1DEF, 2DEF, 7DEF).
Run Test 13 Diesel fuel conformity check.
Run Test 3 Injector check.
Check the valve clearance and adjust if necessary.
Check the inlet ducts and the EGR valve, and clean them if necessary.
If the fault is still present, replace the injector.

DDCR_V14_DF059
MR-425-X35-13B050$062.mif
V2
13B-58
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF060 MISFIRING ON CYLINDER 2

PRESENT
OR
STORED
Special notes: If DF060, engine speed maintained at 1000 rpm, level 1 warning light
illuminated and engine performance reduced to 75%.

NOTES
The fault is present with the engine idling.


DDCR_V14_DF060
MR-425-X35-13B050$062.mif
V2
13B-59
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14

PRESENT
OR
STORED

NOTES


DDCR_V14_DF061
MR-425-X35-13B050$062.mif
V2
13B-60
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14

PRESENT
OR
STORED

NOTES


DDCR_V14_DF062
MR-425-X35-13B050$062.mif
V2
13B-61
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
INLET MANIFOLD PRESSURE SENSOR CIRCUIT

DF089 1.DEF: Below minimum threshold
PRESENT 2.DEF: > maximum threshold
OR 3.DEF: Permanent low level
STORED 4.DEF: Permanent high signal
5.DEF: Consistency.

NOTES
Special notes:
– If 5.DEF, level 1 warning light lit.
Check the condition and connection of the turbocharging pressure sensor connector, component code 1071.
● 3LN between components 1071 and 120,
● 3LP between components 1071 and 120,
● 3LQ between components 1071 and 120.
Check for consistency between the atmospheric pressure and the manifold pressure (PR035 = PR312).
With the engine stopped, the pressure should be approximately the same between the 2 sensors.
Replace the turbocharging pressure sensor, component code 1071 if necessary.
If the fault is still present, contact the Techline

DDCR_V14_DF089
MR-425-X35-13B050$062.mif
V2
13B-62
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF098 FUEL TEMPERATURE SENSOR CIRCUIT

STORED
NOTES None.
Check the connection and condition of the fuel temperature sensor connector, component code 1066.
Check the insulation, continuity and the absence of interference resistance of the following connections:
● 3FAB between components 1066 and 120,
● 3LD between components 1066 and 120.
Measure the resistance at the terminals of the fuel temperature sensor, component code 1066.
Replace the fuel temperature sensor if the resistance is not approximately 2.2 kΩ at 25˚C.

DDCR_V14_DF098
MR-425-X35-13B050$062.mif
V2
13B-63
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF107 COMPUTER MEMORY

PRESENT 1.DEF: RAM memory integrity
OR
STORED

The fault is declared present with the engine at idle speed.
NOTES
Special notes:
Engine stopped and impossible to restart.
Check that the individual injector correction (C2I) correctly corresponds to the injectors (see the identification
screen on the diagnostic tool) otherwise write the C2I using command SC002 Enter injector codes.

DDCR_V14_DF107
MR-425-X35-13B050$062.mif
V2
13B-64
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF112 CYLINDER REFERENCE SENSOR CIRCUIT

PRESENT 1. DEF: Consistent
OR 2. DEF: No signal.
STORED

NOTES
The fault is declared present with the engine under the starter or when idling.
Check the connection and condition of the cylinder reference sensor connector, component code 746.
Check for the presence of + 12 Volts after ignition feed on connection 3FB of the sensor connector.
● 5CT between components 746 and 120,
● 3CQ between components 746 and 120.
Check the timing setting.

DDCR_V14_DF112
MR-425-X35-13B050$062.mif
V2
13B-65
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF113 SENSOR SUPPLY VOLTAGE

PRESENT 1.DEF: Below minimum threshold
OR 2.DEF: > maximum threshold.
STORED
Special notes:
NOTES – The engine stops and cannot be restarted, the level 1 and 2 warning lights are
illuminated.
Check the condition and connection of the injection computer connectors, component code 120.
Check the condition and connection of the connectors on all sensors with a 5 V feed.
– Refrigerant pressure sensor, component code 1202,
– Turbocharging pressure sensor, component code 1071,
– Rail pressure sensor, component code 1032,
– Accelerator potentiometer sensor, component code 921
– Exhaust gas recirculation valve position sensor, component code 398,
– Cylinder reference sensor, component code 746.
To locate any internal fault in one of the sensors with a 5 V supply (short circuit), disconnect each of the sensors
on the list above in turn, checking after each disconnection whether the fault changes status from "present" to
"stored".
If the faulty sensor is located, check its connections and that it is in order.
Connect the bornier in place of the computer and check the insulation, continuity and absence of interference
resistance on the following connections:
● 38Y between components 120 and 1202,
● 3LQ between components 120 and 1071,
● 3LX between components 120 and 1032,
● 3LR between components 120 and 921,
● 3GC between components 120 and 398.
If the fault is still present, apply the fault finding procedure for each sensor with a 5 V supply.

DDCR_V14_DF113
MR-425-X35-13B050$062.mif
V2
13B-66
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF121 ACCELEROMETER CIRCUIT

PRESENT
OR
STORED
Priorities when dealing with a number of faults:

– DF001 Coolant temperature sensor circuit,
– DF002 Air temperature sensor circuit,
– DF098 Fuel temperature sensor circuit,
– DF003 Atmospheric pressure sensor circuit.
NOTES DF026 to 029 Cylinder 1 to 4 injector control circuit, 1.DEF or 2. DEF
A fault on these sensors could lead to incorrect fault finding on the accelerometer.

– The fault is present with the engine idling.
Check the conformity of the injectorsfitted to the vehicle in relation to the type of vehicle and engine number
(low, high or very high injector pressure).
Check that the injector codes (C2I) are correctly entered in the computer.
Check the connection and condition of the accelerometer connector, component code 146.
Check the condition of the injection computer connector, component code 120 and the sensor shielding on
connection TB1.
● 3S between components 146 and 120,
● 3DQ between components 146 and 120.

If the fault is still present, replace the accelerometer, component code 146.

DDCR_V14_DF121
MR-425-X35-13B050$062.mif
V2
13B-67
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF159 POWER-ASSISTED STEERING RELAY CONTROL CIRCUIT

PRESENT CC.1: Short circuit to +12 volts
OR CO.0: Open circuit or short circuit to earth
STORED
Special notes:
– This fault is active if the vehicle is fitted with electric power-assisted steering.
NOTES
– CC.1: The fault is declared present after running command AC056 Power-assisted
steering assembly relay.
Check the connection and condition of the pump assembly relay mounting (Power-assisted steering pump
assembly) component code 409.
Check the insulation, continuity and absence of interference resistance on the following connection:
● 3FK between components 120 and 409.
Check for the presence of + after ignition feed between tracks 1 and 3 of the relay.
If the fault is still present, replace the power-assisted steering assembly relay, component code 409.

DDCR_V14_DF159
MR-425-X35-13B050$062.mif
V2
13B-68
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF179 INJECTION <-> AIR CONDITIONING CONNECTION

PRESENT 1.DEF: consistent.
OR 2.DEF: Permanent low level.
3.DEF: Permanent high level.
STORED

– The fault is declared present with the engine idling, and air conditioning either
activated or off.
NOTES
Special notes:
– Check that the air conditioning option is correctly configured on the vehicle using
command LC009 Air conditioning.
Check the connection and condition of the air conditioning control relay connector, component code 419.
● 38AR between components 120 and 419.
If the fault is still present, refer to the fault finding procedure for the air conditioning.

DDCR_V14_DF179
MR-425-X35-13B050$062.mif
V2
13B-69
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF238 THERMOPLUNGER No. 3 RELAY CIRCUIT

STORED
Special notes:
NOTES
This fault is active if the vehicle is equipped with a thermoplunger no.3 relay.
Check the connection and condition of the thermoplunger no.3 relay connector.
Check the insulation, continuity and absence of interference resistance of the connections:
Computer connector C track D1 → Track 2 of the thermoplunger no.3 relay.
With the ignition on, check for a + 12 V supply on track 1 and track 3 of the relay.
If the fault is still present, replace the thermoplunger no.3 relay.

DDCR_V14_DF238
MR-425-X35-13B050$062.mif
V2
13B-70
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF239 THERMOPLUNGER No. 2 RELAY CIRCUIT

STORED
NOTES None.
Check the connection and condition of the thermoplunger no.2 relay connector, component code 1068.
● 3JAA between components 120 and 1068.
With the ignition on, check for a + 12V supply between connections 3FB and BP9 of the thermoplunger no.2
relay, component code 1068.
If the fault is still present, replace the thermoplunger no.2 relay, component code 1068.

DDCR_V14_DF239
MR-425-X35-13B050$062.mif
V2
13B-71
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF240 THERMOPLUNGER NO.1 RELAY CIRCUIT

STORED
NOTES None.
Check the connection and condition of the thermoplunger no.1 relay connector, component code 1067.
● 3JA between components 120 and 1067.
With the ignition on, check for a + 12V supply on connections 3FB and BP9 of the thermoplunger no.1 relay,
component code 1067.
If the fault is still present, replace the thermoplunger no.1 relay, component code 1067.

DDCR_V14_DF240
MR-425-X35-13B050$062.mif
V2
13B-72
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
DF289 AIR CONDITIONING COMPRESSOR CONTROL

STORED

NOTES – CC.1: The fault is declared present after the air conditioning is activated.
– CO.0: Fault finding procedure to be applied only if the fault is present.
Check the connection and condition of the air conditioning compressor relay connectors, component code 419.
● 38AR between components 120 and 419.
If the fault is still present, replace the air conditioning compressor relay, component code 419.

DDCR_V14_DF489
MR-425-X35-13B050$062.mif
V2
13B-73
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Conformity check
Only check conformity after a full check with the diagnostic tool.
NOTES The values shown in this conformity check are given as a guide.
Application conditions: Engine off, ignition on.
Parameter or Status
Function Display and notes Fault finding
Checked or Action
In the event of a fault, carry out

Battery voltage PR074: Battery voltage 12 V < X < 13.5 V
fault finding on the charge circuit.
ET006: Code
YES In the event of a fault, consult the
Engine programmed
interpretation of faults for the
immobiliser ET003: Engine
INACTIVE immobiliser system.
immobiliser
PR030: Accelerator No load: X = 0%

pedal position Full load: X = 100% In the event of a fault,
Consult the interpretation of faults
Accelerator PR320: Pedal sensor No load: 0.3 V < X < 0.5 V DF008 and DF009 Pedal
pedal voltage gang 2 Full load: 1.7 V < X < 2.3 V potentiometer circuit gang 1 and
gang 2 and DF012 Sensor supply
PR321: Pedal sensor No load: 0.2 V < X < 0.7 V voltage no.2.
voltage gang 1 Full load: 3.6 V < X < 4.6 V
In the event of a fault, consult the

Preheating ET204: Preheating ACTIVE during the preheating
interpretation of status ET204
warning light warning light control phase, then INACTIVE
Preheating control.
In the event of a fault, refer to the
PR005: EGR valve X = 0%
interpretation of fault DF016 EGR
opening setpoint PR005 = PR051
control circuit.
Exhaust gas PR051: EGR valve X = 0%
recirculation position feedback PR051 = PR005 In the event of a fault, consult the
PR077: EGR valve interpretation of fault DF010 EGR
position sensor 1V<X<2V position sensor circuit.
voltage
ET122: Brake switch DEPRESSED: when depressing
no.1 signal the pedal
Brake contact Indicates recognition of brake interpretation of status ET123
ET123: Brake switch pedal contacts. Brake switch no. 2 signal
no.2 signal ACTIVE: when depressing
the pedal
If NOT COMPLETED, see the
New pump ET637: New pump
COMPLETED "Replacement of components"
chamber filling chamber filling
section.
DDCR_V14_CCONF
MR-425-X35-13B050$070.mif
V2
13B-74
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Application conditions: Engine off, ignition on.
Parameter or Status
Checked or Action
ET143: Low-speed fan

INACTIVE
assembly control
ET144: High speed fan

INACTIVE
assembly relay control
ET205: Thermoplunger
INACTIVE
No.1 relay control
ET206: Thermoplunger
INACTIVE
No.2 relay control
Relays ET207: Thermoplunger WITHOUT

INACTIVE
No.3 relay control
ET821: Power-assisted
INACTIVE
steering
ACTIVE: Only in preheating

ET160: Preheating relay phase.
control INACTIVE: After the
preheating phase.
ET214: AC compressor
INACTIVE
relay control
DDCR_V14_DF060
MR-425-X35-13B050$070.mif
V2
13B-75
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Application conditions: Idling, engine warm.
Parameter or Status
Checked or Action
In the event of a fault, carry

Battery voltage PR074: Battery voltage 12 V < X < 13.5 V out fault finding on the
charge circuit.
In the event of a fault, consult

Coolant PR064: Coolant the interpretation of
90˚C < X < 100˚C
temperature temperature parameter PR064 "Coolant
temperature".

External air
PR061: External air X = External temperature the interpretation of fault
temperature
temperature ± 5˚C DF002 Air temperature
sensor
sensor circuit.
PR311: Manifold air X = Under bonnet In the event of a fault, refer to
Manifold air temperature temperature + 5˚C the interpretation of fault
temperature
PR083: Air temperature DF039 Inlet air temperature
sensor 1.8 V < X < 2.2 V
sensor voltage sensor circuit.
X = Atmospheric pressure In the event of a fault, consult

PR035: Atmospheric + 10 mbar. the interpretation of fault
pressure Engine stopped: DF003 Atmospheric
PR035 = PR312 pressure sensor circuit.
X = Manifold pressure In the event of a fault, consult
+ 20 mbar the interpretation of fault
PR312: Manifold pressure
Engine stopped: DF089 Inlet manifold
Inlet
PR312 = PR035 pressure sensor circuit.
the interpretation of faults
DF003 Atmospheric
PR018: Estimated air flow 250 mg/st < X < 300 mg/st
pressure sensor circuit and
DF089 Inlet manifold
pressure sensor circuit.
PR030: Accelerator pedal
X = 0% In the event of a fault, consult
position
the interpretation of faults
PR320: Pedal sensor No load: 0.3 V < X < 0.5 V DF008 and DF009 Pedal
Accelerator pedal
voltage gang 2 Full load: 1.7 V < X < 2.3 V potentiometer circuit gang 1
and gang 2 and DF012
PR321: Pedal sensor No load: 0.2 V < X < 0.7 V
Sensor supply voltage no. 2.
voltage gang 1 Full load: 3.6 V < X < 4.6 V
MR-425-X35-13B050$070.mif
V2
13B-76
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Parameter or Status
Checked or Action
In the event of a fault, refer to

PR037: Refrigerant the interpretation for fault
1.5 bar < X < 30 bar
pressure DF049 Refrigerant pressure
sensor circuit.
Air conditioning
ET018: Air conditioning
ACTIVE or INACTIVE WITHOUT
request
ET214: AC compressor
ACTIVE or INACTIVE WITHOUT
relay control
the interpretation of fault
PR063: Fuel temperature X = Fuel temperature + 5˚C.
DF098 Fuel temperature
sensor circuit.
the interpretation of fault
PR017: Fuel flow 2 mg/st < X < 5 mg/st
DF024 Low pressure
actuator control circuit.
Fuel
In the event of a fault,
consult the interpretation of
PR038: Rail pressure 225 bar < X < 235 bar
fault: DF007 Rail pressure
sensor circuit.
PR008: Rail pressure
X = 230 bar WITHOUT
setpoint
ET009: High pressure pump
ACTIVE WITHOUT
control
PR005: EGR valve opening X = 16 + 5% the interpretation of fault
setpoint
DF016 EGR control circuit.
PR051: EGR valve position In the event of a fault, consult
Setpoint: X = + 2%
Exhaust gas feedback the interpretation of fault
recirculation PR077: EGR valve position DF010 EGR position sensor
1V<X<2V circuit.
sensor voltage
ET008: EGR solenoid valve
ACTIVE the interpretation of fault
control
DF016 EGR control circuit.
MR-425-X35-13B050$070.mif
V2
13B-77
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Parameter or Status
Checked or Action
ET143: Low-speed fan Activation

assembly control Fan assembly 1 = 99˚C
ET022: Low speed fan Off
assembly request Fan assembly 1 = 96˚C
Fan assembly 2 activation =
ET144: High speed fan
102˚C
assembly relay control
Fan assembly 1 off = 99˚C
ET021: High speed fan It is only active if the vehicle is
assembly request fitted with air conditioning.
ET205:
Relays Thermoplunger No.1 INACTIVE WITHOUT
relay control
ET206:
Thermoplunger No.2 INACTIVE
relay control
ET207: INACTIVE
Thermoplunger No.3 ACTIVE with air conditioning
relay control option.
INACTIVE
ET821: Power-
ACTIVE with air conditioning
assisted steering
option.
PR055: Engine speed Setpoint: X = + 5 rpm interpretation of fault DF005
Engine speed sensor circuit.
PR010: Idle speed

X = 850 rpm WITHOUT
regulation setpoint
engine speed
ET023: Request for INACTIVE
WITHOUT
fast idle Except with consumers
In the event of a fault, refer to the

PR089: Vehicle speed X = 0 mph interpretation of fault DF014
Vehicle speed signal circuit.
New pump ET637: New pump If NOT COMPLETED, refer to

COMPLETED
chamber filling chamber filling "Component replacement".
MR-425-X35-13B050$070.mif
V2
13B-78
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Status summary table
Tool status Diagnostic tool title
ET003 Engine immobiliser.
ET004 Air conditioning authorised.
ET006 Code programmed.
ET008 EGR solenoid valve control.
ET009 High pressure pump control.
ET018 Air conditioning request
ET021 High speed fan assembly request.
ET022 Low speed fan assembly request.
ET023 Fast idling speed request.
ET038 Engine.
ET077 Impact detected.
ET079 Air conditioning present.
ET118 OBD warning light.
ET122 Brake switch no. 1 signal.
ET123 Brake switch no. 2 signal.
ET143 Low speed fan assembly relay control.
ET144 High speed fan assembly control relay.
ET160 Preheating relay control.
ET204 Preheating warning light control.
ET205 Thermoplunger No. 1 control relay.
ET214 Air conditioning compressor relay control.
ET460 Coolant warning light.
ET637 New pump chamber filling
ET821 Power-assisted steering.
MR-425-X35-13B050$080.mif
V2
13B-79
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Interpretation of statuses
BRAKE CONTACT No. 2 SIGNAL

ET123
Special notes: Only perform the checks if the INACTIVE and ACTIVE statuses are not
NOTES
consistent with the position of the pedal.
INACTIVE STATUS: Brake pedal released.
If the brake lights are working:

– Check and ensure the continuity of connection 65A between the connector of the brake light switch,
component code 160 and the connector of the injection computer, component code 120.
If the brake lights are not working:
– Check the condition and fitting of the brake light switch and the brake lights fuse.
– Remove and test the operation of the brake light switch:
Continuity between the following Insulation between the

connections: following connections:
Switch depressed(Brake pedal
AP10 and 5A 65A and AP10
released)
Switch released (Brake pedal
65A and AP10 AP10 and 5A
depressed)
– Check for + after ignition feed on connections AP10 of the brake light switch connector.
ACTIVE STATUS: Brake pedal depressed
AFTER REPAIR Carry out a road test followed by a check with the diagnostic tool.
DDCR_V14_ET123
MR-425-X35-13B050$090.mif
V2
13B-80
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ET123
CONTINUED
– Check the condition and fitting of the brake light switch and the brake lights fuse.
– Remove and test the operation of the brake light switch:
Continuity between the following Insulation between the

connections: following connections:
Switch depressed(Brake pedal
AP10 and 5A 65A and AP10
released)
Switch released (Brake pedal
65A and AP10 AP10 and 5A
depressed)
– Check and ensure the insulation to + 12V of connection 65A between the connector of the brake light
switch, component code 160 and the connector of the injection computer, component code 120.
MR-425-X35-13B050$090.mif
V2
13B-81
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
PREHEATING WARNING LIGHT COMMAND

ET204
NOTES None.
Use command AC060 Preheating warning light and check that the warning light comes on properly.
If the warning light comes on, contact the Techline.
Check the condition and connection of the preheating warning light connector, component code 247.
Check the condition and connection of the injection computer connector, component code 120.
● 3BK between components 247 and 120.
DDCR_V14_ET204
MR-425-X35-13B050$090.mif
V2
13B-82
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Parameter summary table
Tool Parameter Diagnostic tool title
PR005 EGR valve opening setpoint
PR008 Rail reference pressure
PR010 Idle speed regulation setpoint.
PR017 Fuel flow
PR018 Estimated air flow
PR030 Accelerator pedal position
PR035 Atmospheric pressure
PR037 Refrigerant pressure
PR038 Rail pressure
PR051 EGR valve position feedback
PR055 Engine speed.
PR061 External air temperature
PR063 Fuel temperature
PR064 Coolant temperature,
PR074 Battery voltage
PR077 EGR valve position sensor voltage
PR080 Rail pressure sensor voltage
PR083 Air temperature sensor voltage
PR089 Vehicle speed.
PR125 Power consumed by the air conditioning compressor
PR311 Manifold air temperature
PR312 Inlet manifold vacuum
PR320 Pedal sensor voltage gang 2
PR321 Pedal sensor voltage gang 1
MR-425-X35-13B050$100.mif
V2
13B-83
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Interpretation of parameters
COOLANT TEMPERATURE
PR064
Special notes:
NOTES
– Only apply the checks if the parameter is inconsistent.
Check the condition of the coolant temperature sensor connections, component code 244.
Measure the resistance between connections 3JK and 3C of the coolant temperature sensor, component code
244.
If the theoretical values are not between:
11332 Ω < X < 13588 Ω at - 10˚C,
2139.4 Ω < X < 2364.6 Ω at 25˚C,
773 Ω < X < 849.8 Ω at 50˚C,
274.77 Ω < X < 290.43 Ω at 80˚C, replace the coolant temperature sensor.
DDCR_V14_PR064
MR-425-X35-13B050$110.mif
V2
13B-84
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Dealing with command modes
Tool Diagnostic tool title Comments

command
RZ002 EGR programming Use this command when replacing the EGR valve or after it has been
adaptives cleaned.
RZ007 Fault memory This command is used to clear the faults stored in the computer.
RZ008 Engine parameter This command is used to reinitialise all the engine adaptive
adaptives programming.
RZ009 Vehicle function this command enables you to reinitialise the entire computer
programming configuration according to the vehicle.
AC002 EGR solenoid valve This command is used to control the EGR valve. This command is to be
used when carrying out an audible check of the mechanical operation
of the EGR valve.
AC005 Cylinder 1 injector This command is used to perform an audible check on injector 1.
AC010 High pressure pump This command lets you listen for the operation of the high pressure
pump.
AC028 Static test This command should be used after the computer has been replaced or
(re)programmed. It restores the operation of the vehicle's available
components (thermoplungers, air conditioning and power-assisted
steering)
AC029 High pressure circuit This command checks the sealing of the high pressure circuit after work
sealing test has been carried out, and also checks the return volume for each
injector to detect any internal leak on the injectors.
This command can only be used if the engine temperature is: X > 60˚C.
AC031 Thermoplunger No. 3 This command actuates the relay for thermoplunger No. 3 to test the
relay supply of thermoplunger No. 3.
AC037 Preheating relay This command actuates the preheating relay to test the heater plug
supply.
MR-425-X35-13B050$120.mif
V2
13B-85
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Dealing with command modes
Tool Diagnostic tool title Comments

command
AC038 Low speed fan assembly This command actuates the low-speed fan assembly relay to test the
relay supply to the low speed fan assembly.
AC039 High speed fan assembly This command actuates the high speed fan assembly. Depending on
relay vehicle equipment.
AC047 OBD warning light This command actuates the OBD warning light on the instrument
panel
AC056 Power-assisted steering This command actuates the power-assisted steering pump
assembly relay
AC060 Preheating warning light This command actuates the preheating warning light on the instrument
panel
AC061 Overheating indicator This command actuates the engine overheating warning light on the
light instrument panel.
AC063 Thermoplunger No.1 This command actuates the relay for thermoplunger No. 1 to test the
relay supply to thermoplunger No. 1.
AC064 Thermoplunger No.2 This command actuates the relay for thermoplunger No. 2 to test the
relay supply to thermoplunger No. 2.
AC070 Air conditioning This command actuates the air conditioning compressor clutch.
compressor
AC212 New pump chamber This command must only be activated after the high pressure pump has
filling been replaced (see Replacement of components). This command is
used to activate the pump repriming sequence.
SC001 Write saved data This command is used to enter the data that was saved in the computer
using command SC003, after the computer has been replaced or
(re)programmed (see Replacement of components).
SC002 Enter injector codes This command enables you to manually write the calibration code
inscribed on the injectors. Run this command after replacing the
injectors. (see Replacement of components).
SC003 Save computer data This command is used to save the computer operating data and C2I
codes before the computer is replaced or (re)programmed (see
Replacement of components).
MR-425-X35-13B050$120.mif
V2
13B-86
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Tests
Only consult these tests when dealing with a fault finding chart (ALP) or when
NOTES
interpreting faults.
Low pressure circuit check → TEST 1
Electrical circuit check → TEST 2
Injector check → TEST 3
Inlet circuit check → TEST 5
High pressure system check → TEST 6
High pressure circuit sealing check → TEST 7
Injector return flow → TEST 8
Diesel filter check → TEST 9
Turbocharger solenoid valve check → TEST 10
Turbocharger air chain → TEST 11
Turbocharger → TEST 12
Diesel fuel conformity check → TEST 13
MR-425-X35-13B050$130.mif
V2
13B-87
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 1 Low pressure circuit check
Check the conformity of the low pressure circuit

connections
Are the low pressure circuit connections

NO Carry out the necessary repairs.
correct?
YES
Check the condition of the priming bulb, and

that it is working properly.
Look for leaks at the unions.

Carry out the necessary repairs
Are there leaks from the hoses and unions? YES
NO
Check that there are no air bubbles in the – Bleed the low-pressure circuit.
diesel fuel. – Place a container under the filter.
– Disconnect the return hose from the filter and plug
Are air bubbles present in the low pressure the filter.
YES – Pump using the priming bulb until there is no air left.
circuit?
– Reconnect the return hose immediately.
NO
Low pressure circuit correct.
DDCR_V14_TEST01
MR-425-X35-13B050$130.mif
V2
13B-88
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 2 Electrical circuit check
Check the battery charge and that the alternator

is working properly NO Carry out the necessary repairs
Is the charging circuit in good order?
YES
Check the fuses.

NO Carry out the necessary repairs
Are the fuses correct?
YES
Check that the injection locking relay is

operating correctly. NO Carry out the necessary repairs
Is the injection locking relay working properly?
YES
Check the engine earths.

Are the engine earths correct?
YES
The electrical circuit is in good order.
DDCR_V14_TEST02
MR-425-X35-13B050$130.mif
V2
13B-89
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 3 Injector check
Conduct a visual inspection around the injectors. Locate the source of the leak and carry out the
YES
Is diesel fuel present around the injectors? necessary repairs.
NO
Control the injectors with the commands AC005

Cylinder 1 injector, Check the insulation and the continuity of the
AC006 Cylinder 2 injector, electrical circuit.
AC007 Cylinder 3 injector, Run test 9 Diesel filter check.
AC008 Cylinder 4 injector. If test 9 is correct, replace the faulty injector(s) (MR 423
Mechanical, 13B, Diesel injection, Diesel injector:
Can the movement of the valve be heard at a Removal - Refitting).
distance of 1 metre from the vehicle? NO
YES
End of TEST 3.
DDCR_V14_TEST03
MR-425-X35-13B050$130.mif
V2
13B-90
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 5 Inlet circuit check
Check for air leaking in or out.

YES Carry out the necessary repairs
Is air leaking in or out?
NO
Check the condition of the air filter. Replace the air filter (seeMR 423, Mechanical, 12A,
Is the air filter in order? NO Fuel mixture, Air filter: Removal - Refitting)
YES
Check that the inlet manifold is not obstructed

(clogged). YES Clean the inlet manifold.
Is the inlet manifold blocked?
NO
Air system in good order.
DDCR_V14_TEST05
MR-425-X35-13B050$130.mif
V2
13B-91
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 6 High pressure system check
Special note:
Certain faults make it impossible to carry out this test - deal with these first.
NOTES
IMPORTANT: It is pointless and dangerous to engage the starter motor for more
than 5 seconds.
Preliminary checks:
– Check for the presence of fuel
– Check that there is no air in the low pressure circuit. Run TEST 1: Low pressure circuit check.
– Ensure that the correct fuel is being used. Run TEST 13 Diesel fuel conformity check.
It is possible to check the high pressure supply pump capacity by carrying out the following procedure:
– With the ignition off, disconnect the low pressure actuator from the pump (IMV brown connector) and connect
a test IMV or the MOT. 1711 adapter.
– Electrically disconnect the four injectors.
– Switch on the ignition, connect the diagnostic tool and re-establish dialogue with the injection system.
– Go to the Main computer statuses and parameters screen.
– Run the test with the engine cold (PR064 Coolant temperature), the coolant temperature must be: X < 30˚C or
X = ambient temperature.
– Activate the starter for 5 seconds.
– Read the rail pressure maximum value (PR038) during the test on the diagnostic tool.
Is the rail pressure (PR038 Rail pressure): X > 1050 bar?
NO YES
A B
DDCR_V14_TEST06
MR-425-X35-13B050$130.mif
V2
13B-92
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 6
CONTINUED
A B
NO YES
– Switch off the ignition, reconnect the electrical The pump can supply the operating pressure.
connections to the four injectors and the low-pressure Switch off the ignition, reconnect the electrical
actuator. connections
– Switch on the ignition again, and clear the injection to the four injectors and the low pressure actuator.
faults using the diagnostic tool. Switch on the ignition again, and clear the injection
– Check if there is no fuel leak in the high pressure circuit. faults using the diagnostic tool.
Check if there is no fuel leak in the high pressure
Run TEST 7 High pressure circuit sealing check
circuit. Run TEST 7 High pressure circuit sealing
– Check the conformity of the diesel filter. Run TEST 9
check.
Diesel fuel filter check. Carry out fault finding on the injectors by checking the
– Carry out fault finding on the injectors by checking the volume of the return flow from the four injectors. Run
volume of the return flow from the four injectors. Run TEST 8 Injector return flow.
TEST 8 Injector return flow. If TEST 8 is correct, the high pressure fuel circuit is
Is TEST 8 OK? correct.
NO YES
Replace the faulty injector(s) (see

MR 423, Mechanical, 13B, Diesel Replace the high pressure pump (see MR 423 Mechanical, 13B, Diesel
injection, Diesel injector: injection, High pressure pump: Removal - Refitting).
Removal - Refitting)
IMV = fuel flow actuator
MR-425-X35-13B050$130.mif
V2
13B-93
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 7 High pressure circuit sealing check
Special note:
NOTES
The command AC029 High pressure circuit sealing test can locate a leak in the high pressure circuit if a union
is incorrectly fitted or screwed on. This command does not identify a union not tightened to torque.
This command can be used only if the engine temperature is: X > 60ºC.
Watch out for any objects (tool or others) on the sides of the engine housing during the 4 accelerations
(possible vibrations).
Run command AC029, the engine will automatically carry out a cycle of four accelerations to increase the rail
pressure. Check if there are leaks on the high pressure circuit.
DDCR_V14_TEST07
MR-425-X35-13B050$130.mif
V2
13B-94
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 8 Injector return flow
Special note:
NOTES
Does the engine start? NO A

YES
Command AC029 High pressure circuit sealing test is also used to check the return volume of each injector
to detect any internal injector leak.
Be careful with any objects (tool or other) on the engine housing during the four cycles of the operation
(possible vibrations).
Tooling required
– Mot. 1711 Injector flow measuring kit.
Or: Use four tubes of internal diameter 4 mm and approximately 50 cm long, and four graduated measuring cylinders.
Procedure
– Ensure that the engine coolant temperature (PR064 Coolant temperature) is: X > 60˚C,
– switch off the ignition,
– disconnect the return pipes from the four injectors,
– cap the pump venturi tube to prevent the low-pressure circuit from depriming,
– connect the four transparent tubes in place of the return pipes,
– put the other ends of the four pipes into four graduated measuring cylinders.
– Having carried out these preparations, start the engine and let it idle for 2 minutes.
Note: This idle time must be respected for the test results to be interpreted correctly.
– Run command AC029 High pressure circuit sealing check.
– The engine will automatically carry out a cycle of four accelerations to increase the rail pressure and measure the
internal injector leaks under these conditions.
– Once the cycle is complete, run command AC029 again to obtain a correct reading of the return volume of
each injector.
– Switch off the engine at the end of the cycle.
At the end of both cycles, the return volume of each injector should be X = 35 ml maximum.
If the return volume of one of the injectors is: X > 35 ml, replace the faulty injector (see MR 423, Mechanical, 13B,
Diesel injection, Diesel injector: Removal - Refitting).
Disconnect the 4 transparent pipes and reconnect the injector return circuit.
DDCR_V14_TEST08
MR-425-X35-13B050$130.mif
V2
13B-95
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 8
CONTINUED 1
Carry out the following test to confirm the repair:

– With the ignition off, disconnect the low pressure actuator from the pump (brown IMV connector) and connect
the test adapter (test IMV, Mot. 1711),
– electrically disconnect the 4 injectors,
– switch on the ignition, connect the diagnostic tool and re-establish dialogue with the injection system,
– go to the Main computer statuses and parameters screen,
– engage the starter for 5 seconds,
– read the rail pressure maximum value (PR038) during the test on the diagnostic tool.
If the rail pressure (PR038) is: X < 1050 bar, run TEST 6 High pressure system check.
– Switch off the ignition, and reconnect the four injectors electrically,
– disconnect the test filling actuator (test IMV) and reconnect the low pressure actuator connector (IMV) to the pump
Switch the ignition back on, and clear the injection faults using the diagnostic tool.
If the rail pressure (PR038) is: X > 1050 bar, the repair is correct.
End of TEST 8.
MR-425-X35-13B050$130.mif
V2
13B-96
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 8
CONTINUED 2
A
NO
If the engine does not start, only the static leak can be measured, that is the leak with the injector closed, not being
actuated and under high pressure.
Make sure that the ignition circuit is working correctly (minimum speed is: X = 200 rpm).
Tooling required
– Mot. 1711 Injector flow measuring kit.
Or: Use four tubes of internal diameter 4 mm and approximately 50 cm long and a test adapter (TEST IMV).
Procedure
– Switch off the ignition,
– disconnect the return pipes from the four injectors,
– cap the pump venturi tube to prevent the low-pressure circuit from depriming,
– connect the four transparent pipes in place of the return pipes (Mot. 1711),
– disconnect the low pressure actuator from the pump (brown IMV connector) and connect a test IMV or the adapter
of Mot. 1711,
– electrically disconnect the four injectors,
– switch on the ignition and engage the starter for 5 seconds,
– measure the amount of diesel fuel in each pipe.
Replace the injector(s) whose leak return is: X > 10 cm (see MR 423, Mechanical, 13B, Diesel injection, Diesel
injector: Removal - Refitting).
Switch off the ignition, and reconnect the four injectors electrically.
Disconnect the test IMV and reconnect the low-pressure actuator connector to the pump. Disconnect the
four transparent tubes and reconnect the injectors return circuit. Switch on the ignition again, and clear the injection
faults using the diagnostic tool.
Carry out the following test to confirm the repair:
– With the ignition off, disconnect the low pressure actuator from the pump (brown IMV connector) and connect
the test adapter (test IMV, Mot. 1711),
– electrically disconnect the four injectors,
– switch on the ignition, connect the diagnostic tool and re-establish dialogue with the injection system,
– go to the Main computer statuses and parameters screen,
– engage the starter for 5 seconds,
– read the maximum rail pressure value PR038 Rail pressure during the test on the diagnostic tool.
If the rail pressure (PR038) is: X < 1050 bar, run test 6 High pressure system check.
– Switch off the ignition, and reconnect the four injectors electrically,
– disconnect the test IMV and reconnect the low-pressure actuator connector to the pump,
– switch on the ignition again, and clear the injection faults using the diagnostic tool.
If the rail pressure (PR038) is: X > 1050 bar, the repair is correct.
End of TEST 8.
MR-425-X35-13B050$130.mif
V2
13B-97
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 9 Diesel filter check
Replace the filter with an original part (see MR 423,

Check the conformity of the diesel filter.
NO Mechanical, 13A, Fuel supply, Fuel filter:
Is the diesel filter in order?
Removal - Refitting).
YES
– Switch off the ignition and analyse the diesel fuel in the diesel filter.
– Disconnect the diesel supply and return hoses from the filter.
– Block the filter inlets and outlets straight away with appropriate plugs.
– Remove the filter from its holder and shake it firmly while holding the caps in place. Tap the edge of the filter with
a screwdriver handle to detach any contamination. Empty the contents of the filter into a glass container by lifting
a protective plug, then loosening and completely removing the bleed screw.
Is there a deposit of black particles at the bottom of the container?
YES NO
Pass a magnet beneath the container to collect all the

metal particles. Take the magnet away from the Diesel filter in good order.
container.
Do the particles (only those gathered using the magnet)
cover a surface area: X > 1 cm2 ?
YES NO
Replace the entire Diesel filter in good

injection system order.
DDCR_V14_TEST09
MR-425-X35-13B050$130.mif
V2
13B-98
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 10 Turbocharger solenoid valve check.
Check the vacuum at the pressure regulator inlet

Let the engine idle.
Check the engine temperature using PR064 Coolant temperature.

Let the engine warm up until the temperature reaches: X = 80˚C.
Disconnect the vacuum pipe of the end piece of the pressure regulator.
Connect a vacuum gauge to the end of the disconnected pipe and set it to vacuum measurement.
Perform a quick acceleration by depressing the accelerator pedal completely and then releasing it immediately.
The total duration of pressing and holding in the full load position must be: X < 1 second.
During this acceleration, the engine speed must reach a value between 3000 rpm < X < 4000 rpm.
Repeat the operation 3 times.
Read the maximum vacuum displayed by the pressure gauge during the increase in speed, the decrease in speed
and after returning to idle speed.
Tolerance intervals to be respected for the vacuum value:

-1 bar < X < - 0.6 bar (CORRECT vacuum value),
- 0.6 bar <X < 0 bar (INCORRECT vacuum value).
Is the vacuum at the turbocharging pressure regulator inlet displayed on the vacuum gauge within the
tolerance interval?
NO YES
A The solenoid valve is in order.
DDCR_V14_TEST10
MR-425-X35-13B050$130.mif
V2
13B-99
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 10
CONTINUED 1
A
NO
Reconnect the vacuum pipe to the turbocharging pressure regulator
Checking the vacuum at the solenoid valve outlet

Disconnect the vacuum pipe from the end piece of the solenoid valve outlet.
This pipe connects the solenoid valve to the turbocharging pressure regulator.
Connect a vacuum pressure gauge to the solenoid valve outlet and put it in the vacuum measurement position.
Perform a quick acceleration by depressing the accelerator pedal completely and then releasing it immediately.
The total duration of pressing and holding in the full load position must be: X < 1 second.
During this acceleration, the engine speed must reach a value between: 3000 rpm < X < 4000 rpm.
Repeat the operation 3 times.
Read the maximum vacuum displayed by the pressure gauge during the increase in speed, the decrease in speed
and after returning to idle speed.

- 1 bar < X < - 0.6 bar (CORRECT vacuum value),
- 0.6 bar < X < 0 bar (INCORRECT vacuum value).
Is the vacuum displayed by the pressure gauge at the solenoid valve outlet within the tolerance interval?
NO YES
Replace the vacuum pipe between the

Reconnect the vacuum pipe to the
solenoid valve and the turbocharging
turbocharging pressure regulator
pressure regulator
MR-425-X35-13B050$130.mif
V2
13B-100
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 10
CONTINUED 2
Visual inspection of the electrical connector of the solenoid valve

Switch off the engine.
Note:
The requested checks are entirely visual.
1. Check that the connector is correctly connected and locked.

2. Check the absence of damage to the electric wires where they leave the installation.
3. Disconnect the connector to continue the checks.
4. Check the absence of thermal damage to the unit and mechanical damage to the lock.
5. Check the absence of deformations of the contacts (clips and tabs).
6. Check the sealing of the connector.
Do the visual inspections highlight any damage?
YES
NO
Refer to Technical Note 6015A, Electrical wiring repair. A
Checking the vacuum at the solenoid valve inlet

Disconnect the vacuum pipe from the end piece of the solenoid valve inlet.
This pipe connects the vacuum pump to the turbocharger solenoid valve.
Connect a vacuum gauge to the end of the disconnected pipe and set it to vacuum measurement.
Read the vacuum displayed by the pressure gauge.

- 1 bar < X < - 0.85 bar (CORRECT vacuum value),
- 0.85 bar < X < 0 bar (INCORRECT vacuum value).
Is the vacuum displayed by the pressure gauge at the solenoid valve inlet within the tolerance interval?
NO YES
Carry out the following operations.

– Reconnect the vacuum pipe to the turbocharger solenoid
valve. Replace the solenoid valve (see MR 423,
– Check the vacuum pipe or pipes are connected correctly. 12B, Turbocharging).
– Visually check the condition of the vacuum pipes leaving the
vacuum pump to the different supplied components.
MR-425-X35-13B050$130.mif
V2
13B-101
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 11 Turbocharger air chain
Check for the air filter

Check the replacement interval of the air filter on the maintenance booklet.
Compare the part numbers of the air filter fitted to the vehicle and that of the air filter recommended by the
manufacturer.
Check the air filter direction of fitting.
Is the air filter fitted to the vehicle correct?

YES NO
Check the condition of the air filter

Visually inspect the condition of the filtering section of the air Replace the air filter (see MR 423,
filter. YES Mechanical, 12A, Fuel mixture, Air
Is either the air filter or its seal damaged? filter, Removal - Refitting).
Is the air filter fouled (does it contain a lot of impurities)?
NO
Low pressure circuit check

Note:
Depending on the vehicle type, the best visual access will be
either from above or from below. Replace the faulty parts (see MR 423,
YES Mechanical, 12B, Turbocharging).
Visually inspect the condition of the following components:
fresh air inlet scoop on the front panel of the vehicle,
air inlet pipe to the air filter,
air pipe of the filter until the compressor inlet,
mountings of the air flowmeter.
Is one of these components incorrect (disconnected, cut,

bent, pierced or kinked pipes)?
NO
DDCR_V14_TEST11
MR-425-X35-13B050$130.mif
V2
13B-102
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 11
CONTINUED
A
NO
High pressure circuit check Replace the faulty parts

Note: (see MR 423,
Depending on the vehicle type, the best visual access will be either from above YES Mechanical, 12B,
or from below. Turbocharging).
Visually inspect the condition of the following components:
– the compressor outlet pipe to the turbocharging air cooler (the turbocharging
air cooler does not exist for all engines),
– outlet pipe of the turbocharging air cooler to the inlet manifold,
– inlet manifold,
– temperature and pressure sensors.
Is one of these components incorrect (disconnected, cut, bent, pierced or
kinked pipes)?
NO
Exhaust system check Replace the faulty parts

Visually inspect the condition of the following engine sections: (see MR 423,
– from the exhaust manifold circuit to the turbocharger turbine, YES Mechanical, 12B,
– from the turbine outlet pipe to the end of the exhaust pipe, Turbocharging).
– from the inlet manifold to the EGR valve
– check that the temperature and pressure sensors are connected.
Do some of these components have black or white marks on them?
NO
Run TEST 10 Turbocharger solenoid valve check.
MR-425-X35-13B050$130.mif
V2
13B-103
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 12 Turbocharger
IMPORTANT
Perform these checks without removing the turbocharger and with the vehicle ignition switched off.
Checking the turbocharger shaft
WARNING
Respect the following safety precautions:
– wear heat resistant gloves when the engine is hot,
– do not wear loose or baggy clothing and do not wear loose hanging jewellery,
– watch for possible triggering of the motor-driven cooling fan unit and the operation of the accessories belt or belts.
Note:
The turbocharger shaft is the shaft that connects the compressor wheel and the turbine wheel.
Depending on the vehicle type, the best visual access will be either from above or from below.
Disconnect the air pipe located between the turbocharger and the air filter.
Wearing gloves, check the operation of the turbocharger shaft by turning the vanes manually without forcing.
Does the shaft have a kickdown point in rotation?
Does the compressor wheel touch the turbocharger housing?
If for these 2 questions the If YES for one of these 2 questions

response is NO
Replace the turbocharger (see MR 423, Mechanical, 12B
Turbocharging, Turbocharger: Removal - Refitting and Technical
A Note 3938A, Broken turbocharger: Replacement instructions).
DDCR_V14_TEST12
MR-425-X35-13B050$130.mif
V2
13B-104
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 12
CONTINUED 1
Check the condition of the turbocharger vanes.
Note:
This check is facilitated by using a mirror and a lamp.
Visually check that the compressor vanes are in good condition.
Are the vanes damaged or twisted?
NO YES
Replace the turbocharger (see MR 423, Mechanical,

12B, Turbocharging, Turbocharger: Removal -
What is the type of turbocharger?
Refitting and Technical Note 3938A, Broken
turbocharger: Replacement instructions).
Variable geometry Turbocharger with
turbocharger fixed geometry
B C
MR-425-X35-13B050$130.mif
V2
13B-105
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 12
CONTINUED 2
Checking the turbocharging pressure regulator for a turbocharger with variable geometry
Note:
The pressure regulator rod of a variable geometry turbocharger is orthogonal to the turbocharger shaft.
Turbochargers with variable geometry are controlled by a solenoid valve.
Note:
If necessary and depending on the vehicle type and the accessibility of the pressure regulator, connect the vacuum
pump to the end of the pressure regulator pipe, at the solenoid valve outlet.
Using a manual vacuum pump, apply a vacuum on the turbocharging pressure regulator of approximately:
X = 650 mbar.
1. Check that the fitting is completely leaktight.

2. Check that the control rod is resting against its stop.
3. Lock the vacuum device and check that the pressure variation is not: X > 100 mbar in 10 seconds.
4. Release the pressure and check that the control rod returns to its initial position smoothly.
Repeat the entire sequence three times.
Is the pressure regulator leaktight and is the rod movement correct?
YES NO
Replace the turbocharger (see MR 423, Mechanical, 12B,

The turbocharger is correct. Turbocharging, Turbocharger: Removal - Refitting and
End of procedure. Technical Note 3938A, Broken turbocharger:
Replacement instructions).
MR-425-X35-13B050$130.mif
V2
13B-106
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 12
CONTINUED 3
Checking the turbocharging pressure regulator for a turbocharger with fixed geometry
Note:
The pressure regulator rod of a fixed geometry turbocharger is aligned with the turbocharger shaft.
Turbochargers with fixed, regulated geometry are controlled by a solenoid valve.
Note:
If necessary and depending on the vehicle type and the accessibility of the pressure regulator, connect the vacuum
pump to the end of the pressure regulator pipe, at the solenoid valve outlet.
Using a manual vacuum pump, apply a vacuum on the turbocharging pressure regulator of approximately:
X = 650 mbar.
1. Check that the fitting is completely leaktight.

2. Check that the control rod moved several millimetres.
3. Lock the vacuum device and check that the pressure variation is not: X > 100 mbar in 10 seconds.
4. Release the pressure and check that the control rod returns to its initial position smoothly.
Repeat the entire sequence three times.
Is the pressure regulator leaktight and is the rod movement correct?
YES NO
Replace the turbocharger (see MR 423, Mechanical, 12B,

The turbocharger is correct. Turbocharging, Turbocharger: Removal - Refitting and
End of procedure. Technical Note 3938A, Broken turbocharger:
Replacement instructions).
MR-425-X35-13B050$130.mif
V2
13B-107
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 12
CONTINUED 4
Deformed, twisted blade ("soft" foreign body)
Broken blades ("hard" foreign body)
End of TEST 12
MR-425-X35-13B050$130.mif
V2
13B-108
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 13 Diesel fuel conformity check
WARNING
During this operation, it is essential to:
– refrain from smoking or bringing incandescent objects close to the work area,
– guard against petrol splashes caused by the residual pressure in the pipes,
– wear safety goggles with side guards,
– wear leaktight gloves (Nitrile type).
IMPORTANT
– To avoid any corrosion or damage, protect the areas on which fuel is likely to run.
– To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components
exposed to the open air.
Preparations:
Weigh an empty 1300 ml plastic cup (part no. 77 11 171 413) with its cover (part no. 77 11 171 416) using
electronic scales such as those used in body paint workshops (example: PANDA part no. 77 11 224 995). Record
the weight of the empty plastic cup.
This type of plastic cup is used to prepare paint.
Remove 1 L of fuel at the diesel filter outlet (see MR 423, Mechanical, 19C, Tank, Fuel tank: Draining), using
a pneumatic transfer pump (part no. 634-200) and place it in the 1300 ml plastic cup.
Cover the plastic cup with its cover and let it settle for approximately 2 minutes.
Presence of water in diesel fuel, the fuel is not compliant.

Is the fuel cloudy or does it
YES Drain the fuel circuit, including the tank (see MR 423, Mechanical,
separate into two parts?
19C, Tank, Fuel tank: Draining).
NO
DDCR_V14_TEST13
MR-425-X35-13B050$130.mif
V2
13B-109
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 13
CONTINUED 1
A
NO
Weigh the diesel fuel and note the fuel weight after subtracting the weight of the empty plastic cup and its cover.
Does the fuel weight fall between the minimum and maximum weights given in the table below?
Calculated weight (g.)

Fuel temperature (˚C)
Min. weight Max. weight
821 846 13
821 846 14
820 845 15
819 844 16
819 844 17
818 843 18
817 842 19
816 841 20
816 841 21
815 840 22
814 839 23
814 839 24
813 838 25
Check the fuel temperature by immersing a thermometer in the plastic cup.
YES NO
The fuel is not correct.

If the fuel weight is less than the minimum value then there is petrol in the
diesel fuel.
End of test. If the fuel weight is greater than the minimum value then there is oil in the
diesel fuel.
Drain the fuel circuit, including the tank (see MR 423, Mechanical, 19C,
Tank, Fuel tank: Draining).
MR-425-X35-13B050$130.mif
V2
13B-110
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
TEST 13
CONTINUED 2
Note:
If the weight measured reaches the limit values, the measurement can be performed with a 2230 ml plastic cup
(part no. 77 11 171 414) and its cover (part no. 77 11 171 417):
– Carry out a quick test drive in order to mix the fuel, then remove 2 l of fuel.
– Perform the test again and check the results by multiplying the limit values by 2.
Contact the Techline if you have doubts or problems with the customer.
MR-425-X35-13B050$130.mif
V2
13B-111
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Customer complaints
Special note:
NOTES
Only consult this customer complaint after a complete check with the diagnostic tool.
No dialogue with the computer → ALP1
Starting fault:
The engine will not start → ALP2
The engine starts with difficulty, or starts then stalls → ALP3
Starting difficult with warm engine → ALP4
Rough idle (pumping) → ALP5
Idling speed too high or too low → ALP6
Behaviour while driving:
Erratic acceleration/deceleration and engine racing → ALP7
Acceleration gap → ALP8
Engine cut-out (stalling) → ALP9
Engine hesitation → ALP10
Loss of power → ALP11
Too much power → ALP12
Excessive consumption → ALP 13
Overspeed when releasing accelerator or changing gear → ALP14
Engine dies on pulling away → ALP15
Noise, odours or smoke:
Engine rattling, noisy engine, turbocharger noise → ALP16
Blue, white or black smoke → ALP17
Oil leaks from the turbocharger → ALP18
MR-425-X35-13B050$140.mif
V2
13B-112
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
Fault finding – Fault finding charts
ALP1 No dialogue with the computer
NOTES Only consult this customer complaint after a full check with the diagnostic tool.
To check that the diagnostic tool is not causing the fault, try to establish dialogue with a computer on another
vehicle. If the diagnostic tool is not the cause and communication cannot be established with any other computer
on the same vehicle, it is possible that another computer is disrupting the multiplex network. Check the battery
voltage and make the necessary adjustments to obtain a correct voltage (9.5 V < Battery voltage < 17.5 V).
Check for the injection fuses and their condition on the passenger compartment fuse board, and in the engine fuse
box.
Check the connection of the injection computer connectors, component code 120 and the condition of its
connections.
Check the injection computer earths (quality, oxidation, earth bolt secure on front left-hand shock absorber cup).
Check that the computer is correctly supplied on the following connections:
● N between components 120 and earth,
● 3FB between components 120 and 1047,
● AP15 of component 120.
Check and ensure the continuity and insulation of the connection between:
● 3FAC between components 120 and 1047.
Check that the diagnostic socket is correctly supplied on the following connections:
● M and N between components 225 and the earths.
Check and ensure the continuity and insulation of the following connection:
● HK between components 120 and 225.
If dialogue has still not been established after these checks, contact the techline.
AFTER REPAIR Carry out a road test, then check with the diagnostic tool.
DDCR_V14_ALP01
MR-425-X35-13B050$150.mif
V2
13B-113
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP2 The engine will not start
NOTES Only consult this customer complaint after a complete check with the diagnostic tool.
Check that the fuel tank is correctly filled and that the fuel is correct by running TEST 13 Diesel fuel conformity
check.
Check the levels of engine oil and coolant.
Check the air inlet circuit by running TEST 5 Air inlet circuit check.
Replace the catalytic converter (see MR

Is the catalytic converter clogged or damaged? YES 423, Mechanical, 19B, Exhaust, Catalytic
converter: Removal - Refitting).
NO
Check the electrical circuit by running TEST 2 Electrical circuit check.
Check the electrical conformity of the heater plugs (the value of the heater plug resistance should be: X < 2 Ω).
Is the timing set correctly? NO Carry out the necessary repairs.

YES
Visually check the condition of the engine wiring harness.
DDCR_V14_ALP02
MR-425-X35-13B050$150.mif
V2
13B-114
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP2
CONTINUED
Is the starter operating correctly (minimum engine

speed 200 rpm)?
YES
Is the compression in order? NO Carry out the necessary repairs

YES
Using the diagnostic tool, check that the injector codes (C2I) are correctly entered on the identification screen. If
not, configure the correct injector codes using command SC002 Enter injector codes
Is PR038 Rail pressure: X < 50 bar under + after Apply the fault finding procedure for DF007 Rail
ignition feed? YES pressure sensor circuit
NO
Check the low pressure circuit by running TEST 1 Low pressure circuit check.
Check the injectors by running TEST 3 Injector check.
Visually check that there are no leaks on the high pressure circuit by running TEST 7 High pressure circuit sealing
check.
Check the high pressure circuit by running TEST 6 High pressure system check.
Check that the computer connectors are properly locked.

Check the condition of the computer connections (bent pin, signs of corrosion, silicone, etc.).
If the connector(s) are faulty and if there is a repair procedure (see Technical Note 6015A, Repairing electrical
wiring, Wiring: Precautions for repair), repair the connector, otherwise replace the wiring.
Contact the Techline if the customer complaint is still present.
MR-425-X35-13B050$150.mif
V2
13B-115
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP3 The engine starts with difficulty, or starts then stalls
check.
Check the air inlet circuit by running Test 5 Inlet circuit check.
Replace the catalytic converter (see MR 423,

Is the catalytic converter clogged or damaged? YES Mechanical, 19B, Exhaust, Catalytic
NO
Check the electrical conformity of the heater plugs (the value of the heater plug resistance should be: X < 2 Ω).
YES
Is the compression in order? NO Carry out the necessary repairs.

YES
Check the electrical circuit by running TEST 2 Electrical circuit check.
DDCR_V14_ALP03
MR-425-X35-13B050$150.mif
V2
13B-116
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP3
CONTINUED
Check the low pressure circuit: run TEST 1 Low pressure circuit check.
check.
Check the high pressure system by running TEST 6 High pressure system check.

MR-425-X35-13B050$150.mif
V2
13B-117
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP4 Starting difficult with warm engine
Only consult this customer complaint after carrying out a complete check with the
NOTES
diagnostic tool.
check.
YES
YES
DDCR_V14_ALP04
MR-425-X35-13B050$150.mif
V2
13B-118
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP4
CONTINUED
Control the injectors using the commands:

– AC005 Cylinder 1 injector, Run Test 9 Diesel filter check.
– AC006 Cylinder 2 injector, If test 9 is correct, only replace the faulty
– AC007 Cylinder 3 injector, NO injector(s) (see MR 423 Mechanical, 13B,
– AC008 Cylinder 4 injector. Diesel injection, Diesel injector: Removal -
Can you hear the valve moving when you are Refitting).
1 metre from the vehicle?
YES

If the connector(s) is faulty and if there is a repair procedure (see Technical Note 6015A, Repairing electrical
MR-425-X35-13B050$150.mif
V2
13B-119
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP5 Rough idle (pumping)
Check that the fuel tank is correctly filled and that the fuel is correct by running TEST 13 Diesel fuel
conformity check.
Visually check that there are no leaks on the high pressure circuit by running TEST 7 High pressure circuit
sealing check.
YES
Check the electrical conformity of the heater plugs (the value of the heater plug resistance should be: X < 2Ω).
DDCR_V14_ALP05
MR-425-X35-13B050$150.mif
V2
13B-120
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP6 Idling speed too high or too low
Check the electrical circuit by running TEST 2 Check electrical circuit.
Is the clutch clearance set correctly? NO Carry out the necessary repairs
YES

DDCR_V14_ALP06
MR-425-X35-13B050$150.mif
V2
13B-121
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP7 Unexpected acceleration/deceleration and engine racing
Check that the engine has not sucked up its oil (engine racing).

DDCR_V14_ALP07
MR-425-X35-13B050$150.mif
V2
13B-122
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP8 Acceleration gap
YES
Check that the turbocharger is working properly.

Run TEST 11 Air line at the turbocharger.
Run TEST 10 Turbocharger solenoid valve check. NO Carry out the necessary repairs.
Run TEST 12 Turbocharger.
Is the turbocharger in order?
YES
DDCR_V14_ALP08
MR-425-X35-13B050$150.mif
V2
13B-123
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP8
CONTINUED
check.

MR-425-X35-13B050$150.mif
V2
13B-124
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP9 Engine cut-out (stalling)
check.
Replace the catalytic converter (see MR 423,

Is the catalytic converter clogged or
YES Mechanical, 19B, Exhaust, Catalytic converter:
damaged?
NO
Check the electrical circuit by running TEST 2 Check electrical circuit.
DDCR_V14_ALP09
MR-425-X35-13B050$150.mif
V2
13B-125
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP9
CONTINUED
check.
Check the injectors: run TEST 3 Injector check.

MR-425-X35-13B050$150.mif
V2
13B-126
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP10 Engine hesitation
check.
Is the engine wiring harness cut or pinched? YES Carry out the necessary repairs.
NO
YES
Is the valve clearance set correctly? NO Carry out the necessary repairs.
YES
DDCR_V14_ALP10
MR-425-X35-13B050$150.mif
V2
13B-127
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP10
CONTINUED
A
YES
Check the computer:

MR-425-X35-13B050$150.mif
V2
13B-128
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP11 Loss of power
Special note:
In this case, the lack of power is due to insufficient vacuum for the OCR * setpoint given.
Check the diesel filter.

Is it close to the replacement mileage? YES
Replace the diesel filter (see MR 423,
NO Mechanical, 13A, Fuel supply, Fuel filter:
Using the diagnostic tool, check that the injector codes ¨
(C2I) are correctly entered on the identification screen. If
not, configure the correct injector codes using command
SC002 Enter injector codes
Check the air inlet circuit by running TEST 5 Air inlet

circuit check.
Is the engine oil level correct? NO Top up the oil level.
NO

Is the catalytic converter clogged or damaged? YES 423, 19B, Exhaust, Catalytic converter:
NO
OCR*: opening cyclic ratio
DDCR_V14_ALP11
MR-425-X35-13B050$150.mif
V2
13B-129
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP11
CONTINUED
A
NO

YES
Is the valve clearance set correctly? NO Carry out the necessary repairs.
YES
Contact the Techline if the customer complaint is still

present.
MR-425-X35-13B050$150.mif
V2
13B-130
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP12 Too much power


DDCR_V14_ALP12
MR-425-X35-13B050$150.mif
V2
13B-131
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP 13 Excessive consumption
check.
Replace the fuel temperature sensor

(see MR 423, Mechanical, 13B, Diesel
Is the fuel temperature sensor leaking? YES injection, Rail pressure sensor: Removal
- Refitting).
NO
check.
DDCR_V14_ALP13
MR-425-X35-13B050$150.mif
V2
13B-132
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP 13
CONTINUED
YES

NO

YES
Is the turbocharger in order? NO Carry out the necessary repairs.

MR-425-X35-13B050$150.mif
V2
13B-133
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP14 Engine races when accelerator is released or when changing gear
Check that there are no obstacles that might impede the accelerator pedal travel (carpet, point of resistance, etc.).
Is the clutch clearance set correctly? NO Carry out the necessary repairs.
YES
YES
DDCR_V14_ALP14
MR-425-X35-13B050$150.mif
V2
13B-134
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP14
CONTINUED
A
NO

Run TEST 10 Turbocharger solenoid valve check. NO Carry out the necessary repairs.
YES

If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A, Repairing electrical
MR-425-X35-13B050$150.mif
V2
13B-135
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP15 Engine dies on pulling away
Is the clutch clearance set correctly? NO Carry out the necessary repairs.
YES

NO

DDCR_V14_ALP15
MR-425-X35-13B050$150.mif
V2
13B-136
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP16 Engine rattling, noisy engine, turbocharger noise
If the noise is coming from the turbocharger, apply the Technical Note 5164A, Fault finding of noises.
Note:
Pay close attention to faulty components that might result in unjustified replacement of the turbocharger. For
example, whistling does not necessarily indicate damage to the turbocharger (this could be coming from the
exhaust, the timing, the gearbox, etc.).
check.
YES
YES
DDCR_V14_ALP16
MR-425-X35-13B050$150.mif
V2
13B-137
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP16
CONTINUED
MR-425-X35-13B050$150.mif
V2
13B-138
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP17 Blue, white or black smoke
check.
YES

NO
Run TEST 5 Inlet circuit check

DDCR_V14_ALP17
MR-425-X35-13B050$150.mif
V2
13B-139
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP17
CONTINUED

NO Carry out the necessary repairs.
YES

MR-425-X35-13B050$150.mif
V2
13B-140
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP18 Oil leaks from the turbocharger
Before analysing this customer complaint, check that there are no faults, and the
conformity (or otherwise) of the parameters and statuses, using the diagnostic
NOTES
tool.
If the customer complaint is not eliminated, perform the following checks.
Check the area around the turbocharger

Note:
An oil leak does not correspond always to a fault of the turbocharger, the oil leak can arise from the area around the
turbocharger.
● Do not start the engine.
Check the area around the turbocharger and identify the origin of the leaks.
Clean the oil traces on the turbocharger.
● start the engine and let it warm up for several minutes.
IMPORTANT
If the air filter was previously removed, refit it before starting the engine (risk of aspirating foreign bodies into the air
inlet circuit).
Accelerate with no load several times, progressively increasing the duration before releasing the accelerator pedal.
Visually inspect the exterior condition of the fuel supply pipes and the turbocharger oil return and the area around it.
Identify the origin of the leaks.
Is an oil leak present at the air compressor inlet or outlet?
NO
YES
A
Check the air compressor inlet or outlet
Check for a loose interface (inlet or outlet) that is the cause Tighten the interface or the pipe concerned.
of the air leak. NO End of procedure.
Note:
It is normal to find oil traces inside the pipes at the
turbocharger inlet or outlet, because the air entering the
compressor was laden with oil from the engine rebreathing
circuit.
Is the suspected interface properly tightened?
YES
Replace the pipe concerned (see MR 423, Mechanical, 12B, Turbocharging).
DDCR_V14_ALP18
MR-425-X35-13B050$150.mif
V2
13B-141
DDCR INJECTION
DIESEL INJECTION
13B
Program No.: BE
Vdiag No.: 14
ALP18
CONTINUED
Is an oil leak present only at the casing of the compressor section?
YES
The turbocharger is not faulty. The oil leak is from another engine component and the oil NO
is flowing onto the turbocharger.
End of procedure.
Is an oil leak present at the turbocharger oil supply inlet or outlet?

YES
Check the turbocharger oil supply inlet and outlet

Check for a loose interface (inlet or outlet) that is the cause of the oil Tighten the pipe
leak. NO concerned.
End of procedure.
Is the suspected interface properly tightened? NO
YES
Only replace the seal or the pipe of the section concerned (see MR 423,
Mechanical, 12B, Turbocharging).
YES
Is an oil leak present at the interfaces of the turbine casing and the exhaust pipes?
YES NO
The turbocharger is not faulty. There is probably another fault in

the engine.
Identify the component that is the source of the leak and refer to End of procedure.
the repair manual (see MR 423, Mechanical, 10A, Engine and
peripherals).
MR-425-X35-13B050$150.mif
V2
13B-142

Renault

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Renault

Uploaded by

Copyright:

Available Formats

1 Engine and peripherals

Fault finding – Introduction 13B - 2

© Renault s.a.s. 2008

1. SCOPE OF THIS DOCUMENT

Vehicle(s): THALIA 2/ SYMBOL 2 Computer name: DDCR INJECTION

Engine: K9K 700, 706 Program No.: BE

Function concerned: DIESEL INJECTION

2. PREREQUISITES FOR FAULT FINDING

Fault finding procedures (this manual):

Type of diagnostic tools:

Special tooling required

Elé. 1590 112-track computer bornier.

Elé. 1681 Universal bornier

Mot.1711 Injector flow measuring kit.

To run fault finding on the vehicle computers, switch on the ignition.

For vehicles with key/radiofrequency remote control unit,

To cut off + after ignition feed, proceed as follows:

For vehicles with key/radiofrequency remote control unit,

If the fault is not confirmed, check:

Customer complaints - Fault finding chart

4. FAULT FINDING PROCEDURE

Perform a pre-diagnostic on the system

Print the system fault finding log (available on

Read the faults

Deal with present faults

Deal with stored faults Use fault finding charts (ALPs)

The cause is still The cause is still

Fault solved Fault solved

YES Contact Techline with the completed fault

4. FAULT FINDING PROCEDURE (continued)

Fault finding problems

Inspection of each component

If a fault is detected, repair or replace the wiring harness.

5. FAULT FINDING LOG

You will always be asked for this log:

7. CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH-

1. Risks relating to contamination:

What are the sources of contamination?

– metal or plastic swarf,

Use a brush and cleaning agent to clean the unions to be opened.

Wash your hands before and during the operation if necessary.

Instructions to be followed during the operation

EGR: Exhaust Gas Recirculation.

GMV: Cooling Fan Assembly.

UCH: Passenger Compartment Central Unit.

12 Volts APC: 12 Volts After ignition.

12 Volts AVC: 12 Volts Before ignition.

ABS: Anti-lock Brake System.

ESP: Electronic Stability Program.

BVA: Automatic Gearbox.

CAN: Controller Area Network.

TDC: Top Dead Centre.

VIN: Vehicle Identification Number.

POWER LATCH: Maintained supply phase.

C2I: Individual injector correction.

AC: Air conditioning.

PAS: Power assisted steering.

IMV: Fuel flow actuator.

– Engine speed (Crankshaft + Cam for synchronisation)

– Rail pressure check

– Idling speed regulation

– Engine coolant temperature

– Individual injector correction (C2I)

– Measuring the angular position (Cylinder reference sensor)