Ec k9k

ENGINE CONTROL SYSTEM
SECTION EC
1K9K
DIESEL EQUIPMENT
Cleanliness K9K
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE
DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
– damage or destruction of the high pressure injection system and the engine,
– seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:

– metal or plastic chips,
– paint,
– fibres:
● boxes,
● brushes,
● paper,
● clothing,
● cloths,
– foreign bodies such as hair,
– ambient air,
– etc.
IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection problems.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
● Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan part No.:
16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they must be thrown
away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be
thrown away.
● Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will therefore be
less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away.
● Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. Each
lint-free cloth should only be used once.
EC-K9K-1
DIESEL EQUIPMENT
Cleanliness K9K
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
● For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
● For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
● Use a brush and thinners to clean the connections to be opened.
● Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles remain adhered.
● Wash your hands before and during the operation if necessary.
● When wearing leather protective gloves, cover these with latex gloves.
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 Stores - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206
804. They must not, under any circumstances, be reused.
● Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries
contamination.
● All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once
the plugs have been inserted.
● The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
These items are likely to allow impurities 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.
EC-K9K-2
DIESEL EQUIPMENT
Cleanliness K9K
Instructions For Fitting The Plugs
Nissan part number: 16830 BN700

(Renault part number: 77 01 206 804)
MBIB0321E
CAUTION:
● The engine must not run with:
– Diesel containing more than 10% diester
– Petrol, even in very small amounts.
2
● The system can inject the diesel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428 kg/cm ,
20,300 psi). Before carrying out any work, check that the injector rail is no longer pressurized and that the
fuel temperature is not too high.
● You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
EC-K9K-3
DIESEL EQUIPMENT
Special features K9K
The high pressure injection system is intended to deliver a specific quantity of diesel to the engine at a specific time.
DESCRIPTION
● DELPHI and type "LVCR" flash EEPROM injection controlling 112 terminals computer.
● The system consists of:

– a priming bulb on the low pressure circuit,
– a diesel filter,
– a high pressure pump incorporating a low pressure pump (transfer pump),
– a flow actuator attached to the pump,
– an injector rail,
– a pressure sensor located in the rail,
– four solenoid injectors,
– a diesel temperature sensor,
– a coolant temperature sensor,
– an intake (upstream) air temperature sensor,
– a camshaft position sensor (cylinder reference sensor),
– a charge air (turbocharging) pressure sensor,
– an accelerometer,
– an EGR solenoid valve,
– an accelerator pedal potentiometer,
– and a computer.
● The "common rail" direct high pressure injection system works sequentially (based on the operation of multipoint
injection for petrol engines).
● This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and
produces high engine torque at low engine speeds thanks to a pre-injection procedure.
● The high pressure pump generates the high pressure sent to the injector rail. The flow actuator on the pump
controls the quantity of diesel engine fuel supplied according to the demand determined by the computer. The rail
supplies each injector through a steel pipe.
EC-K9K-4
DIESEL EQUIPMENT
● The computer:
– determines the value of injection pressure necessary for the engine to operate well and then controls the pressure
regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor
located on the rail,
– determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should
be started,
– controls each injector electrically and individually after determining these two values.
● The injected flow to the engine is determined by:

– the duration of injector control,
– the injector opening and closing speed,
– the needle travel (determined by a constant for the type of injector),
– the nominal hydraulic flow of the injector (unique to each injector),
– the high pressure rail pressure controlled by the computer.
● The computer controls:

– the idle speed adjustment,
– the exhaust gas flow reinjected into the inlet,
– the fuel supply control (advance, flow and rail pressure),
– the cooling fan assembly control (GCTE function),
– the heat adjustment of the coolant circuit (thermoplungers),
– the pre/post heating control.
● The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump). It supplies
the rail whose pressure is controlled for charge by the flow actuator and for discharging by the injector valves. Falls
in pressure can be compensated for in this way. The flow actuator allows the high pressure pump to provide just
the amount of diesel fuel necessary to maintain the pressure in the rail. Thanks to this element, heat generation is
minimised and engine output improved.
In order to discharge the rail using the injector valves, the valves are controlled by short electrical impulses:
– short enough not to open the injector, (through the return circuit from the injectors),
– long enough to open the valves and discharge the rail.
● The injection computer controls the cooling fan assemblies and the coolant temperature warning light on the
instrument panel (GCTE function).
EC-K9K-5
DIESEL EQUIPMENT
IMPORTANT
● The engine must not operate with:

– diesel engine fuel containing more than 10% diester,
– petrol, even in tiny quantities.
● The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out any
work, check that the injector rail is not under pressure and that the fuel temperature is not too high.
● You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
● Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the diesel
temperature sensor and the venturi can be replaced.
● For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is
running.
● It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination problems. If the pressure sensor fails, the pressure sensor, the rail and the five high
pressure pipes must be replaced.
● It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being
replaced, the pulley must be replaced.
● It is forbidden to repair the wiring connecting the accelerometer and the engine speed sensor. If the wiring
should fail, it has to be replaced with new wiring.
● Applying 12 volts directly to any component in the system is prohibited.
● Ultrasonic carbon removal and cleaning are prohibited.
● Never start the engine without the battery being connected correctly.
● Disconnect the injection system computer when carrying out any welding work on the vehicle.
● It is essential to replace all the disconnected air inlet plastic pipes.
EC-K9K-6
DIESEL EQUIPMENT
There is a 16 character code on the injectors called individual injector correction. This code is specific to
each injector, and takes into account differences in manufacture and specifies the flow injected by each of
them.
When an injector is replaced, it is necessary to program the code of the new injector into the computer.
When a computer is reprogrammed or replaced, it is necessary to program the codes of the four injectors.
There are two possibilities:
● If it is possible to communicate with the computer:

– read out the data from the computer using the "WORK SUPPORT" mode with CONSULT-II
– change the computer
– enter the data from the "WORK SUPPORT" mode with CONSULT-II manually to the computer
– using the "WORK SUPPORT" mode with CONSULT-II manually, ensure that the computer has not detected
faults relating to the injector codes and check that the instrument panel warning light is off.
● If it is not possible to communicate with the computer:

– change the computer
– read the data on the injectors
– enter the data in the computer using the "WORK SUPPORT" mode with CONSULT-II manually
– reconfigure the different elements such as the power-assisted steering pump assembly and the
thermoplungers etc.
– using CONSULT-II, ensure that the computer has not detected faults relating to the injector codes and
check that the instrument panel warning light is off.
EC-K9K-7
DIESEL EQUIPMENT
All the high pressure pipe removed must be sys- Rail/injector pipes
tematically replaced along with the clips.
– Undo the rail,
TIGHTENING THE HIGH PRESSURE PIPES – Grease the threads of the high pressure pipe nuts,
– Insert the high pressure pipe olive into the taper of
NOTE: fit the pump/rail pipe before the rail/injector the high pressure injector inlet,
pipes. – Insert the high pressure pipe olive into the taper of
the high pressure rail outlet,
Rail-pump pipe – Move the nuts into position by hand, on the injector
side then the rail side,
– Undo the rail, – Tighten the rail,
– Grease the threads of the high pressure pipe nuts, – Ensure that the new clip, supplied with the new high
– Insert the high pressure pipe olive into the taper of pressure pipe, is fitted,
the high pressure pump outlet, – Tighten the nuts of the high pressure pipes on the
– Insert the high pressure pipe olive into the taper of injector side first and then on the fuel rail side.
the high pressure rail inlet.
– Move the nut into position by hand, on the rail side NOTE: Before fitting a new high pressure pipe,
then the pump side, move back the nuts on the pipe then lightly
– Tighten the rail, lubricate the nut threads with the oil from the
– Tighten the high pressure pipe nuts on the rail side sachet (1) provided in the parts kit.
then on the pump side.
EC-K9K-8
DIESEL EQUIPMENT
CHECKING SEALING AFTER REPAIR
After any operation, check that there are no diesel leaks.
Reprime the circuit using the priming bulb.
Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
Once the coolant temperature is above 50°C and provided there are no faults present, carry out a road test, taking
the engine speed up to 4000 rpm at least once to check that there are no leaks.
Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
Clean off the tracing fluid.
EC-K9K-9
DIESEL EQUIPMENT
REPLACING OR REPROGRAMMING THE ECM (COMPUTER)
The system can be reprogrammed using CONSULT-II.
Before a computer is reprogrammed or replaced in after-sales, the following must be done.
● Check the individual correction value from "WORK SUPPORT" mode using print out function of CONSULT-II.
● After replacing ECM, enter each injector’s individual correction value using "WORK SUPPORT" mode with
CONSULT-II.
● Also set the system configuration using "CONFIGURATION" mode with CONSULT-II.
REPLACING THE INJECTORS
NOTE: Individual injector correction is a factory calibration carried out on each injector to adjust the flow of
each one precisely, taking into account differences in manufacture.
The correction values are written on a label affixed to each injector then entered in the computer which can then
control each injector by taking account of their differences in manufacture.
The system can be programmed "WORK SUPPORT" mode with CONSULT-II.
The correction values (parameters) must be replaced after replacing an injector.
● Entering each injector’s individual correction value, when replacing the computer.
EC-K9K-10
DIESEL EQUIPMENT
Location of components K9K
YEC603A
1 Camshaft position sensor

2 Fuel filter
3 Injector
4 Air filter
5 Intake (upstream) air temperature sensor
6 Accelerometer
7 Charge air temperature sensor
8 Spherical injector rail
9 Fuel actuator
10 Fuel (Diesel) temperature sensor
11 High pressure pump
12 ECM (computer)
13 Glow (Pre/postheating) unit
14 Venturi
15 Rail pressure sensor
16 Priming bulb
17 Charge air (turbocharging) pressure sensor
18 Crankshaft position sensor
21 EGR solenoid valve
EC-K9K-11
DIESEL EQUIPMENT
1 Camshaft position sensor 6 Injector
7 Injector rail
8 Rail pressure sensor
9 Accelerometer
2 Flow actuator
3 Fuel (Diesel) temperature sensor
4 High pressure pump
5 Venturi 5 Intake (upstream) air temperature sensor
YEC604A
EC-K9K-12
DIESEL EQUIPMENT
2 Fuel filter
16 Priming bulb 21 EGR solenoid valve
YEC605A YEC606A
7 Engine coolant temperature sensor

17 Charge air (turbocharger) pressure sensor
YEC609A
EC-K9K-13
DIESEL EQUIPMENT
22 Thermoplungers
YEC611A
24 ECM relay (Injection locking relay)
YEC607A
EC-K9K-14
DIESEL1K9K
EQUIPMENT
Specifications K9K
Engines
Vehicles Displace- Emission

Bore Stroke Compression Catalytic
Type Suffix
(mm, in) (mm, in) ment cm3 ratio converter
control
(cu in) standard
76 80.5 1,461
N16 K9K 700 18.25/1 228 EU 00
(2.99) (3.17) (89.15)
ENGINE SPEED (rpm) SMOKE OPACITY
IDLE SPEED Max. - no load Max. - under load Homologation value Max. - legal
800 ± 50 4500 ± 150 5000 ± 150 2.26 m-1 (60%) 3 m-1 (73%)
DESCRIPTION MARQUE/TYPE SPECIAL NOTES

High pressure pump DELPHI 0 to 1400 bars continuous pressure
Fuel pump DELPHI Incorporated into the high pressure pump
Diesel rail pressure sensor Incorporated into the rail

DELPHI
Non measurable resistance
Injectors DELPHI Solenoid injector

Maximum pressure 1400 bar
Non measurable resistance
Diesel flow actuator DELPHI Located on the high pressure pump

Resistance: 5.3 ± 0.7 Ω at 20ºC
Injection computer DELPHI ECM (computer) (112 terminals)
Pre/postheating unit (glow) NAGARES BED 7-12 With pre-postheating function controlled by the
ECM (computer)
Pre-heater plugs (glow) Resistance: 0.6 Ω

BERU
connector disconnected
Accelerator pedal potentiometer CTS Double track potentiometer

(position sensor) Resistance:
– terminals 1: 4 (earth) and 2 (+5 V): 1.7 ± 0.9 kΩ
– terminals 2: 5 (earth) and 1 (+5 V): 2.4 ± 1.2 kΩ
Inlet air temperature sensors JAEGER CTN thermistor

Resistance: 5000 ± 6800 Ω at - 40°C
9500 ± 900 Ω at - 10°C
2051 ± 120 Ω at 25°C
810 ± 47 Ω at 50°C
310 ± 17 Ω at 80°C
EC-K9K-15
DIESEL EQUIPMENT
Specifications K9K
DESCRIPTION MARQUE/TYPE SPECIAL NOTES
Diesel fuel temperature sensor DELPHI Located on the high pressure pump
CTN thermistor
Resistance: 2.2 kΩ at 25°C
Engine coolant temperature sensor ELTH CTN thermistor

Resistance: 76000 ± 7000 Ω at - 40°C
12500 ± 1130 Ω at - 10°C
2252 ± 112 Ω at 25°C
810 ± 40 Ω at 50°C
280 ± 8 Ω at 80°C
115 ± 3 Ω at 110°C
88 ± 2 Ω at 120°C
Crankshaft position (Engine speed) MGI Variable reluctance sensor
sensor Resistance: 760 Ω
Atmospheric pressure sensor DELPHI Incorporated into the computer
Charge air (Turbocharging) DELCO Resistance:

pressure sensor ELECTRONICS – terminals A and B: 9 kΩ
– terminals A and C: 4 kΩ
– terminals B and C: 5 kΩ
Camshaft position sensor SAGEM Hall effect sensor
Accelerometer SAGEM Non measurable resistance
EGR solenoid valve PIERBURG Resistance:

– tracks 1 and 2: 8 ± 5 Ω at 20°C
EGR valve position potentiometer Incorporated into the EGR solenoid valve
Resistance:
– tracks 1 and 3: 1 ± 0.5 kΩ at 20°C
– track 3 and 6: 4 ± 1.6 kΩ at 20°C
Thermoplungers BERU Resistance: 0.6 ± 0.7 Ω at 20ºC
EC-K9K-16
DIESEL EQUIPMENT
Diesel filter K9K
IMPORTANT: Before carrying out any work, wait
for the fuel temperature to drop.
REMOVAL - REFITTING
Disconnect the battery.
Release the diesel fuel filter from its support.
Fit the new diesel fuel filter (do not remove the plugs
until the last moment).
Disconnect all the snap fasteners beginning with the

three vertical snap fasteners. Prevent the snap
fasteners from coming into contact with the
environment.
Disconnect the pump outlet snap fastener last of all;

reconnect it immediately when the new filter is
installed.
Reconnect the other snap fasteners.
Prime the system using the priming bulb (automatic

degassing).
Reconnect the battery.
MBIB0533E
EC-K9K-17
DIESEL EQUIPMENT
High pressure pump K9K
IMPORTANT: It is strictly forbidden to remove any
injection pump pulley marked number 070 575. If
the pump is being replaced, the pulley must be
replaced.
SPECIAL TOOLING REQUIRED
Nissan No. Tool for removing and refitting high

KV113E0010 pressure pipes
(Mot. 1566)
EQUIPMENT REQUIRED
Low torque wrench
High pressure pipe wrench (for example, Facom
"DM19" wrench).
Pipe socket for tightening the injector-rail high
pressure pipes (for example, Facom Crowfoot
18-17 wrench).
Pipe socket for tightening the pump-rail high
pressure pipe (for example, Facom Crowfoot
19-17 wrench).
TIGHTENING TORQUES (in daNm)
High pressure pipe nuts 3.8

Rail nuts 2.8 ± 0.3
Filler neck nut on the rail 2.1
High pressure pump mounting bolts 1.2 ± 2.2
IMPORTANT: Before carrying out any work,

connect the After-Sales diagnostic tool, set up
communication with the injection computer and check
that the injection rail is not under pressure.
Wait until the fuel temperature drops.
Order the special high pressure injection circuit plug
kit.
EC-K9K-18
DIESEL EQUIPMENT
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY
It is strictly forbidden to remove any injection pump

pulley marked number 070 575 (see diagram). If the
pump is being replaced, the pulley must be replaced.
The high pressure pump may be removed after having

first removed the timing belt (see section 11 "Timing
belt")
Remove:
– the neck (1) located on the fuel rail,
– the dipstick guide and plug the hole.
Undo the mounting nuts of the rail (2) a few turns.
EC-K9K-19
DIESEL EQUIPMENT
Carefully disconnect:
– the connectors from the flow actuator (3) and diesel temperature sensor
(4),
– the pre-heater (glow) plugs and the injectors (5),
– the return pipe (8) connecting the injector with the pump.
EC-K9K-20
DIESEL EQUIPMENT
Remove the high pressure pipe (9) connecting the Refit the high pressure pipe, to do this:
pump to the rail. To do this:
– remove the protective plugs,
– undo the nut on the pump side then the nut on the rail – insert the high pressure pipe olive into the taper of
side, the high pressure pump outlet,
– Move the nut along the tube keeping the olive in – insert the high pressure pipe olive into the taper of
contact with the taper. the high pressure rail inlet.
Plug all the holes of the injection circuit. Finger tighten the nuts of the high pressure pipe
starting with the one located on the rail side.
Remove the three mounting bolts (10) from the
injection pump then remove it. Tighten the rail mounting nuts to a torque setting of
2.8 daNm.
IMPORTANT: Do not touch the pipes with the

wrench when torque tightening.
Using the recommended tools, tighten the following in

the order and to the torques shown:
– the nut on the rail side to 3.8 daN.m,

– the nut on the pump side to 3.8 daN.m,
Tighten the mounting bolts (10) on the high pressure

pump to a torque of 2.1 daN.m.
REFITTING
Fit the pump then position the mounting bolts without

tightening them.
IMPORTANT: All the high pressure pipes

removed must be systematically replaced.
Before fitting the new high pressure pipe, lightly

lubricate the nut threads with the oil from the sachet
provided in the new parts kit.
Refit in the reverse order to removal for the other

refitting operations.
Test the sealing of the high pressure after it has been

repaired (see EC-K9K-04).
EC-K9K-21
DIESEL EQUIPMENT
Flow actuator K9K
EQUIPMENT REQUIRED
Low torque wrench
Pipe socket for tightening the high pressure pipe
(for example, Facom Crowfoot 18-17 wrench).
Flow actuator mounting bolt 0.55 ± 0.06

kit.
EC-K9K-22
DIESEL EQUIPMENT
Flow actuator K9K
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS

INSTRUCTIONS CLOSELY
Remove the engine cover.
Disconnect the connector from the flow actuator (1)

and from the diesel temperature sensor carefully (2).
Unscrew the two retaining bolts from the bracket (4).
Withdraw the flow actuator (by hand using small

successive turns. Do not use the electrical connector
as a lever arm).
REFITTING
Remove the new component from its packaging just

before fitting it.
NOTE: Do not lubricate the seals with grease or used

Disconnect the fuel return pipe (3). diesel oil. Use the applicator provided in the kit for the
new part.
Remove the high pressure pipe from injector no. 4
(see section on high pressure pipes). Position the actuator. (Important: when fitting the
regulator, do not mark the seal.)
Plug the holes in the injection circuit.
Position the two mounting bolts then tighten them.
Disconnect the pre-heater plug and the injectors from
cylinders 3 and 4. Fit a new high pressure pipe to injector no. 4 plus a
new clip (see section on high pressure pipes).
Reconnect:
– the diesel return pipe,
– the electrical connectors.
EC-K9K-23
DIESEL EQUIPMENT
Flow actuator K9K
Test the sealing of the high pressure circuit after it has

been repaired (see EC-K9K-04).
EC-K9K-24
DIESEL EQUIPMENT
Diesel fuel temperature sensor K9K
EQUIPMENT REQUIRED
Low torque wrench
Fuel (Diesel) temperature sensor 1.5 ± 0.15

kit.
EC-K9K-25
DIESEL EQUIPMENT
Diesel fuel temperature sensor K9K
REMOVAL REFITTING
Grease the O-ring with the lubricant from the sachet

provided with the new part.
Take care not to damage the O-ring when installing the
Disconnect the battery. sensor.
Remove the engine cover. Position the fuel (diesel) temperature sensor then
tighten to torque.
Disconnect the connector from the fuel (diesel)
temperature sensor carefully (1). Reconnect:
– the electrical connector.
Undo then remove the fuel (diesel) temperature – the battery.
sensor.
EC-K9K-26
DIESEL EQUIPMENT
Venturi K9K
EQUIPMENT REQUIRED
Low torque wrench
Venturi mounting bolts 0.55 ± 0.06

kit.
EC-K9K-27
DIESEL EQUIPMENT
Venturi K9K
REMOVAL REFITTING
Grease the O-ring with the lubricant from the sachet

provided with the new part.
Take care not to damage the O-ring when installing the
Disconnect the battery. venturi.
Remove the engine cover. Position the venturi then tighten it to torque.
Disconnect: Reconnect the different pipes.

– the fuel return pipe on the pump (1).
– the return pipe (2) connecting the injector with the Test the sealing of the high pressure circuit after it has
pump. been repaired (see EC-K9K-04).
Remove the venturi mounting bolts (3) then take it out.
EC-K9K-28
DIESEL EQUIPMENT
Injector rail K9K

(Mot. 1566)
EQUIPMENT REQUIRED
Low torque wrench
"DM19" wrench).
18-17 wrench).
19-17 wrench).


connect the After-Sales diagnostic tool, st up
kit.
IMPORTANT: The pressure sensor cannot be

separated from the rail.
EC-K9K-29
DIESEL EQUIPMENT
Injector rail K9K
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY
Remove the engine cover.
Carefully disconnect:
– the connectors from the flow actuator (1),
– the connectors from the diesel temperature sensor (2),
– the injector connectors (3),
– the glow (heater) plugs,
– on the pump, the fuel supply (4) and return (5) pipes.
– the return pipe (6) connecting the injectors with the pump.
Remove:
– the neck (7) located on the fuel rail,
– the dipstick guide and plug the hole.
Disconnect the pressure sensor connector from the rail (8).
EC-K9K-30
DIESEL EQUIPMENT
Injector rail K9K
Remove the clips connecting the high pressure pipes. Remove all the high pressure pipes (12).
Plug all the holes in the injection circuit.

IMPORTANT: When undoing the high pressure
pipes, it is essential to maintain the central union
Remove the rail (13).
of the injector (9).
IMPORTANT: Do not damage the injector's leak

return duct (10).
NOTE: Undo the nut on the pump side or the

injector side, then the nut located on the rail side.
Undo the nuts for each pipe in turn.
Move the nut along the pipe keeping the olive in
contact with the taper.
EC-K9K-31
DIESEL EQUIPMENT
Injector rail K9K
REFITTING – remove the protective plugs from the high pressure
rail outlet, the injector high pressure inlet and the
pipe.
– insert the high pressure pipe olive into the taper of
removed must be replaced as a matter of course.
the high pressure injector inlet,
Fit a new high pressure rail on the studs. the high pressure rail outlet.
– finger tighten the nuts of the high pressure pipe
Finger tighten the nuts. starting with the one located on the injector side.
Before fitting the new high pressure pipes, lightly Fit the remaining high pressure pipes as you did
lubricate the nut threads with the oil from the sachet previously.
NOTE: Fit the pump/rail pipe before the rail/injector NOTE: The order in which the pipes are installed
pipes. is not important.
Fit the pump-rail high pressure pipe: Fit the clips supplied with the new pipes onto the high
pressure pipes:
– remove the protective plugs from the high pressure – Insert the first half of the clip using adjustable pliers,
pump outlet, the high pressure rail inlet and the pipe. – Insert the second half of the clip using adjustable
– insert the high pressure pipe olive into the taper of pliers.
the high pressure pump outlet,
IMPORTANT: Pay attention to the direction of
installation of the second clip. The tabs located
in the centre of the clip will only fit together in
one position.
Fit the rail-injector high pressure pipe:
IMPORTANT: When tightening the high pressure

EC-K9K-32
DIESEL EQUIPMENT
Injector rail K9K
Tighten the rail nuts to a torque of 2.8 daNm. Using the recommended tools, tighten the nuts on
the rail - injector high pressure pipes:
– tighten the nut on the injector side to a torque of
3.8 daN.m.
– tighten the nut on the rail side to a torque of
IMPORTANT: Follow the order and tightening 3.8 daN.m.
torque of the high pressure pipes.
NOTE: Tighten one pipe fully before moving on to

Using the recommended tools, tighten the nuts on the next pipe.
the rail - pump high pressure pipe:
– tighten the nut on the rail side to a torque of

3.8 daN.m.
– tighten the nut on the pump side to a torque of
3.8 daN.m.


EC-K9K-33
DIESEL EQUIPMENT
Pressure sensor K9K
The pressure sensor (1) cannot be separated from the
fuel rail. If the pressure sensor fails, the pressure
sensor assembly - rail and high pressure pipes - must
be replaced (see fuel rail section).
EC-K9K-34
DIESEL EQUIPMENT
Injectors K9K

(Mot. 1566)
EQUIPMENT REQUIRED
Low torque wrench
DM19 wrench).
18-17 wrench).
19-17 wrench).

Injector mounting 2.8 ± 0.3

kit.
IMPORTANT: It is forbidden to open an injector. If you

open an injector by mistake, you will have to change it.
This is because of the manufacturing and installation
tolerances and because there is a risk of
contaminating the inside of the injector.
The rod filter of the injector must not be removed.
EC-K9K-35
DIESEL EQUIPMENT
Injectors K9K
REMOVAL
NOTE: It is possible to replace a single high pressure

pipe.

Remove:
– the engine cover,
– the neck (1) located on the high pressure rail,
– the dipstick guide then plug the hole.
Disconnect:
– the fuel return pipe (3),
– the injector electrical connector.
Remove the clip (4) connecting the high pressure
pipes.

Undo the nut on the injector side, then the nut located
on the rail side of the high pressure pipe.
Move the nut along the tube keeping the olive in


return duct (6).
EC-K9K-36
DIESEL EQUIPMENT
Injectors K9K
REFITTING
NOTE: Read the 16 digit code on the new injector

before refitting it and programming the code into
the computer using the CONSULT-II (see EC-K9K-
04, Replacing injectors"). The code is unique to
each injector, it specifies the flow.
Clean the injector sockets and the injector bodies, as

well as their brackets using a lint-free cloth (use the
wipes recommended for this purpose, dipped in clean
solvent.
Dry off using a different new wipe.
Replace the flameshield washer with a new one.
Position the injector.
Tighten its mounting clamp to a torque of 2.8 daN.m.

* 16 digit code
Remove the high pressure pipe (7). IMPORTANT: All the high pressure pipes
Disconnect the diesel return pipe on the injector.
Plug all the holes of the injection circuit.

Before fitting the new high pressure pipe, lightly
lubricate the nut threads with the oil from the sachet
Unscrew the injector bracket (8).
Remove the injector.
Pull off the flameshield washer.
EC-K9K-37
DIESEL EQUIPMENT
Injectors K9K
Fit the high pressure pipe: Tighten the rail nuts to a torque of 2.8 daNm.
– remove the protective plugs from the rail, the injector

inlet and the pipe.
the injector inlet,
the rail outlet. IMPORTANT: When tightening the high pressure
Move the nut into position by hand, injector side first of the injector.
then the rail side.
Fit a new clip supplied with the new pipes onto the high
pressure pipes: Using the recommended tools, tighten the following in
– Insert the first half of the clip using adjustable pliers, the order and to the torques shown:
– Insert the second half of the clip using adjustable – the nut on the injector side to a torque of 3.8 daN.m.
pliers. – the nut on the rail side to a torque of 3.8 daN.m.
IMPORTANT: Pay attention to the direction of

installation of the second clip. The tabs located
in the centre of the clip will only fit together in
one position.


EC-K9K-38
DIESEL EQUIPMENT
High pressure pipes K9K

(Mot. 1566)
EQUIPMENT REQUIRED
Low torque wrench
DM19 wrench).
18-17 wrench).
19-17 wrench).


kit.
EC-K9K-39
DIESEL EQUIPMENT
REMOVAL
NOTE: It is possible to replace a single high pressure

pipe.

Remove:
– the engine cover,
– the neck (1) located on the high pressure rail,
– the dipstick guide then plug the hole.
Undo the nut on the pump side or the injector side,

then the nut located on the rail side.
Move the nut along the tube keeping the olive in


return duct (5).
Remove the clip (3) connecting the high pressure

pipes.

EC-K9K-40
DIESEL EQUIPMENT
Remove the high pressure pipe(s). Fit the remaining high pressure pipes as you did
previously.
Plug all the holes of the injection circuit.

REFITTING
NOTE: Fit the pump/rail pipe before the rail/injector
pipes.
Fit a new clip supplied with the new pipes onto the high
Before fitting the new high pressure pipes, lightly pressure pipes:
lubricate the nut threads with the oil from the sachet – insert the first half of the clip using adjustable pliers,
provided in the new parts kit. – insert the second half of the clip using adjustable
pliers.
Fit the pump-rail high pressure pipe:
– remove the protective plugs from the high pressure IMPORTANT: Pay attention to the direction of
pump outlet, the high pressure rail inlet and the pipe. installation of the second clip. The tabs located
– insert the high pressure pipe olive into the taper of in the centre of the clip will only fit together in
the high pressure pump outlet, one position.
Fit the rail-injector high pressure pipe:
– remove the protective plugs from the high pressure

rail outlet, the injector high pressure inlet and the
pipe.
the high pressure injector inlet,
the high pressure rail outlet,
starting with the one located on the injector side.
EC-K9K-41
DIESEL EQUIPMENT
Tighten the rail nuts to a torque of 2.8 daN.m. NOTE: Tighten one pipe fully before moving on to
the next pipe.


– the nut on the pump - rail high pressure pipe starting
with the one located on the rail side to a torque of
3.8 daN.m.
– the nut on the pump side to a torque of 3.8 daN.m.


IMPORTANT: When tightening the high pressure


– the nut on the injector side to a torque of 3.8 daN.m.
– the nut on the rail side to a torque of 3.8 daN.m.
EC-K9K-42
DIESEL EQUIPMENT
Computer K9K
NOTE: When replacing or reprogramming a computer, it is necessary to program the individual injector
correction and the other vehicle configurations using CONSULT-II.
REPLACING OR REPROGRAMMING THE COMPUTER
Before a computer is reprogrammed or replaced in after-sales, the following must be checked using
CONSULT-II:
● Injectors individual correction value (parameter)

● System configulation
Refer to EC-K9K-7.
EC-K9K-43
DIESEL EQUIPMENT
Computer K9K
REMOVAL REFITTING
Disconnect: Fit the new computer, taking care to engage the

– the battery, positioning tab, then fit the computer on its mounting
– the computer connectors. studs.
Unclip the power steering reservoir and attach it to the Tighten the computer mounting nuts.
front bulkhead.
Clip the power steering reservoir back in.
Remove the mounting nuts from the computer (1) on
the battery tray. Reconnect the computer.
Tilt the computer slightly to the rear to free up the Connect the battery.
studs and pull it out upwards to free the positioning
tab. Turn the engine on and read the fault codes using the
fault finding tool.
If necessary repair the faults that appear then clear

them.
Check that the vehicle is operating correctly.
YEC608A
EC-K9K-44
DIESEL EQUIPMENT
Computer K9K
COMPUTER ALLOCATION OF TRACKS
CONNECTOR E237
1 .... Not used
2 →← K-line
3 .... Not used
4 → Comsumption signal (computer)
5 ← Stop light switch signal

6 --- Accelerator pedal potentiometer earth sensor 2
7 .... Not used
8 ← Software lock signal
9 .... Not used

10 .... Not used
11 .... Not used
12 ← Accelerator pedal potentiometer signal sensor 2
13 .... Not used

14 → Vehicle (engine) speed signal
15 .... Not used
16 .... Not used
17 → Air conditioning on/off signal

18 --- Accelerator pedal potentiometer supply sensor 2
19 → Glow (pre-heating) warning light control
20 → Injection fault control
21 .... Not used

22 --- Ignition (+after ignition supply) signal
23 → Engine coolant temperature (malfunction) warning light control
24 → Electronic On Board Fault finding warning light control
25 .... Not used

26 .... Not used
27 .... Not used
28 --- Accelerator pedal potentiometer earth sensor 1
29 --- Accelerator pedal potentiometer supply sensor 1

30 ← Accelerator pedal potentiometer signal sensor 1
31 .... Power supply for ECM
32 .... Not used
EC-K9K-45
DIESEL EQUIPMENT
Computer K9K
CONNECTOR F90
33 .... Not used
34 --- Accelerator pedal position sensor shielding
35 .... Not used
36 .... Not used
37 .... Not used

38 → EGR solenoid valve earth
39 → Flow actuator control
40 .... Not used
41 .... Accelerometer shielding

42 .... Not used
43 .... Not used
44 ← Accelerometer signal
45 --- Accelerometer earth

46 .... Not used
47 --- Fuel pressure sensor power
48 --- Charge air pressure sensor power supply
49 .... EGR solenoid valve power supply

50 .... Not used
51 --- Intake air temperature sensor power supply
52 ← Charge air pressure signal
53 .... Engine coolant temperature

54 ← Fuel (Diesel) temperature sensor signal
55 ← Crankshaft position sensor signal
56 ← Camshaft position sensor signal
57 --- Fuel pressure sensor earth

58 --- Charge air (turbocharger) pressure sensor earth
59 --- EGR solenoid valve signal
60 .... Not used
61 --- Intake air temperature sensor earth

62 .... Charge air temperature earth
63 --- Engine coolant temperature
64 ← Fuel temperature sensor earth
65 --- Crankshaft position sensor earth

66 ← Camshaft position sensor earth
67 --- Rail pressure sensor signal
68 ← Charge air (turbocharger) pressure sensor signal
69 --- EGR solenoid valve

70 .... Not used
71 .... Not used
72 .... Not used
73 ← Control - injector N° 2
74 --- Control - injector N° 2 (GND)
79 → Control - injector N° 1
EC-K9K-46
DIESEL EQUIPMENT
Computer K9K
CONNECTOR F90
81 .... Not functioning
82 .... Not used
83 .... Not used
84 .... Not used
85 .... Not used

86 .... Not used
87 .... Not used
88 .... Not used
89 .... Not used

90 → Glow relay control
91 ← Air conditioner signal
92 .... Not used
93 .... Not used

94 → Cooling fan control
95 ← Thermoplunger relay control
96 ← Thermoplunger relay control
97 .... Not used

98 → Glow relay control
99 .... Not used
100 → Cooling fan control
101 → Power-assisted steering pump assembly relay control

102 .... Not used
103 ← Vehicle speed sensor signal
104 → ECM relay control
105 .... Not used

106 .... Not used
107 .... Not used
108 .... Not used
109 --- Power supply for ECM

110 --- Power supply for ECM
111 .... ECM earth (GND)
112 .... ECM earth (GND)
EC-K9K-47
DIESEL EQUIPMENT
Injection warning light K9K
Vehicles that operate with the high pressure diesel system Delphi LVCR are fitted with three warning lights,
dependent on the level of seriousness of the fault detected, to inform the customer and determine the diagnostic.
These warning lights are used during the preheating phase and in case of an injection fault or engine overheating.
PRINCIPLE FOR LIGHTING UP OF THE WARNING LIGHTS
Pre/postheating (glow) and injection fault orange warning light (severity level 1)
This warning light is used as an operating indicator light and as a system fault indicator light.
● The orange preheating warning light comes on when the ignition is switched on, remains lit during the preheating
phase and then goes out, see section 13 Pre/post-heating (glow) control.
● After the preheating phase and an automatic timed 3 second stop, a severity level 1 problem is indicated by
flashing. It indicates reduced level operation and a limited safety level. The driver should carry out repairs as soon
as possible.
These faults are connected to:

– the engine immoblizer,
– a code error (individual injector correction),
– an injector,
– the injector controls,
– the fuel supply (injector leak etc.),
– an engine speed sensor fault,
– the ECM relay,
– the EGR solenoid valve (short circuit or open circuit),
– the accelerator pedal potentiometer (sensors 1 and 2),
– the accelerator pedal potentiometer supply,
– the charge air (turbocharger) pressure sensor (in the event of overpressure).
Engine coolant temperature red warning light (severity 2)
This warning light is used as an operating indicator light and as a system fault indicator light.
● When the ignition is switched on, the engine coolant temperature warning light lights up for 3 seconds then goes
out.
EC-K9K-48
DIESEL EQUIPMENT
Injection warning light K9K
● When there is a serious fault, the engine coolant temperature warning light lights up continuously and signals
a fault linked to the injection system or engine overheating.
In the event of an injection system fault, the engine is automatically switched off after 1 minute 30 seconds or
immediately.
In the event of engine overheating, it is the driver's choice to stop the car or continue driving.
These faults are connected to:

● Timed stop
– the flow actuator (loop deviation and overpressure),
● Immediate stop
– the engine speed sensor (no signal),
– the diesel flow actuator,
– the rail pressure sensor,
– the supply of all the injectors,
– the sensor supply voltage,
– an internal computer fault.
Excess pollution orange warning light "OBD" (On Board Diagnostic)
This warning light, depicted by an engine, lights up for about 5 seconds when the engine is switched on then goes
out. It is never visible when the engine is running (not operational).
EC-K9K-49
DIESEL INJECTION
Immobilizer function K9K
This vehicle is fitted with an engine immobilizer system which is controlled by a key recognition system.
REPLACING THE INJECTION COMPUTER (ECM)
The injection computers (ECMs) are supplied without a code but they must all be programmed with one.
If an ECM (computer) is replaced, it must be programmed with the code of the vehicle and the correct operation of
the engine immobilizer function must be checked. (Refer to EL section.)
WARNING:
These vehicles have a special injection computer which does not function unless it is coded.
Consequently, it is strongly recommended that you do not carry out tests using computers borrowed from the
warehouse or on another vehicle to prevent coding and uncoding problems which may leave the computer useless.
UNCODING PROCEDURE
If the injection computer has learnt a code and must be returned to the workshop it is imperative that you uncode it
before removing it. (See the repair manual or the engine immobilizer TSB).
EC-K9K-50
DIESEL INJECTION
Idle speed adjustment K9K
The computer takes over calculation of the idle speed to maintain the idle speed at the recommended level and
to compensate for any variation in the mechanical or electrical couple as regards:
– the coolant temperature,
– battery voltage,
– the gear selected on the gearbox,
– the electrical consumers (thermoplungers, climate control system, fan assembly etc.),
– any faults found.
At the engine operating temperature, without high electrical consumer, the idle speed is 850 rpm.
IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
X. Engine speed in rpm

Y. Temperature in °C
SPEED ADJUSTMENT WHEN THERE IS AN ACCELERATOR PEDAL POSITION SENSOR (POTENTIOMETER)

FAULT
● If one or both tracks of the accelerator pedal position sensor (potentiometer) are faulty, the computer overrides
the idle speed to maintain it at 1100 rpm. This defect mode limits performance. The orange injection warning light
lights up and flashes.
● If the accelerator pedal position sensor (potentiometer) is blocked, is no longer being supplied, or is not
transmitting an output signal, the computer overrides the idle speed to maintain it at 1300 rpm. This mode limits
performance. The orange injection warning light lights up and flashes.
● In both cases, when the brake pedal is depressed, the idle speed is stabilised at the recommended speed.
● If the information from the accelerator pedal position sensor (potentiometer) and the brake switch
information does not correspond, the speed is changed to 1100 rpm.
EC-K9K-51
DIESEL INJECTION
Idle speed adjustment K9K
IDLE SPEED ADJUSTMENT WHEN THERE IS AN INJECTOR CODE FAULT
When there is an injector code fault, the computer overrides the idle speed to maintain it at 1300 rpm. This mode
limits performance. The orange injection warning light lights up and flashes.
CORRECTION OF THE IDLING SPEED ACCORDING TO THE GEAR RATIOS
The idling speed is modified according to the gear selected in the gearbox:
– in neutral, 1st and 2nd gear, the speed is (at the engine operating temperature) 850 rpm (graph A),
– for the other gears, the speed is (at the engine operating temperature) 900 rpm (graph B).
X. Engine speed in rpm

EC-K9K-52
DIESEL INJECTION
Injection/air conditioning management K9K
INJECTION (ECM) COMPUTER / AIR CONDITIONING COMPUTER CONNECTION
The compressor is a variable is a variable displacement type.
The injection computer and the air conditioning computer are connected by three wires:
– the signal for output absorbed by the compressor passes through terminal 85 of ECM harness connector F90. It
is possible to see the output absorbed using the diagnostic tool. With air conditioning switched on, the reading
should be between 250 and 5000 watts.
– the compressor is activated or deactivated via terminal 17 of connector E237.
– terminal 91 of connector F90, is not operational.
When the air conditiuoning switch is activated, the injection computer authorises the clutch compressor according to
the parameters and adopts a fast idling speed. In this case, the engine speed can reach 900 rpm depending on how
much power is absorbed by the compressor.
IMPORTANT: The value for the parameter "PR power absorbed by the AC compressor" (PR044) is never equal
to 0, whatever the status of the compressor. The minimum value read is approximately 250 watts.
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the injection computer stops the compressor from functioning.
Engine starting program
The compressor is prevented from operating for 4 seconds after the engien has started.
Thermal protection program
The compressor is not engaged when the engine temperature is higher than 115 °C or from 110 °C at high speed,
4500 rpm for more than 3 seconds.
Fan assembly control programming
At idling speed and also when driving, with the air conditioning activated, the speed of the fan assembly is
determined according to the refrigerant fluid pressure and the vehicle speed.
EC-K9K-53
DIESEL INJECTION
Injection/air conditioning management K9K
Recovery of performance
When pressure is applied to the accelerator pedal above 70%, the compressor is disengaged for 5 seconds.
Recovery of output when the vehicle starts moving
In order to help the vehicle move off, the air conditioning compressor is disengaged if the position of the accelerator
pedal is above 35 % and the idling speed less than 1250 rpm.
Anti-stall protection
The compressor is disengaged if the engine speed is lower than 750 rpm.
Engine overspeed timed protection program
The compressor is disengaged when the speed reaches 4500 rpm for more than 3 seconds.
NOTE: The time between the compressor being disengaged twice is always greater than 10 seconds.
EC-K9K-54
DIESEL INJECTION
Pre/postheating control K9K
The pre/postheating function is controlled by the preheating unit.
PRE/POSTHEATING OPERATING PRINCIPLE 2) "Post heating" with the engine running
1) Ignition on "preheating" During this phase the plugs are supplied continuously
according to coolant temperature.
a) Variable preheating
The time period for the warning light to light up and
the feed to heater plugs depends on the coolant
temperature and the battery voltage.
X. Time in seconds
For idle speed without pressing the accelerator pedal.

X. Time in seconds
Whatever the situation, the preheating warning

light cannot be lit for more than 15 seconds
(except in the event of a coolant temperature
sensor fault).
b) Fixed preheating
After the warning light goes out the plugs remain
supplied for a fixed period of 5 seconds.
EC-K9K-55
DIESEL EQUIPMENT
Pre-heater plugs K9K
The resistance of a heater plug is 0.6 Ω.
TIGHTENING TORQUE (in daNm)
Heater plug 1.5
Plugs may be removed without having to open the high

pressure circuit.
REMOVAL
Unclip the plug connector.
Clean the outside of the plug to avoid any dirt entering

the cylinder.
Loosen and remove the plugs.
To undo the plug on cylinder 4 use a 10 mm long radio

socket attached to a universal joint. Once the plug is
loosened use a hose to unscrew it completely.
REFITTING
Proceed in the reverse order to removal.
EC-K9K-56
DIESEL EQUIPMENT
Coolant temperature management (GCTE) K9K
The cooling fan unit is controlled by the injection computer.
COOLING FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING
The cooling fan assembly is controlled:
● at slow speed if the engine coolant temperature exceeds 99°C or if there is an engine coolant temperature sensor
fault, and is switched off when the temperature falls below 96°C.
● at high speed if the engine coolant temperature exceeds 102°C or if there is a low speed fault, and is switched off
when the temperature falls below 99°C.
The cooling fan assembly low and high speeds are controlled when the air conditioning function is selected on the
instrument panel.
If the low speed setting is faulty, the high speed setting operates under the low speed conditions.
OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT
The engine coolant temperature warning light remains lit if the coolant temperature exceeds 114°C. It goes out when
the temperature falls below 111°C.
EC-K9K-57
DIESEL EQUIPMENT
Thermoplungers K9K
The three or four thermoplungers are located on a Control strategy
water unit (22), attached to the gearbox by a retaining
bracket. When the thermoplungers are operating the idle speed
is brought to 900 rpm.
The system is designed to reheat the coolant intended
for the passenger compartment heating system. Thermoplungers cannot operate in the case of:
– preheating,
The thermoplungers are supplied with 12 volts by two – postheating,
or three relays. – engine speed below 700 rpm.
When there are two relays: one relay controls one If the conditions mentioned above apply, the
thermoplunger and the other controls two thermoplungers are controlled according to a mapping
thermoplungers. This enables control of one, two or related to the air and coolant temperature.
three thermal plungers.
When there are three relays: two relays control one

thermoplunger each and the other controls two
thermoplungers. This enables control of one, two,
three or four thermoplungers.
The resistance of the thermoplungers is:
0.6 ± 0.05 Ω at 20 °C
Unhatched area: thermoplunger not supplied

Shaded zone: thermoplunger supplied
YEC611A
EC-K9K-58
ZCDIESEL EQUIPMENT
Thermoplungers K9K
3 OR 4 RELAY THERMOPLUNGER CONTROL PROGRAM
If the battery voltage is > 13 volts
If not then
Thermoplungers not One thermal plunger

supplied supplied
If, after 20 seconds, the battery

voltage
is > 13 volts
If not then
Thermoplungers not Two thermoplungers

supplied supplied

voltage
is > 13 volts
If not then
Thermoplungers not Three thermoplungers

supplied supplied

voltage
is > 13 volts
If not then
Thermoplungers not Four thermoplungers supplied

supplied while the battery voltage
is > 13.5 volts and if the
conditions mentioned above are
met.
EC-K9K-59
1K9K
ANTI-POLLUTION
Oil vapour rebreathing K9K
CIRCUIT DIAGRAM
A. When there is a low charge, the vacuum in the air
intake duct is below the spring set point. The oil
vapours are extensively rebreathed by the
vacuum in the air intake duct.
B. When there is a medium or high charge, the

pressure in the air intake duct exhausts the valve
diaphragm, the oil vapours are breathed in small
quantities via a calibrated hole.
CHECKING
To ensure the correct operation of the anti-pollution

system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
1 Cylinder head cover

2 Oil vapour rebreathing duct
3 Oil vapour recirculation valve
4 Air inlet duct
5 Turbocharger
Pa Atmospheric pressure
EC-K9K-60
ANTI-POLLUTION
Exhaust gas recirculation (EGR) K9K
CIRCUIT DIAGRAM
1 Engine
2 Air filter unit
3 Air distributor
4 Exhaust manifold
5 EGR unit with solenoid valve
6 Turbocharger
7 Injection computer
A Air inlet
B Exhaust gas outlet
PURPOSE OF THE EGR SYSTEM
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
The computer authorises gas to pass by controlling a solenoid valve.
EC-K9K-61
1K9K
DIESEL INJECTION
Fault finding - Introduction K9K
GENERAL APPROACH TO FAULT FINDING:
– Use CONSULT-II to identify the system fitted to the vehicle.
– Locate the Fault finding documents corresponding to the system identified.
– Read the faults stored in the computer memory and use the Fault interpretation section of the documents.
Reminder: Each fault is interpreted for a particular type of storage (fault present, fault stored, fault present or
stored). The checks defined for handling each fault are therefore only to be performed if the fault shown by
CONSULT-II is interpreted in the document for its type of storage. The storage type should be considered when
using the fault finding tool after the ignition has been switched off and switched back on.
If a fault is interpreted when it is declared stored, the conditions for applying the fault finding procedure appear in
the NOTES box. When these conditions are not satisfied, use the fault finding procedure to check the circuit of the
faulty part since the fault is no longer present on the vehicle. Follow the same procedure when a fault is declared
stored by CONSULT-II but is only interpreted in the documentation for a present fault.
NOTE
– It is possible to consult the fault environment, using CONSULT-II, to facilitate the fault finding procedure, i.e. the
conditions in which the fault appeared (different temperatures, pressures, gears etc.). To consult these
environmental conditions, just press the appropriate fault icon. Example: ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT.
– Perform the conformity check (appearance of possible incorrect operations not yet declared by the system's self
diagnosis procedure) and apply the associated fault finding strategy according to results.
– Confirm the repair (disappearance of the problem reported by the customer).
– Use the fault finding strategy for each Customer complaint if the problem persists.
SPECIAL TOOLING REQUIRED:
– CONSULT-II,
– multimeter.
CR DELPHI 1.0
EC-K9K-62
DIESEL INJECTION
GENERAL OBSERVATIONS
1 - FAULT WARNING LIGHT (Malfunction indicator) MANAGEMENT
Pre/post heating (glow) and electronic fault warning light (level 1)
This warning light is used as an operating indicator light and as a system fault indicator light (malfunction
indicator).
Steady lighting: the function is working normally (heating the glow plugs).
Flashing: after preheating and an automatic 3 second stop, flashing indicates a level 1 fault (the function is not
working to optimum standards and safety levels are reduced. The driver should carry out repairs as soon as
possible).
Engine Coolant temperature warning light (ENG CHECK) (level 2 fault):
This warning light is used as an operating indicator light and as a system fault indicator light (malfunction
indicator). It lights up for 3 seconds when the ignition is switched on (automatic test procedure).
Steady lighting: this indicates engine overheating or a level 2 fault.
If the fault reaches critical level, the injection cuts off automatically after a few seconds.
In the event of overheating, it is the driver's choice to stop the car or continue driving.
OBD (On Board Diagnostics) excess pollution orange warning light
This warning light with engine symbol lights up when the ignition is switched on for about 3 seconds then goes out. It
is never lit when the engine is running.
2 - PROGRAMMING
Climate control and cruise control are the only options on the vehicle that are self-programmed.
These two systems control programming.
3 - REPLACING OR REPROGRAMMING THE ECM (COMPUTER C/U)
The system can be reprogrammed at the DLC using CONSULT-II.
Before reprogramming or replacing the ECM (COMPUTER C/U) in after sales, the following information must be
saved.
The individual injector correction parameters and the configurations using the CONSULT-II. After replacing the
computer, then enter injector’s individual correction value to re-establish the injector’s individual correction value and
the configurations.
CR DELPHI 1.0
EC-K9K-63
DIESEL INJECTION
Replacing the injectors
N.B.: the injectors are calibrated in the factory with individual injector correction, which allows the flow of each
injector to be precisely adjusted. The correction values are written on a label affixed to each injector then entered
in the computer which can then control each injector by taking account of their dispense as manufactured.
The system can be configured using CONSULT-II.

When replacing one or more injectors, it is necessary to replace the individual injector correction parameters; to do
this, rewrite the individual injector correction codes in the computer using "WORK SPPORT" mode with CONSULT.
CR DELPHI 1.0
EC-K9K-64
DIESEL INJECTION
Fault finding - Fault Interpretation K9K
ECM (COMPUTER)
1.DEF : Analogue converter
2.DEF : Write EEPROM memory
DF001 3.DEF : Read EEPROM memory
PRESENT 4.DEF : Injection calibration data
5.DEF : Memory self-test
6.DEF : Non refreshed watchdog
7.DEF : Interference on the injector control line
8.DEF : Watchdog activation
NOTES None.
7.DEF Check the condition of the ECM harness connector F90 .

Repair it if necessary.
Check the insulation, continuity and absence of interference resistance of the

connections:
l ECM F90 terminal 80 and No.1 injector terminal 2
lECM F90 terminal 75 and No.4 injector terminal 1
(Refer to wiring diagram "EC-INJECT-01 AND -02".)
Repair if necessary.
If the fault persists, replace ECM
Deal with any other possible faults.

AFTER REPAIR
Erase the stored faults.
CR DELPHI 1.0
EC-K9K-65
DIESEL INJECTION
DF001
Continued
4.DEF Check the condition of the ECM harness connector F90 .

Check that the individual injection correction (C2I) matches the injectors. If not
write the C2I codes (see "Fault filing - Introduction").
If C2I corresponds correctly to the injectors, replace ECM.
1.DEF Replace ECM.

2.DEF
3.DEF
5.DEF
6.DEF
8.DEF
Follow the instructions to confirm repair.

AFTER REPAIR Deal with any other possible faults.
CR DELPHI 1.0
EC-K9K-66
DIESEL INJECTION
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
DF002 CC.0 : Short circuit to earth
PRESENT CO.1 : Open circuit or short circuit to + 12V
Special notes:
NOTES
if fault DF002 is present: run the cooling fan assembly at low speed .
Check the condition of the engine coolant temperature sensor harness connector.
Check the condition of the ECM harness connector F90 and repair if necessary.
At the terminal, measure the resistance of the engine coolant temperature sensor, if it is not approximately
2252 Ω ± 112.16 Ω at 25 °C, replace the engine coolant temperature sensor.
Check the insulation, continuity and absence of interference resistance of the connections:
l ECM F90 terminal 63 and ECT sensor terminal 1
l ECM F90 terminal 53 and ECT sensor terminal 4
l ECT sensor terminal 2 and combination meter (Refer to EL-section)
l ECT sensor terminal 3 and ground
(Refer to wiring diagram "EC-ECTS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-67
DIESEL INJECTION
VEHICLE SPEED INFORMATION
DF095
Fault finding procedure

NOTES
None.
Check the condition and connection of the vehicle speed sensor connector.
Check the condition of the ECM harness connector F90 and replace it if necessary.
Check the continuity and absence of interference resistance of the

connections:
l Vehicle speed sensor terminal 1 for power supply circuit
l Vehicle speed sensor terminal 2 and ground
(Refer to wiring diagram "EC-VSS-01".)
Check the insulation against +12 volts of the connection:

lECM F90 terminal 103 and combination meter terminal 57
(Refer to wiring diagram "EC-VSS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-68
DIESEL INJECTION
BATTERY VOLTAGE
DF012 1.DEF : < Minimum threshold
STORED 2.DEF : > Maximum threshold
Conditions for applying the fault finding procedure to the fault stored::
NOTES
Fault declared present with the engine running above 1000 rpm.
Check the battery voltage when the ignition is switched on, if the battery voltage is < 10V recharge the
battery.
Check the condition of the battery terminals.

Check the vehicle's charge circuit.

Check the condition of the ECM harness connector E237 and repair if necessary.
l ECM E237 terminal 22 for power supply circuit
lECM F90 terminal 111, 112 and ground
(Refer to wiring diagram "EC-MAIN-01".)

CR DELPHI 1.0
EC-K9K-69
DIESEL INJECTION
IMMOBILISER
DF015
PRESENT
Fault finding procedure

NOTES
None.
Check the condition of the ECM harness connector E237 and repair if necessary.
Check NATS IMMU harness connector and repair if necessary.

connection:
l ECM E237 terminal 8 and NATS IMMU terminal 5
(see wiring diagram for the vehicle).

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-70
DIESEL INJECTION
FUEL TEMPERATURE SENSOR CIRCUIT
PRESENT CO.1 : Open circuit or short circuit + 12V
NOTES None.
Check the condition of the fuel temperature sensor harness connector and repair it if necessary.
At the terminal, measure the resistance of the fuel temperature sensor, if it is not approximately 2.2K Ω at
25 °C, replace the fuel temperature sensor.
l ECM F90 terminal 64 and fuel temperature sensor terminal 1
l ECM F90 terminal 54 and fuel temperature sensor terminal 2
(Refer to wiring diagram "EC-FTS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-71
DIESEL INJECTION
CHARGE (INTAKE) AIR TEMPERATURE SENSOR CIRCUIT
PRESENT CO.1 : Open circuit or short circuit + 12V
1.DEF : Incoherent information
NOTES None.
Check the condition of the air temperature sensor harness connector and repair it if necessary.
At the terminal, measure the resistance of the air temperature sensor, if it is not approximately
2051 Ω ± 20 Ω at 25 °C replace the air temperature sensor.
l ECM F90 terminal 52 and intake air temperature sensor terminal 1
l ECM F90 terminal 62 and intake air temperature sensor terminal 2
(Refer to wiring diagram "EC-BTS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-72
DIESEL INJECTION
CRANKSHAFT POSITION SENSOR CIRCUIT (FLYWHEEL)
1.DEF : Consistency
DF023 2.DEF: No tooth signal
PRESENT 3.DEF : Too many additional teeth
4.DEF : Teeth missing
5.DEF : Additional teeth
6.DEF : Too many teeth missing
If faults 3.DEF, 1.DEF, 4.DEF and 6.DEF are present, the engine will stop and
Malfunction indicator lights up (level 1 and 2).
NOTES
If faults 2.DEF and 5.DEF are present, performance will be reduced to 75 % with no
speed limitation and the warning light will not light up.
Check the condition of the crankshaft position sensor 2 harness connector and repair if necessary.
At the terminal, measure the resistance of the crankshaft position sensor, if it is not approximately 760Ω
replace the flywheel signal sensor.
l ECM F90 terminal 55 and crankshaft position sensor terminal 1
l ECM F90 terminal 65 and crankshaft position sensor terminal 2
(Refer to wiring diagram "EC-CKPS-01".)
Check that the flywheel ring gear is not faulty (missing teeth).

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-73
DIESEL INJECTION
ATMOSPHERIC PRESSURE SENSOR CIRCUIT (ATOMOS PRES
DF024 SEN)
PRESENT CC.1 : Short-circuit to + 12 volts
CO.1 : Open circuit or short circuit to the earth
NOTES None.
Replace the ECM.

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-74
DIESEL INJECTION
EGR VOLUME CONTROL VALVE CIRCUIT
DF027 CC.1 : Short circuit to +12 volts
STORED CO.0 : Open circuit or short circuit to the earth
Conditions for applying the fault finding procedure to the fault stored:
Fault declared present: at idle speed.
NOTES
If fault DF027 is present Malfunction indicator (level 1) lights up.
Check the condition and connection of EGR solenoid valve harness connector and repair it if necessary.
Measure the resistance between terminal 4 and 6 of the EGR solenoid valve, if it is not approximately 8Ω
± 0.5Ω at 25° replace the solenoid valve.
l EGR volume control valve terminal 4 for power supply circuit
lECM F90 terminal 38 and EGR volume control valve terminal 6
(Refer to wiring diagram "EC-EGRC/V-01".)

CR DELPHI 1.0
EC-K9K-75
DIESEL INJECTION
EGR VOLUME CONTROL VALVE SIGNAL CIRCUIT
DF163 1.DEF : At minimum stop
STORED 2.DEF : At maximum stop
3.DEF : > Maximum threshold
4.DEF : Blocked component
Fault declared present: at idle speed.
NOTES
If fault DF163 is present Malfunction indicator (level 1) lights up.
Check the condition and connection of the EGR solenoid valve harness connector and repair it if necessary.
Measure the resistance between terminal 4 and 6 of the EGR solenoid valve, if it is not approximately 8Ω
± 0.5Ω at 25° replace the solenoid valve.
lEGR volume control valve terminal 4 for power supply circuit
l ECM F90 terminal 38 and EGR volume control valve terminal 6

CR DELPHI 1.0
EC-K9K-76
DIESEL INJECTION
DF037 STOP LIGHT SWITCH CIRCUIT
PRESENT 1.DEF : Consistency
OR 2.DEF : Signal absent
STORED
Conditions for applying fault finding procedure to a stored fault:

the fault is declared present in 3rd gear, on deceleration, when the brake pedal is
NOTES
depressed.
Deal with the fault even if it is stored.
Check the switch connection and repair if necessary.
Check for the presence of + 12 volts on the switch supply.

Check the condition of the ECM harness connector E237 and the ECM harness connector F90 repair if
necessary.
Check that the switch is working.

Change it if necessary.
l Stop lamp switch terminal 1 for power supply circuit
lECM E237 terminal 5 and stop lamp switch terminal 2

(Refer to wiring diagram "EC-BRK/SW-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-77
DIESEL INJECTION
GLOW RELAY CONTROL CIRCUIT (PRE HEAT)
DF045 CC.1 : Short circuit to +12 volts
PRESENT CC.0 : Open circuit or short circuit to the earth
NOTES None.
Check the condition and connection of the preheating unit connector.

l Glow relay F87 terminal 5 for power supply circuit
l ECM F90 terminal 98 and glow relay terminal 1
lECM F90 terminal 90 and glow relay terminal 6
(Refer to wiring diagram "EC-GLOW-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-78
DIESEL INJECTION
SENSOR REFERENCE VOLTAGE
DF058
PRESENT CC.0 : Short circuit to earth
CO.1 : Open circuit or short circuit to + 12V
If fault DF058 is present: engine speed maintained above 1000 rpm.

Malfunction indicator lights up (level 1).
If faults DF058 and DF071 are present: engine speed fixed at 1300 rpm.
NOTES
Special note:
There are two different types of pedal potentiometer:
– a CTS sensor fitted in the engine compartment
– an APP sensor fitted on the accelerator pedal
CTS sensor Check the connection and condition of the APP sensor harness connector.
CC.0
Check the condition of the ECM E237 harness connector and repair if necessary.
Check that APP sensor terminal 2 is correctly supplied on the sensor side.

connection:
ECM E237 terminal 30 and APP sensor terminal 3 (Refer to wiring diagram.)
CO.1 Check the connection and condition of the APP sensor harness connector.
Disconnect ECM harness connector E237 from the ECM and the connector
from the APP sensor and test the insulation between the two lines
ECM E237 terminal 18 and ECM E237 terminal 12
Check the continuity of the connections:

l ECM E237 terminal 18 and APP sensor terminal 1
lECM E237 terminal 6 and APP sensor terminal 5
(Refer to wiring diagram "EC-APPS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-79
DIESEL INJECTION
DF058
Cont'd
APP sensor Check the connection and condition of the APP sensor harness connector.
CC.0

connection:
ECM E237 terminal 18 and APP sensor terminal 5 (Refer to wiring diagram
"EC-APPS-01".)
CO.1
Check the connection and condition of the APP sensor harness connector.
Disconnect ECM E237 harness connector from the ECM and the connector
from the APP sensor and test the insulation between the two lines
ECM E237 terminal 12 and APP sensor terminal 18
(Refer to wiring diagram)


AFTER REPAIR
CR DELPHI 1.0
EC-K9K-80
DIESEL INJECTION
GLOW PLUG CIRCUIT (PRE HEAT)
DF061 CO : open circuit
PRESENT
NOTES None.
Check the condition and connection of the glow relay harness connector.
Check the condition and connection of the glow plug harness connectors.
Change them, if necessary.
Measure the resistance of each glow plug. The resistance should be less than 1 Ω. If not, replace the faulty
plugs.
Check the insulation, continuity and absence of interference resistance of the connection:
ECM F90 terminal 98 and glow relay terminal 1 (Refer to wiring diagram "EC-GLOW-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-81
DIESEL INJECTION
PEDAL SENSOR CIRCUIT TRACK 1
1.DEF : Consistency
DF071 CO.0 : Open circuit or short circuit to the earth
PRESENT CC.1 : Short-circuit to + 12V
2.DEF : Signal absent
3.DEF : Blocked component
Priority when dealing with a number of faults:

If faults DF071 and DF127 are both present, deal with fault DF127 sensor voltage
supply first.

NOTES If faults DF071 and DF073 are present: engine speed fixed at 1300 rpm.
Special note:
Be aware that state 3.DEF may be present after sports style driving, when the brake
pedal and accelerator pedal are depressed at the same time (heel and toe).
non multiplex Disconnect ECM harness connector E237 from the computer and the
vehicle CTS connector from the APP sensor and test the insulation between the two lines
sensor ECM E237 terminal 30 and 12 (Refer to wiring diagram)
(vdiag 04) Repair if necessary.
1.DEF
Check the condition of the ECM harness connector E237 and replace it if
necessary.
Measure the resistance at the APP sensor terminal:

terminal 4 (ground) and terminal 6 (+5 V)
CO.0 If it is not approximately 1.7 KΩ ± 0.9 KΩ, replace the pedal potentiometer.
CC.1
2.DEF Check the insulation, continuity and absence of interference resistance of the
connections:

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-82
DIESEL INJECTION
DF071
(CONT. 1)
NOTES
CTS sensor Check that the accelerator pedal is not blocked with parameter PR240 Accelerator
3.DEF pedal position.
Replace the accelerator pedal potentiometer if necessary.
Check that the brake pedal is not blocked with state ET154 Brake pedal.
Replace the stop light switch if necessary.
Let the customer know that heel and toe sports driving (pressing the brake and
accelerator pedal at once) may raise a fault.
DF071
CONTINUED
APP sensor Disconnect connector A from the computer and the connector from the pedal
1.DEF potentiometer and test the insulation between the two lines:
ECM E237 terminal 30 and 12 (Refer to wiring diagram "EC-APPS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-83
DIESEL INJECTION
DF071
(CONTINUED 2)
APP sensor Check the condition of the APP sensor harness connector and repair it if
necessary.
CO.0 Check the condition of the ECM harness connector E237 and replace it if
CC.1 necessary.
2.DEF
Measure the resistance at the APP sensor terminals:
terminal 2 (+5 V) and terminal 4 (ground)
If it is not approximately 1.2 KΩ ± 0.5 KΩ, replace the pedal potentiometer.

connections:
NOTES
APP sensor Check that the accelerator pedal is not blocked by parameter PR240 Accelerator
pedal position.
3.DEF
Replace the accelerator pedal if necessary.
Check that the brake pedal is not blocked by state ET154 Brake pedal.
Replace the stop light switch if necessary.
Inform the customer that heel and toe sports driving (pressing the brake and
accelerator pedal at once) may raise a fault.

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-84
DIESEL INJECTION
TRACK 2 PEDAL SENSOR CIRCUIT
DF073 CO.0 : Open circuit or short circuit to eartrh
PRESENT CC.1 : Short circuit to + 12V

supply first.

NOTES
If faults DF073 and DF071 are present: engine speed fixed at 1300 rpm.
Special note:
CTS sensor Check the condition of the APP harness connector and repair it if necessary.
CO.0 necessary.
Measure the resistance at the APP sensor terminal:

terminal 5 (ground) and terminal 3 (+5 V)
If it is not approximately 2.4 KΩ ± 1.2 KΩ, replace the APP sensor.
Check the insulation against the earth and the continuity of the connection:
ECM E237 terminal 12 and APP sensor terminal 1 (Refer to wiring diagram
"EC-APPS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-85
DIESEL INJECTION
DF073
CONTINUED 1
CTS sensor Check the condition of the APP sensor harness connector and repair it if
necessary.
CC.1
necessary.

terminal 5 (Ground) and terminal 3 (+ 5V)
Check the insulation against + 12 volts of the connections:


Disconnect connector A from the computer and the connector from the pedal
potentiometer and test the insulation between the two lines:
lECM E237 terminal 18 and 12

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-86
DIESEL INJECTION
DF073
CONTINUED 2
necessary.
CO.0 Check the condition of the ECM harness connector E237 and replace it if
necessary.

l Terminal 1 (ground) and terminal 5 (+ 5V)
Check the insulation against the earth and the continuity of the connection:

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-87
DIESEL INJECTION
DF073
CONTINUED 3
necessary.
CC.1
necessary.

APP sensor terminal 1 (Ground) and 5 (+ 5V)
If it is not approximately 1.7 KΩ ± 0.7 KΩ, replace the APP sensor.

connection:
ECM E237 terminal 12 and APP sensor terminal 6
Check the insulation against + 12 volts of the connections:


Disconnect connector A from the computer and the connector from the APP
sensor and test the insulation between the two lines:
lECM E237 terminal 12 and 18

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-88
DIESEL INJECTION
EGR VALVE POSITION SENSOR CIRCUIT
DF084 CO.0 : Open circuit or short circuit to earth
STORED CC.1 : Short-circuit to + 12V
1.DEF : < minimum threshold
2.DEF : > maximum threshold
Priority when dealing with a number of faults::

If faults DF084 and DF127 are both present, deal with fault DF127 Sensor voltage
supply first.
NOTES
The fault is declared present after the engine is started.
Check the condition of the EGR volume control valve harness connector and replace it if necessary.
Measure the resistance at the EGR control valve terminal, if it is not

approximately 4 KΩ ± 1.6KΩ at 20°C between terminal 1 and 2 and
approximately 1 KΩ ± 0.5KΩ at 20°C between terminal 2 and 3, replace the solenoid valve.
l ECM F90 terminal 49 and 1
l ECM F90 terminal 59 and 3
lECM F90 terminal 69 and 2

CR DELPHI 1.0
EC-K9K-89
DIESEL INJECTION
MICROCONTROLLER
DF093 1.DEF : RAM memory defect
STORED
The fault is declared present: with the engine running.
NOTES
If fault DF093 is present: it is impossible to stop and restart the engine.
Re-enter C2I using the fault finding tool.
If the fault persists, replace the ECM.

CR DELPHI 1.0
EC-K9K-90
DIESEL INJECTION
CYLINDER INJECTOR CIRCUIT 1
DF099 CO : Open circuit
STORED CC : Short circuit
1.DEF : At minimum stop
NOTES Fault declared present: engine at idle speed
CO With the ignition switched off, wait 15 seconds.

Check the connection and condition of the injector harness connector.
Check the continuity between the two injector terminals using a multimeter.
Replace the injector if necessary.
Check the condition of the ECM harness connector F90 and replace it if
necessary.

connections:
l ECM F90 terminal 80 and injector terminal 2
lECM F90 terminal 79 and injector terminal 1
(Refer to wiring diagram "EC-INJECT-01 and 02".)

CR DELPHI 1.0
EC-K9K-91
DIESEL INJECTION
DF099
Cont'd
CC With the ignition switched off, wait 15 seconds.

3.DEF Check the connection and condition of the injector connector.
Disconnect the ignition, restart the ignition and check if the fault is stored.
Replace the injector if the fault is stored.
necessary.
Disconnect ECM harness connector F90 and the connector from injector 1.
Check the insulation of the two lines:
lECM F90 terminal 79 and 80 (Refer to wiring diagram "EC-INJECT-02".)
When the injector has been disconnected, check that the injector winding has not
short circuited with a multimeter.
The fault is declared present with: the engine running and engine temperature
above 80°C.
NOTES

If faults DF99 and DF130 are both present, deal with fault DF99: Cylinder 1 injector
circuit first.
1.DEF Replace injector 1.

CR DELPHI 1.0
EC-K9K-92
DIESEL INJECTION
DF100 CO : open circuit
NOTES Fault declared present: engine at idle speed.

Check the connection and condition of the injector harness connector.
necessary.

connections:
(Refer to wiring diagram "EC-INJECT-02".)

CR DELPHI 1.0
EC-K9K-93
DIESEL INJECTION
DF100
Cont'd

Check the connection and condition of the injector connector.
necessary.
ECM F90 terminal 73 and 74 (Refer to wiring diagram "EC-INJECT-02".)
When the injector has been disconnected, using a multimeter, check that the
injector winding has not short circuited.
above 80°C.
NOTES

circuit first.

CR DELPHI 1.0
EC-K9K-94
DIESEL INJECTION

necessary.

connections:

CR DELPHI 1.0
EC-K9K-95
DIESEL INJECTION
DF101
Cont'd
CC Ignition off.
Disconnect the injector and check to see if the fault is stored.

necessary.
ECM F90 terminal 77and 78 (Refer to wiring diagram "EC-INJECT-02".)
When the injector has been disconnected, check that the injector winding has not
short circuited using a multimeter.
above 80°C.
NOTES

circuit first.

CR DELPHI 1.0
EC-K9K-96
DIESEL INJECTION

necessary.

connections:

CR DELPHI 1.0
EC-K9K-97
DIESEL INJECTION
DF102
Cont'd

necessary.
lECM F90 terminal 75 and 76
With the injector disconnected, check that the injector winding has not short
circuited using a multimeter.
Fault declared present: with the engine running and engine temperature above
80°C.
NOTES

circuit first.

CR DELPHI 1.0
EC-K9K-98
DIESEL INJECTION
CHARGE AIR PRESSURE SENSOR CIRCUIT (INLET MANIFOLD)
1.DEF : < Minimum threshold
2.DEF : > Maximum threshold
DF115 3.DEF : Permanent low signal
PRESENT 4.DEF : Permanent high signal
5.DEF : Consistency
6.DEF : At minimum limit
7.DEF : At maximum limit
None.
NOTES
Malfunction indicator lights up.
1.DEF Check the condition of the charge air (intake manifold) pressure sensor harness
2.DEF connector and replace it if necessary.
3.DEF
4.DEF Check the condition of the ECM harness connector F90 and replace it if
necessary.

connections:
l ECM F90 terminal 68 and intake manifold pressure terminal 2
l ECM F90 terminal 58 and intake manifold pressure terminal 3
lECM F90 terminal 48 and intake manifold pressure terminal 1
(Refer to wiring diagram "EC-BOOST-01".)
5.DEF Visually check that the turbocharger circuit is leak tight.

6.DEF Repair if necessary.
7.DEF
Remove the air supply ducts and check that they are not blocked.
Check the consistency between the atmospheric pressure and inlet manifold
vacuum.
With the engine stopped, the pressure should be approximately the same between
the two sensors.
Replace the inlet manifold vacuum sensor if necessary.
Check the turbocharger.


AFTER REPAIR
CR DELPHI 1.0
EC-K9K-99
DIESEL INJECTION
CAMSHAFT POSITON SENSOR CIRCUIT (CYLINDER
DF116 REFERENCE)
STORED 1.DEF : Consistency
2.DEF : Signal Absent

supply first.
NOTES
The fault is declared present when the engine is started or at idle speed (600 rpm).
Check the condition of the camshaft position sensor harness connector and replace it if necessary.
l ECM F90 terminal 56 and CMP sensor terminal 2
l ECM F90 terminal 66 and CMP sensor terminal 3
l Check power supply between CMP sensor terminal 1 and ECM relay
(Refer to wiring diagram "EC-CMPS-01".)
If necessary, replace the sensor.
Check the timing gear setting using the appropriate Workshop Repair Manual.

CR DELPHI 1.0
EC-K9K-100
DIESEL INJECTION
COMMON RAIL FUEL PRESSURE SENSOR CIRCUIT
1.DEF : Consistency
STORED 3.DEF : > Maximum threshold
CC.0 : Short circuit to earth
CO.1 : Open circuit or short circuit to + 12V

If faults DF117 and DF127 are both present, deal with fault DF127 Sensor voltage
supply first.
NOTES Conditions for applying the fault finding procedure to the fault stored:
The fault is declared present after the engine is started.
If DF117 is present, the engine stops and is impossible to restart.

Check the condition of the common rail fuel pressure sensor harness connector and replace it if
necessary.
l ECM F90 terminal 67 and common rail fuel pressure sensor terminal 2
lECM F90 terminal 47 and common rail fuel pressure sensor terminal 1
(Refer to wiring diagram "EC-CRFPS-01".)

CR DELPHI 1.0
EC-K9K-101
DIESEL INJECTION
ECM RELAY CONTROL CIRCUIT
DF125 1.DEF : Relay cut-off too soon
PRESENT 2.DEF : Relay cut-off too late
NOTES None.
Check the main relay supply fuse in the engine compartment: (30A).
Check the condition and connection of the ECM relay connector and replace it if
necessary.
necessary.

connections:
l 30A fuse and ECM relay terminal 3
l ECM F90 terminal 104 and ECM relay terminal 1
l ECM F90 terminal 109, 110 and ECM relay terminal 5
lECM F90 terminal 111 and ground

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-102
DIESEL INJECTION
FUEL FLOW ACTUATOR CIRCUIT
DF126 CC.1 : Short-circuit to + 12 volts
PRESENT CO.0 : Open circuit or short circuit to earth
If fault DF126 is present with CO.0 or CC.1, malfunction indicator lights up (level 1
and 2).
NOTES
The fuel flow actuator is fully opened and the engine is stopped to prevent
stalling.
Check the condition and connection of the fuel flow actuator harness connector.
Measure the resistance between terminals 1 and 2 of the fuel flow actuator, if it is not approximately 5.3 Ω
± 0.5 at 20°C, replace the actuator.
ECM F90 terminal 39 and fuel flow actuator terminal 2
(Refer to wiring diagram "EC-IMV/D-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-103
DIESEL INJECTION
SUPPLY VOLTAGE SENSORS
PRESENT 2.DEF : > Maximum threshold
Order of priority in the event of more than one fault:

If faults DF127 and DF071, DF084, DF116, DF117 are present, deal with DF117
sensor voltage supply first.
NOTES
If fault DF127 is present, the engine stops immediately and cannot be restarted.
Check the condition and connection of all the sensor connectors as follows:
– engine coolant pressure sensor
– turbocharger pressure sensor
– common rail fuel pressure sensor
– APP sensor
– EGR valve position sensor
– camshaft position sensor
Check the condition of ECM harness connector F90 and E237 and replace them if necessary.
Connect the bornier in place of the computer and check the insulation, continuity and absence of
interference resistance of the connections:
l ECM F90 terminal 48 and CHARGE AIR (intake manifold) pressure sensor terminal 1
lECM F90 terminal 49 and EGR control valve terminal 1
lPower supply circuit between ECM relay terminal 5 and camshaft position sensor terminal 4
If the fault persists, apply the fault finding strategy to each sensor supplied by an external track.

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-104
DIESEL INJECTION
CHARGE AIR (INTAKE AIR) TEMPERATURE SENSOR CIRCUIT
PRESENT CO.1 : Open circuit or short circuit to + 12V
NOTES None.
Check the condition of the intake air temperature sensor harness connector and replace it if necessary.
At the terminal, measure the resistance of the intake air temperature sensor, if it is not approximately
2051 Ω ± 120 Ω at 25 °C replace the intake air temperature sensor.
l ECM F90 terminal 52 and intake air temperature sensor harness connector 1
lECM F90 terminal 62 and intake air temperature sensor terminal 2
(Refer to wiring diagram "EC-BTS-01".)

AFTER REPAIR
CR DELPHI 1.0
EC-K9K-105
DIESEL INJECTION
CYLINDER No.1 COMBUSTION
DF130
STORED
Fault declared present: engine at idle speed.

If faults DF099 (CC or CO) and DF130, are present, deal first with fault DF099 (CC or
NOTES
CO): Cylinder 1 injector circuit.

If faults DF137 (1.DEF, 2.DEF, 5.DEF) and DF130, are present, deal with fault DF137:
Pressure regulation. first.
Check the tightness of the cylinder and repair if necessary.
Check the valve clearances and adjust them if necessary.
Check the air inlet conduits and the EGR valve and clean them if necessary.
Replace the injector.

CR DELPHI 1.0
EC-K9K-106
DIESEL INJECTION
CYLINDER No. 2 COMBUSTION
DF131
STORED

If faults DF100 (CC or CO) and DF131, are present, deal with fault DF100 (CC or CO):
NOTES
Cylinder 2 injector circuit.


CR DELPHI 1.0
EC-K9K-107
DIESEL INJECTION
DF132
STORED

If faults DF101 (CC or CO) and DF132, are present, deal first with fault DF101 (CC or
NOTES
CO): Cylinder 3 injector circuit.


CR DELPHI 1.0
EC-K9K-108
DIESEL INJECTION
DF133
STORED

If faults DF102 (CC or CO) and DF133, are present, deal with fault DF102 (CC or CO):
NOTES
Cylinder 4 injector circuit. first.

Pressure regulation first.

CR DELPHI 1.0
EC-K9K-109
DIESEL INJECTION
ACCELEROMETER CIRCUIT
DF134
STORED
Processing priority in the event of a number of faults:

If faults DF134 and DF002, DF021, DF024 are present, first deal with faults DF002
Coolant temperature, DF022 Air temperature, DF021 Fuel temperature, and
DF024 Atmospheric pressure.
A fault on one of these sensors could lead to an incorrect diagnostic on the
NOTES
accelerometer.
Check the conformity of the injectors fitted to the vehicle in relation to the type of vehicle and engine
number (low injector, high or very high pressure).
Check the accelerometer connection.

Check the condition of the ECM harness connector F90 and the sensor shielding on track ECM F90
terminal 41. Change it if necessary.
l ECM F90 terminal 45 and accelometer terminal 1
l ECM F90 terminal 44 and accelometer terminal 2
(Refer to wiring diagram "EC-ACCEL-01".)

CR DELPHI 1.0
EC-K9K-110
DIESEL INJECTION
INJECTOR COMMAND
STORED CC.1 : Short circuit to + 12 volts
NOTES
Switch off the ignition and check the injector connections.

Disconnect the injectors and switch the ignition back on.

Check to see if the fault is still present.
If the fault persists, an injector is faulty; switch of the ignition and reconnect one injector of the four. Restart
the ignition and if the fault disappears, replace the injector. If not follow the same procedure for the other
injectors.
If the fault disappears when the injectors are disconnected, check the condition of the ECM harness
connector F90 and replace it if necessary.
l ECM F90 terminal 80 and No.1 injector terminal 1 (+)
l ECM F90 terminal 79 and No.1 injector terminal 2 (ground)
lECM F90 terminal 75 and No.4 injector terminal 1 (ground)
(Refer to wiring diagram "EC-INJECT-01 and -02".)

CR DELPHI 1.0
EC-K9K-111
DIESEL INJECTION
PRESSURE REGULATION FUNCTION
1.DEF : At minimum limit
2.DEF : At maximum limit
DF137 3.DEF : < minimum threshold
STORED 4.DEF : > maximum threshold
8.DEF : Weak flow current > maximum
6.DEF : Strong flow current > maximum
7.DEF : Weak flow current < minimum
5.DEF : Strong flow current < maximum
NOTES
The fault is declared present: with the engine running.
3.DEF Check the fuel flow actuator connection.

4.DEF Repair if necessary.
7.DEF
6.DEF Measure the resistance between terminal 1 and 2 of the fuel flow actuator, if it is
8.DEF not approximately 5.3 Ohms ± 0.5Ω at 20°C, replace the actuator.
Check the condition of the 48 track computer connector B and replace it if

necessary.

connection:
l ECM F90 terminal 39 and fuel flow actuator terminal 2
(Refer to wiring diagram "EC-IMV/D-01".)
Check:
– that fuel is present in the tank,
– that there is no air in the fuel circuit,
– the condition of the diesel filter.

CR DELPHI 1.0
EC-K9K-112
DIESEL INJECTION
DF137
Cont'd
1.DEF Carry out a HIGH PRESSURE PUMP test (see TEST section).
2.DEF
5.DEF

CR DELPHI 1.0
EC-K9K-113
DIESEL INJECTION
Fault finding - Conformity check K9K
Only check the conformity after a complete check with the fault finding tool.
NOTES The values indicated in this conformity check are given as examples.
Test conditions: engine stopped, ignition on.
Parameter or state
Order Function Display and notes Fault finding
Check or action
PR241: battery voltage 12 < X < 12.5 V In the event of a

problem: perform the
1 Battery voltage
charge circuit fault finding
procedure
ET133: code programmed YES

Perform the engine
immobiliser system fault
2 Immobiliser finding procedure if the
ET151: computer locked NO immobiliser code is not
programmed.
PR240: accelerator pedal no load X = 0%

position
full load X = 100%
In the event of a
problem:
PR233: APP sensor no load 0.3V to 0.5V Carry out the fault finding
Accelerator track (terminal) 2 procedure for pedal
3 full load 2V ± 0.3V
pedal voltage sensor circuit tracks 1 and
2 (DF071 and DF073) and
sensor reference voltage
PR234: APP sensor no load 0.7V ± 0.2V
DF058.
track (terminal) 1
full load 4.1V ± 0.5V
voltage
ET128: serious injection ACTIVE

fault warning light
In the event of a
control
problem:
Consult the fault finding
ET127: injection fault ACTIVE procedure for states
Warning light
warning light ET128 and ET127.
4 (Malfunction
control
indicator)
ET104: preheating (glow) ACTIVE during the In the event of a

lamp control preheating phase, then problem:
INACTIVE Refer to diagnostic for
state ET104
CR DELPHI 1.0
EC-K9K-114
DIESEL INJECTION
Parameter or state
Check or action
ET129: coolant ACTIVE for 3 seconds In the event of a

temperature on ignition then goes problem:
warning light (MI) out Refer to the fault finding
Warning light control procedure for state
(Malfunction ET129.
5
indicator) ET197: on board ACTIVE for 3 seconds In the event of a
(continued) diagnostic on ignition then goes problem:
warning light (MI) out Refer to the fault finding
control procedure for state
ET197.
PR034: EGR valve X = 0% In the event of a
opening problem:
specification Apply the fault finding
procedure for the EGR
solenoid valve circuit fault
DF027.
Gas
6 PR088: EGR valve X = 0%
recirculation
position feedback In the event of a
problem:
Carry out the fault finding
PR101: EGR valve 1.5 V ± 0.5 V procedure on the EGR
position sensor valve position sensor
voltage circuit DF084.
ET154: brake pedal DEPRESSED when

the pedal is depressed
In the event of a
problem:
7 Switches Apply the fault finding
ET155: secondary brake ACTIVEwhen the procedure for the stop
pedal pedal is depressed light switch circuit DF037.
CR DELPHI 1.0
EC-K9K-115
DIESEL INJECTION
Parameter or state
Check or action
ET037: low speed fan INACTIVE In the event of a problem:

assembly relay Apply the fault finding
control procedure for the low-
speed fan assembly circuit
DF048.
ET038: high speed fan INACTIVE In the event of a problem:

assembly relay Apply the fault finding
control procedure for the high
speed fan assembly circuit
DF049.
ET106: thermoplunger INACTIVE In the event of a problem:
relay control 1 Apply the fault finding
procedure for
thermoplunger relay circuit 1
DF124.

procedure for
DF123.
8 Relays
procedure for
DF122.
ET025: power-assisted INACTIVE In the event of a problem:
steering relay Apply the fault finding
control procedure for the power-
assisted steering assembly
relay control circuit DF029.
ET054: preheating (glow) ACTIVE during the In the event of a problem:

relay control preheating phase, Apply the fault finding
then INACTIVE procedure for the
preheating (glow) relay
control circuit DF045.
ET116: air conditioning INACTIVE In the event of a problem:

compressor relay Apply the fault finding
control procedure for the air
conditioning cold loop relay
CR DELPHI 1.0
EC-K9K-116
DIESEL INJECTION
Conditions for engine performance: warm at idle speed, no electrical consumers.
Parameter or state
Check or action
PR241: battery voltage 13 < X < 14.4 V In the event of a

problem: perform the
1 Battery voltage
charge circuit fault finding
procedure
ET133: code programmed YES

Perform the engine
immobiliser system fault
3 Immobiliser finding procedure if the
ET151: computer locked NO immobiliser code is not
programmed.
PR002: engine coolant 90 to 100°C In the event of a

temperature problem: Use the fault
Engine coolant
finding procedure for the
4 temperature
engine coolant
sensor
temperature sensor circuit
DF002.
PR212: external air X = external In the event of a

external air temperature temperature ± 5°C problem: Use the fault
5 temperature finding procedure for the
sensor air temperature sensor
circuit DF022.
PR213: intake manifold X = temperature

(charge) air under bonnet ± 5 °C
temperature In the event of a
Intake manifold
problem: Use the fault
(charge) air
6 finding procedure for the
temperature PR249: intake manifold 2.0 V ± 0.2 V intake air temperature
sensor (charge) sensor circuit DF128.
temperature
sensor voltage
CR DELPHI 1.0
EC-K9K-117
DIESEL INJECTION
Parameter or state
Check or action
PR016: atmospheric X = atmospheric In the event of a

pressure pressure ± 10 mb problem: Use the fault
atmospheric pressure
sensor circuit DF024.
PR214: intake manifold X = manifold In the event of a

pressure pressure ± 20 mb problem: Use the fault
Inlet
8 inlet manifold pressure
(Intake)
PR243: estimated air flow 250..300 mg/stroke In the event of a

problem:Use the fault
atmospheric pressure
sensor circuit DF024 and
the manifold pressure
sensor DF115.
PR240: accelerator pedal 0%

position
In the event of a
problem:Use the fault
Accelerator PR233: pedal sensor track finding procedure for
(terminal) 2 no load 0.3V to 0.5V
9 pedal APP sensor circuit
(APP sensor) voltage full load 2V ± 0.3V tracks 1 and 2 DF071 and
DF073 and sensor
PR234: pedal sensor no load 0.7V ± 0.2V reference voltage DF058.
track 1 voltage
full load 4.1V ± 0.5V
PR192: refrigerant fluid 1.5 > X >30 bar In the event of a

pressure problem: carry out the
10 Climate control fault finding procedure
on the coolant pressure
CR DELPHI 1.0
EC-K9K-118
DIESEL INJECTION
Parameter or state
Check or action
ET006 : climate control INACTIVE

request or None.
ACTIVE
ET116: air conditioning ACTIVE In the event of a

compressor relay or problem: perform the
control INACTIVE fault finding procedure
Climate control on the cold loop air
10 conditioning relay control
(continued)
circuit DF111.
PR044: power used by the 250 to 300 Watts

AC compressor without climate control None.
250 to 5000 Watts See operation PR044.
climate control on
PR001: fuel temperature X = fuel temperature In the event of a

± 5°C problem: Carry out the
fault finding procedure
on the fuel temperature
PR033: fuel flow 2 to 5 mg/stroke In the event of a

problem: Carry out the
on the fuel flow actuator
circuit DF126.
11 Fuel
PR103: fuel pressure 1.2 V ± 0.2 V In the event of a

sensor voltage problem:carry out the
on the rail pressure sensor
DF117 and on the sensor
voltage supply DF127.
PR215: advance 0° to 1° flywheel

None.
CR DELPHI 1.0
EC-K9K-119
DIESEL INJECTION
Parameter or state
Check or action
PR217: common rail 230 ± 5 bar

pressure
In the event of a
PR216: common rail 230 bar on the rail pressure sensor
pressure circuit DF117.
specification
11 Fuel (continued)
ET138: high pressure ACTIVE

pump control In the event of a
for the fuel flow actuator
circuit DF126.
ET104: preheating (glow) ACTIVEduring the

In the event of a
warning light preheating phase, then
problem: Consult the
control INACTIVE
fault finding procedure for
state ET104.
Warning light
12 (Malfunction
indicator) ET129: engine coolant ACTIVE for 3 seconds If the state remains
temperature after the ignition is ACTIVE, check the
warning light switched on, then conformity of parameter
control INACTIVE PR002 engine coolant
temperature
CR DELPHI 1.0
EC-K9K-120
DIESEL INJECTION
Parameter or state
Check or action
PR034: EGR valve X = 16 ± 5 % In the event of a

opening problem: Carry out the
specification fault finding procedure
on the EGR solenoid valve
circuit DF027.
PR088: EGR valve specification ± 2 %

position feedback In the event of a
Gas
13 fault finding procedure
recirculation PR101: EGR valve 1.5 V ± 0.5 V on the EGR valve position
position sensor sensor circuit DF084.
voltage
ET021: EGR solenoid ACTIVE In the event of a

valve control problem: Carry out the
on the EGR solenoid valve
circuit DF027.
ET037: low speed cooling The low speed

fan assembly cooling fan assembly In the event of a
relay control switches on at 99°C problem: Carry out the
and runs until the fault finding procedure
temperature drops to on the low speed cooling
ET144: low speed cooling 96°C fan assembly circuit
fan assembly DF048.
request
ET038: high speed The high speed

14 Relays
cooling fan cooling fan assembly
assembly relay switches on at 102°C
control and runs until the In the event of a
engine coolant problem: Carry out the
temperature drops to fault finding procedure
99°C on the high speed cooling
fan assembly circuit
DF049.
ET143: high speed It is only active if the
cooling fan vehicle is fitted with
assembly request climate control
CR DELPHI 1.0
EC-K9K-121
DIESEL INJECTION
Parameter or state
Check or action
ET106: thermoplunger INACTIVE In the event of a

relay control 1 problem: Carry out the
on thermoplunger relay
circuit 1 DF124.

on thermoplunger relay
circuit 2 DF123.

Relays active only with fault finding procedure
14
(continued) extreme cold option on thermoplunger relay
circuit 3 DF122.
ET025: power-assisted INACTIVE In the event of a

steering problem: Carry out the
assembly relay present only on fault finding procedure
control vehicles fitted with on the power assisted
climate control steering assembly relay
ET054: preheating relay ACTIVE during the In the event of a

control preheating phase problem: Carry out the
(warning light comes on) fault finding procedure
then for 8 seconds after on the preheating relay
the light goes out control circuit DF045.
PR006: engine speed specification ± 5 rpm In the event of a
on the flywheel sensor
Vehicle and circuit DF023.
15
engine speeds
PR011: idle speed X = 850 rpm

regulation None.
specification
CR DELPHI 1.0
EC-K9K-122
DIESEL INJECTION
Parameter or state
Check or action
ET145: fast idle speed INACTIVE

request except for electrical
None.
consumer
Engine speed
15 and speed PR018: vehicle speed X = 0 mph In the event of a problem:
(continued) Carry out the fault finding
procedure on the vehicle
speed sensor circuit
DF004.
ET152: engine running

16 Engine None.
ET140: speed limiter INACTIVE

or
ACTIVE
depending on the
switch
ET141: cruise control INACTIVE

or
ACTIVE
depending on the
switch
In the event of a problem:
ET146: speed checking none Carry out the fault finding
Speed limiter/
17 mode procedure on the cruise
cruise control limiter control/speed limiter
cruise control function DF118.
depending on the
switch
ET147: cruise control / more

speed limiter
less
function selector
on the steering restart
wheel
cancel
depending on the
switch
Heated ET153: electric INACTIVE
18 None.
windscreen windscreen
CR DELPHI 1.0
EC-K9K-123
DIESEL INJECTION
Fault finding - Interpretation of states K9K
GLOW INDICATOR LAMP CONTROL (PREHEATING WARNING)
ET104
Enter command AC212 glow indicator lamp and check that it lights up correctly.
If the light comes on, replace the ECM.
Check the glow indicator lamp connection.

Check the condition of the ECM harness connector E237 and replace it if necessary.
lECM E237 terminal 19 and combination meter terminal 47
(Refer to wiring diagram "EC-GLOW-01".)
CR DELPHI 1.0
EC-K9K-124
DIESEL INJECTION
Fault finding - Interpretation of parameters K9K
POWER CONSUMED BY THE CLIMATE CONTROL COMPRESSOR
PR044
NOTES The values listed below are examples only.
Whether the variable capacity compressor is pneumatic or electrically controlled, the power consumed by the
compressor can be anything from several hundred watts to approximately 3 KW depending on weather
conditions, car speed and compressor rotation speed.
The power consumed signal is a function of two parameters:
– continuous high pressure readings,
– compressor rotation speed.
The power consumed value calculated by the climate control computer is transmitted to the engine computer.
This allows the engine computer to anticipate the effect that the load variations induced by the compressor will
have on the car at idle speed and when in motion.
CR DELPHI 1.0
EC-K9K-125
DIESEL INJECTION
Fault finding - Tests K9K
NOTES Only consult the tests after following the fault finding chart procedure.
Some specific checks are grouped under the << tests >> heading and are used as required
in different fault finding charts.
TEST 1: low pressure circuit check
TEST 2: electrical circuit check
TEST 3: injector check
TEST 4: parameter check
TEST 5: air inlet circuit check
TEST 6: ECM check
TEST 7: high pressure pump check
TEST 8: high pressure circuit tightness check
TEST 9: injector tightness check
TEST 10: Test with the plugged rail tool
CR DELPHI 1.0
EC-K9K-126
DIESEL INJECTION
TEST 1 LOW PRESSURE CIRCUIT CHECK
Check the conformity of the connections.
Is the low pressure circuit connection NO Carry out the required repairs.
correct?
YES
Look for leaks on the unions.
Are there leaks in the hoses and unions? YES Carry out the required repairs.
NO
Check the correctness of the diesel filter.
Is the diesel filter correct? NO Replace the filter with an original part.
YES
CR DELPHI 1.0
EC-K9K-127
DIESEL INJECTION
TEST 1
Cont'd
Check for water in the diesel.
Is there water in the diesel? YES Drain the diesel filter.
NO
Bleed the low pressure circuit.
Place a container under the filter:
Check for air bubbles in the diesel.
– Disconnect the return hose at the
filter and block the filter.
Are there any air bubbles in the low YES – Pump using the vacuum pump until
pressure circuit? there is no air left.
– Reconnect the return hose
immediately.
NO
Low pressure circuit OK.
CR DELPHI 1.0
EC-K9K-128
DIESEL INJECTION
TEST 2 ELECTRICAL CIRCUIT CHECK
Check the battery charge and ensure that

the alternator is working properly.
Is the charge circuit correct? NO Carry out the required repairs.
YES
Check the fuses.
Are the fuses correct? NO Carry out the required repairs.
YES
Check that the injection locking relay is in

working order.
Is the injection locking relay working NO Replace the dual relay.

properly?
YES
Check the earth strap.
Is the earth strap correct? NO Replace the earth strap.
YES
The electrical circuit is OK.
CR DELPHI 1.0
EC-K9K-129
DIESEL INJECTION
TEST 3 INJECTOR CHECK
Visually inspect the injector wells.
Is there diesel in the injector wells? YES Injector ice leak, replace the injector.
NO
Run the ISO injector cycle.
Can you hear the valve moving? NO Replace the injector.
YES
Compare the return flow of the four

injectors when hot using a measuring
cylinder. See TEST 9.
Does one of the four injectors have a YES Replace the injector with an unusually
greater return flow than the others? high return flow (leak at the valve).
NO
CR DELPHI 1.0
EC-K9K-130
DIESEL INJECTION
TEST 3
Cont'd
i=1
Disconnect and reconnect injector i.
Is there a noticeable change in engine NO Replace injector i

i = i+1 YES noise? with a new part.
and i<4
YES and i=4
The injector is sound.
CR DELPHI 1.0
EC-K9K-131
DIESEL INJECTION
TEST 4 PARAMETER CHECK
Use the fault finding tool to check that C2I

corresponds to the injectors.
Use the fault finding tool to program

Is C2I correctly programmed? NO
C2I into the memory, paying attention
to the cylinder numbers.
YES
Do the electrical consumer states

displayed on the fault finding tool Perform the fault finding procedure
NO
correspond to the actual states? and any necessary repairs.
YES
Check the consistency of the engine

parameters.
CR DELPHI 1.0
EC-K9K-132
DIESEL INJECTION
TEST 5 AIR INLET CIRCUIT CHECK
Check for the presence of a leak/intake of

air.
Presence of a leak/intake of air. YES Carry out the required repairs.
NO
Check the condition of the air filter.
Air filter ok. NO Replace the air filter with a new part.
YES
Check that the inlet manifold is not

obstructed (dirty).
Is the inlet manifold blocked? YES Clean the inlet manifold.
NO
Air circuit ok.
CR DELPHI 1.0
EC-K9K-133
DIESEL INJECTION
TEST 6 ECM CHECK (COMPUTER)
Check that the computer connectors are

locked correctly.
Are the connectors poorly locked? YES Lock the connectors correctly.
NO
Replace the ECM.
CR DELPHI 1.0
EC-K9K-134
DIESEL INJECTION
TEST 7 HIGH PRESSURE PUMP CHECK
It is possible to check the flow of the high

pressure pump without electrical consumers
as follows:
– disconnect the fuel flow actuator
– electrically disconnect the four injectors
– connect the fault finding tool and check the
PR217 Rail pressure parameter screen
– run the starter motor for 10 seconds while
checking the pressure on the tool. The pump is correct, carry out a fault
finding procedure on the injectors by
Does the rail pressure exceed 280 bar? YES checking the return flow on the four
injectors.
(See TEST 9 checking injector
NO tightness).
Check 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 support and
shake it well keep the plugs in place and
empty the contents of the filter into a glass
container by lifting up a protective plug and
slackening the bleed screw. Carry out a fault finding procedure on the
injectors by checking the return flow of the
Is there residue visible in the bottom of four injectors.
the container? NO (See TEST 9 checking injector
tightness).
YES Is test 9 correct?
Replace the entire injection system. NO YES
Replace the faulty Replace the high

injector(s) pressure pump.
CR DELPHI 1.0
EC-K9K-135
DIESEL INJECTION
TEST 8 HIGH PRESSURE CIRCUIT TIGHTNESS TEST
There is a command that tests the high pressure circuit tightness when the engine is running.
This command can diagnose a leak on the high pressure circuit if a union is improperly fitted or bolted, but cannot
detect a small leak if a union is not torque tightened.
This command can only be used if the engine temperature is above 60°C.
Activate command SC001 High pressure circuit tightness test and the engine automatically performs a cycle of
four accelerations up to 4000 rpm, then decelerates to raise the pressure in the rail. This is to check for leaks in the
high pressure circuit.
Be careful with any objects (tool or other) on the engine housing during the four cycles of the operation
(possible vibrations).
TEST 9 INJECTOR TIGHTNESS CHECK
Command SC001 can also check the leak flow of each injector to detect an internal leak from one or more
injectors. To do this, the engine temperature must be above 60 °C, and you must disconnect:
– The return hoses from the four injectors.

– Connect four 20 cm hoses in place of the return hoses.
– Immerse these four hoses in four graduated measuring cylinders.
Having made these preparations, start the engine, then let it run for 2 minutes at idle speed.
Activate command SC001 High pressure circuit tightness test.
The engine automatically performs a cycle of four accelerations up to 4000 rpm then decelerates to raise the pressure
in the rail. This is to check for internal leaks in the injector return circuit.
When the cycle has ended, it is necessary to run it again to get a correct reading of the flow from each injector.
At the end of the two cycles, the flow from each injector should be approximately 16 ml. If the flow from one of the
injectors is over 16 ml, replace the faulty injector.
Be careful with any objects (tool or other) on the engine housing during the four cycles of the operation
(possible vibrations).
CR DELPHI 1.0
EC-K9K-136
DIESEL INJECTION
TEST 10 TEST WITH PLUGGED RAIL TOOL
The plugged rail test enables the diagnostic tool to show, the performance of the high pressure pump when
starting to give a precise diagnostic.
NOTE:
IMPORTANT: before carrying out any work, connect the diagnostic tool, set up communication with the injection
computer and check that the injection rail is not under pressure (see parameter screen).
Order the special high pressure injection circuit plug kit.
Fit the plugged rail

– Remove the high pressure pipe linking the pump to the rail (see K9K engine Technical Note).
– Block the high pressure pump outlet and rail inlet, while preparing the tool.
– Insert the test pipe olive into the taper of the high pressure pump outlet and finger tighten.
– Insert the test pipe olive into the taper of the plugged rail inlet and finger tighten.
– Tighten the pipe union on the rail side to a torque of 2 daN.m.
– Tighten the pipe union on the pump side to a torque of 2 daN.m.
– Disconnect the injector leak return pipe on the venturi then block it.
– Disconnect the pressure sensor on the rail, then reconnect it to the plugged rail one.
– Connect a pipe to the discharge outlet of the plugged rail, then immerse it in a container
TEST:
– Run the starter motor for a maximum of 10 seconds then read the rail pressure value on the parameter screen of
the fault finding tool.
During the test, the pump should maintain a pressure of approximately 1200 bar on starting.
If the pressure value is less than 1200 bar, the pump is faulty.
NOTE: Before dismantling depressurise using the discharge screw on the plugged rail.
Plugged rail removal

– Disconnect the pressure sensor on the plugged rail, then reconnect it to the one on the rail.
– Remove the high pressure test pipe.
– Block the high pressure pump outlet and rail inlet, while preparing the new high pressure pipe.
– Fit the new pump rail high pressure pipe(see K9K engine technical note).
CR DELPHI 1.0
EC-K9K-137
DIESEL INJECTION
Fault finding - Customer complaints K9K
Only consult this customer complaint after a complete check using the
NOTES
diagnostic tool.
No communication with the computer CHART 1
Starting fault
The engine does not start CHART 2
The engine starts with difficulty or starts then stalls CHART 3
Starting difficult with warm engine CHART 4
Idle speed fault
Rough idle speed (pumping) CHART 5
Idle speed too high or too low CHART 6
Behaviour while driving
Unexpected acceleration/deceleration and engine stalling CHART 7
Response fault CHART 8
Engine stop (timing) CHART 9
Engine jerking CHART 10
Lack of power CHART 11
Too much power CHART 12
CR DELPHI 1.0
EC-K9K-138
DIESEL INJECTION
Fault finding - Customer complaints K9K
Road holding (continued)
Excessive consumption CHART 13
Overspeed when lifting off accelerator or changing gear CHART 14
Engine dies when pulling away CHART 15
The engine does not stop CHART 16
noise, odours or smoke
Clanking engine, noisy engine CHART 17
Squalling noise CHART 18
Varied mechanical noise CHART 19
Exhaust odours CHART 20
Diesel odours CHART 21
Blue, white or black smoke CHART 22
Smoke (blue, white or black) on acceleration CHART 23
CR DELPHI 1.0
EC-K9K-139
DIESEL INJECTION
Diagnostic - Fault finding charts K9K
CHART 1 NO DIALOGUE WITH THE ECM
NOTES
diagnostic tool.
Try the diagnostic tool on another vehicle.
Check the ECM earth point on the left hand front shock absorber cage.
Check:
– the connection between the CONSULT-II and the DLC (wiring in good condition),
– the engine and passenger compartment fuses.
Check for the presence of + 12 volts before ignition on terminal 16, + 12 volts after ignition on terminal 1
and an earth on terminals 4 and 5 of the diagnostic socket.
Connect the bornier and check the insulation, continuity and absence of interference resistance of the
connections:
l ECM E237 terminal 22 and Fuse block terminal A7
l ECM F90 terminal 111 and ground
l ECM F90 terminal 112 and ground
lECM E237 terminal 2 and DLC terminal 7
CR DELPHI 1.0
EC-K9K-140
DIESEL INJECTION
CHART 2 THE ENGINE DOES NOT START
NOTES
diagnostic tool.
Check that the fuel tank is correctly filled

and that the fuel type is suitable.
Is the fuel type suitable and the tank

correctly filled? NO Refill the fuel tank correctly.
YES
Is the starter motor working properly? NO Carry out the required repairs.
YES
Check the low pressure circuit: TEST 1.
Check for leaks in the high pressure

circuit.
Check the electrical circuit: TEST 2.
CR DELPHI 1.0
EC-K9K-141
DIESEL INJECTION
CHART 2
CONTINUED 1
Check the engine parameters: TEST 4.
Check the air inlet circuit: TEST 5.
Is the high pressure actuator blocked? YES Carry out the required repairs.
NO
Is the engine wiring harness cut off or

YES Carry out the required repairs.
jammed?
NO
Check that the glow plugs are working

properly.
Is the glow plug resistance above 1 Ω ?

YES Replace the glow plugs.
NO
CR DELPHI 1.0
EC-K9K-142
DIESEL INJECTION
CHART 2
CONTINUED 2
Are the compressions correct? NO Carry out the required repairs.
YES
Check the injectors: TEST 3.
Check the high pressure pump: TEST 7.
Check the ECM: TEST 6.
End of fault finding.
AFTER REPAIR Check that the system is operating correctly.
CR DELPHI 1.0
EC-K9K-143
DIESEL INJECTION
THE ENGINE STARTS WITH DIFFICULTY OR STARTS THEN
CHART 3
STALLS
NOTES
diagnostic tool.


NO Refill the fuel tank correctly.
correctly filled?
YES

circuit.
CR DELPHI 1.0
EC-K9K-144
DIESEL INJECTION
CHART 3
CONTINUED 1
NO
Is the engine oil level correct? NO Top up the oil.
YES
Is the catalytic converter sealed off or

damaged? YES Replace the catalytic converter.
NO
CR DELPHI 1.0
EC-K9K-145
DIESEL INJECTION
CHART 3
CONTINUED 2

jammed? YES Carry out the required repairs.
NO

properly.
Is the glow plug resistance over 1 Ohm? YES Replace the glow plugs.
NO
YES
Check the computer: TEST 6.
CR DELPHI 1.0
EC-K9K-146
DIESEL INJECTION
CHART 4 STARTING DIFFICULT WITH WARM ENGINE
NOTES
diagnostic tool.
NO
YES
CR DELPHI 1.0
EC-K9K-147
DIESEL INJECTION
CHART 4
Cont'd

NO
CR DELPHI 1.0
EC-K9K-148
DIESEL INJECTION
CHART 5 ROUGH IDLE SPEED (PUMPING)
NOTES
diagnostic tool.

NO
NO

circuit.
CR DELPHI 1.0
EC-K9K-149
DIESEL INJECTION
CHART 5
Cont'd

properly.
Is the glow plug resistance above 1 Ω? YES Replace the glow plugs.
NO
YES
CR DELPHI 1.0
EC-K9K-150
DIESEL INJECTION
CHART 6 IDLE SPEED TOO HIGH/TOO LOW
NOTES
diagnostic tool.
Is the clutch linkage correct? NO Carry out the required repairs.
YES
CR DELPHI 1.0
EC-K9K-151
DIESEL INJECTION
UNEXPECTED ACCELERATION/DECELERATION AND ENGINE
CHART 7
STALLING
NOTES
diagnostic tool.

NO
Check that the engine has not aspirated

its oil (engine stalls).
NO
CR DELPHI 1.0
EC-K9K-152
DIESEL INJECTION
CHART 7
Cont'd
CR DELPHI 1.0
EC-K9K-153
DIESEL INJECTION
CHART 8 RESPONSE FAULT
NOTES
diagnostic tool.
Check that the turbocharger is working

properly.
Is the turbocharger correct? NO Carry out the required repairs.
YES
YES
CR DELPHI 1.0
EC-K9K-154
DIESEL INJECTION
CHART 8
Cont'd

circuit.
NO
CR DELPHI 1.0
EC-K9K-155
DIESEL INJECTION
CHART 9 ENGINE STOP/STALLING
NOTES
diagnostic tool.


YES

circuit.
NO
CR DELPHI 1.0
EC-K9K-156
DIESEL INJECTION
CHART 9
CONTINUED 1
NO

jammed?
NO

YES Replace the catalytic converter.
damaged?
NO

NO
CR DELPHI 1.0
EC-K9K-157
DIESEL INJECTION
CHART 9
CONTINUED 2
CR DELPHI 1.0
EC-K9K-158
DIESEL INJECTION
CHART 10 ENGINE JERKING
NOTES
diagnostic tool.


YES

jammed?
NO
CR DELPHI 1.0
EC-K9K-159
DIESEL INJECTION
CHART 10
CONTINUED 1

properly.
NO
YES
Is the valve clearance properly adjusted? NO Make the necessary adjustments.
YES
CR DELPHI 1.0
EC-K9K-160
DIESEL INJECTION
CHART 10
CONTINUED 2
CR DELPHI 1.0
EC-K9K-161
DIESEL INJECTION
CHART 11 LACK OF POWER
NOTES
diagnostic tool.
YES

damaged?
NO

properly.
YES
CR DELPHI 1.0
EC-K9K-162
DIESEL INJECTION
CHART 11
Cont'd
YES
YES
CR DELPHI 1.0
EC-K9K-163
DIESEL INJECTION
CHART 12 Too much power
NOTES
diagnostic tool.

its oil (engine stalls). YES Carry out the required repairs.
NO
CR DELPHI 1.0
EC-K9K-164
DIESEL INJECTION
CHART 13 EXCESSIVE CONSUMPTION
NOTES
diagnostic tool.
Does the high pressure actuator have: a

leak? YES Carry out the required repairs.
NO
Is the diesel temperature sensor leaking? YES Replace the diesel temperature
sensor.
NO

circuit.
CR DELPHI 1.0
EC-K9K-165
DIESEL INJECTION
CHART 13
CONTINUED 1
YES
Is the catalytic converter clogged or

damaged?
NO

properly.
YES
YES
CR DELPHI 1.0
EC-K9K-166
DIESEL INJECTION
CHART 13
CONTINUED 2
CR DELPHI 1.0
EC-K9K-167
DIESEL INJECTION
OVERSPEED WHEN LIFTING OFF ACCELERATOR OR
CHART 14
CHANGING GEAR
NOTES
diagnostic tool.
Is the engine wiring harness cut or

pinched?
NO
Is the clutch linkage properly adjusted? NO Carry out the required repairs.
YES

NO

properly.
YES
CR DELPHI 1.0
EC-K9K-168
DIESEL INJECTION
CHART 14
Cont'd
CR DELPHI 1.0
EC-K9K-169
DIESEL INJECTION
CHART 15 ENGINE DIES ON PULLING AWAY
NOTES
diagnostic tool.

damaged?
NO
YES
CR DELPHI 1.0
EC-K9K-170
DIESEL INJECTION
CHART 15
Cont'd

pinched? YES Carry out the required repairs.
NO
NO
CR DELPHI 1.0
EC-K9K-171
DIESEL INJECTION
CHART 16 THE ENGINE DOES NOT STOP
NOTES
diagnostic tool.

NO
CR DELPHI 1.0
EC-K9K-172
DIESEL INJECTION
CHART 17 CLANKING ENGINE, NOISY ENGINE
NOTES
diagnostic tool.

properly.
NO
YES
CR DELPHI 1.0
EC-K9K-173
DIESEL INJECTION
CHART 17
Continued
CR DELPHI 1.0
EC-K9K-174
DIESEL INJECTION
CHART 18 SQUALLING NOISE
NOTES
diagnostic tool.

pinched? YES Carry out the required repairs.
NO
NO
CR DELPHI 1.0
EC-K9K-175
DIESEL INJECTION
CHART 19 VARIOUS MECHANICAL NOISES
NOTES
diagnostic tool.
Check that the injectors are not making a

buzzing noise (injector discharge). YES Carry out the required repairs.
NO
Are the mounting clips on the injector

pipes broken or missing?
NO

damaged?
NO
CR DELPHI 1.0
EC-K9K-176
DIESEL INJECTION
CHART 19
Cont'd
YES

properly.
YES
YES
CR DELPHI 1.0
EC-K9K-177
DIESEL INJECTION
CHART 20 EXHAUST ODOURS
NOTES
diagnostic tool.

NO

properly.
YES
YES
CR DELPHI 1.0
EC-K9K-178
DIESEL INJECTION
CHART 20
Cont'd

NO
CR DELPHI 1.0
EC-K9K-179
DIESEL INJECTION
CHART 21 DIESEL ODOURS
NOTES
diagnostic tool.
Is the high pressure actuator leaking? YES Carry out the required repairs.
NO
Is the diesel temperature sensor leaking? YES Replace the diesel temperature
sensor.
NO

circuit.
CR DELPHI 1.0
EC-K9K-180
DIESEL INJECTION
CHART 22 BLUE, WHITE OR BLACK SMOKE
NOTES
diagnostic tool.
NO
YES

NO
CR DELPHI 1.0
EC-K9K-181
DIESEL INJECTION
CHART 22
Cont'd

NO

properly.
NO
YES
CR DELPHI 1.0
EC-K9K-182
DIESEL INJECTION
CHART 23 BLUE, BLACK OR WHITE SMOKE WHEN ACCELERATING
NOTES
diagnostic tool.
YES

properly.
YES
CR DELPHI 1.0
EC-K9K-183
DIESEL INJECTION
CHART 23
CONTINUED 1

NO

NO
Check that the heater plugs are working

properly.
Is the heater plug resistance above 1 Ω?

YES Replace the heater plugs.
NO
YES

circuit
CR DELPHI 1.0
EC-K9K-184
DIESEL INJECTION
CHART 23
Cont'd
Is the engine wiring harness cut or Carry out the required repairs.
YES
pinched?
NO
CR DELPHI 1.0
EC-K9K-185
DIESEL INJECTION
Circuit Diagram K9K
YEC414A
CR DELPHI 1.0
EC-K9K-186
DIESEL INJECTION
Circuit Diagram K9K
YEC415A
CR DELPHI 1.0
EC-K9K-187
DIESEL INJECTION
Wiring Diagram - Main Power Supply and Ground Circuit K9K
YEC367A
CR DELPHI 1.0
EC-K9K-188
DIESEL INJECTION
Wiring Diagram - Engine Coolant Temperature Sensor K9K
YEC368A
CR DELPHI 1.0
EC-K9K-189
DIESEL INJECTION
Wiring Diagram - Accelerator Pedal Position Sensor K9K
YEC369A
CR DELPHI 1.0
EC-K9K-190
DIESEL INJECTION
Wiring Diagram - Common Rail Fuel Pressure Sensor K9K
YEC370A
CR DELPHI 1.0
EC-K9K-191
DIESEL INJECTION
Wiring Diagram - Injector K9K
YEC371A
CR DELPHI 1.0
EC-K9K-192
DIESEL INJECTION
Wiring Diagram - Injector K9K
YEC372A
CR DELPHI 1.0
EC-K9K-193
DIESEL INJECTION
Wiring Diagram - Boost Sensor K9K
YEC373A
CR DELPHI 1.0
EC-K9K-194
DIESEL INJECTION
Wiring Diagram - Crankshaft Position Sensor K9K
YEC374A
CR DELPHI 1.0
EC-K9K-195
DIESEL INJECTION
Wiring Diagram - Camshaft Position Sensor K9K
YEC375A
CR DELPHI 1.0
EC-K9K-196
DIESEL INJECTION
Wiring Diagram - Vehicle Speed Sensor K9K
YEC376A
CR DELPHI 1.0
EC-K9K-197
DIESEL INJECTION
Wiring Diagram - Intake Air Temperature Sensor K9K
YEC377A
CR DELPHI 1.0
EC-K9K-198
DIESEL INJECTION
Wiring Diagram - Fuel Temperature Sensor K9K
YEC378A
CR DELPHI 1.0
EC-K9K-199
DIESEL INJECTION
Wiring Diagram - Boost Temperature Sensor K9K
YEC379A
CR DELPHI 1.0
EC-K9K-200
DIESEL INJECTION
Wiring Diagram - Accelometer K9K
YEC380A
CR DELPHI 1.0
EC-K9K-201
DIESEL INJECTION
Wiring Diagram - Thermo Plug K9K
YEC381A
CR DELPHI 1.0
EC-K9K-202
DIESEL INJECTION
Wiring Diagram - Thermo Plug K9K
YEC825A
CR DELPHI 1.0
EC-K9K-203
DIESEL INJECTION
Wiring Diagram - Fuel Flow Actuator K9K
YEC422A
CR DELPHI 1.0
EC-K9K-204
DIESEL INJECTION
Wiring Diagram - Cooling System K9K
YEC824A
CR DELPHI 1.0
EC-K9K-205
DIESEL INJECTION
Wiring Diagram - Cooling System K9K
YEC385A
CR DELPHI 1.0
EC-K9K-206
DIESEL INJECTION
Wiring Diagram - ECM Relay K9K
YEC386A
CR DELPHI 1.0
EC-K9K-207
DIESEL INJECTION
Wiring Diagram - Glow Control System K9K
YEC826A
CR DELPHI 1.0
EC-K9K-208
DIESEL INJECTION
Wiring Diagram - EGR Control System K9K
YEC388A
CR DELPHI 1.0
EC-K9K-209
DIESEL INJECTION
Wiring Diagram - Brake Switch K9K
YEC389A
CR DELPHI 1.0
EC-K9K-210
DIESEL INJECTION
Wiring Diagram - Power Steering Motor Signal K9K
YEC390A
CR DELPHI 1.0
EC-K9K-211
DIESEL INJECTION
Wiring Diagram - A/C Cut Signal K9K
YEC392A
CR DELPHI 1.0
EC-K9K-212
DIESEL INJECTION
Wiring Diagram - MI & Data Link Connectors K9K
YEC393A
CR DELPHI 1.0
EC-K9K-213

Ec k9k

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ENGINE CONTROL SYSTEM

Risks relating to contamination

WHAT ARE THE SOURCES OF CONTAMINATION?

Contamination is caused by:

● Use a brush and thinners to clean the connections to be opened.

● Wash your hands before and during the operation if necessary.

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

Nissan part number: 16830 BN700

● The system consists of:

● The injected flow to the engine is determined by:

● The computer controls:

● The engine must not operate with:

● Applying 12 volts directly to any component in the system is prohibited.

● Ultrasonic carbon removal and cleaning are prohibited.

● It is essential to replace all the disconnected air inlet plastic pipes.

There are two possibilities:

● If it is possible to communicate with the computer:

● If it is not possible to communicate with the computer:

After any operation, check that there are no diesel leaks.

Reprime the circuit using the priming bulb.

Clean off the tracing fluid.

The system can be reprogrammed using CONSULT-II.

Before a computer is reprogrammed or replaced in after-sales, the following must be done.

REPLACING THE INJECTORS

The system can be programmed "WORK SUPPORT" mode with CONSULT-II.

The correction values (parameters) must be replaced after replacing an injector.

1 Camshaft position sensor

7 Engine coolant temperature sensor

24 ECM relay (Injection locking relay)

Vehicles Displace- Emission

ENGINE SPEED (rpm) SMOKE OPACITY

DESCRIPTION MARQUE/TYPE SPECIAL NOTES

Fuel pump DELPHI Incorporated into the high pressure pump

Diesel rail pressure sensor Incorporated into the rail

Injectors DELPHI Solenoid injector

Diesel flow actuator DELPHI Located on the high pressure pump

Injection computer DELPHI ECM (computer) (112 terminals)

Pre-heater plugs (glow) Resistance: 0.6 Ω

Accelerator pedal potentiometer CTS Double track potentiometer

Inlet air temperature sensors JAEGER CTN thermistor

Engine coolant temperature sensor ELTH CTN thermistor

Atmospheric pressure sensor DELPHI Incorporated into the computer

Charge air (Turbocharging) DELCO Resistance:

Camshaft position sensor SAGEM Hall effect sensor

Accelerometer SAGEM Non measurable resistance

EGR solenoid valve PIERBURG Resistance:

Disconnect the battery.

Release the diesel fuel filter from its support.

Disconnect all the snap fasteners beginning with the

Disconnect the pump outlet snap fastener last of all;

Reconnect the other snap fasteners.

Prime the system using the priming bulb (automatic

Reconnect the battery.

SPECIAL TOOLING REQUIRED

Nissan No. Tool for removing and refitting high

TIGHTENING TORQUES (in daNm)

High pressure pipe nuts 3.8

IMPORTANT: Before carrying out any work,

YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY

It is strictly forbidden to remove any injection pump

The high pressure pump may be removed after having

Disconnect the battery.