Nissan Primastar X83 (2002-2006) Service Manual #6

112
FUEL MIXTURE
F9Q ENGINE
Air intake 12
AIR INTAKE CIRCUIT DIAGRAM
1 Air-to-air intercooler
2 Air filter
3 Flowmeter
4 Inlet manifold
5 Turbocharger
6 Air inlet
12-1
FUEL MIXTURE
F9Q ENGINE
Air filter 12
FILTER ELEMENT REPLACEMENT
Remove the three screws on the air filter cover to gain

access to the filter element.
12-2
FUEL MIXTURE
F9Q ENGINE
Manifolds 12
Disconnect:
TIGHTENING TORQUES (in daNm) – airflow sensor connector (3),
Manifold mounting stud 0.8 – turbocharger air intake pipe (4).
Manifold mounting nut 2.8 Remove:

– air filter unit mounting nuts (5), then remove it,
Exhaust gas recirculation valve
mounting bolt 0.8
REMOVAL
NOTE:
To remove the manifolds it is necessary to remove the
turbochargers (see Section 12 Turbocharging
turbocharger). The two manifolds cannot be removed
separately.
Put the vehicle on a two-post lift.
Disconnect the battery.
Remove the engine undertray.
Disconnect the heater unit connector (1). – the turbocharger (see Section 12 Turbocharging:
turbocharger).
Remove the heater unit mounting bolt and three nuts
(2), then remove the unit.
12-3
FUEL MIXTURE
F9Q ENGINE
Manifolds 12
Disconnect:
– manifold pressure signal pipe (6),
– manifold air intake pipe (7),
– the electrical exhaust gas recirculation valve (8).
Remove the electrical exhaust gas recirculation

valve mounting bolt (9) and remove the valve.
12-4
FUEL MIXTURE
F9Q ENGINE
Manifolds 12
Remove the exhaust gas recirculation pipe and the lifting lug.
12-5
FUEL MIXTURE
F9Q ENGINE
Manifolds 12
Remove:
– nuts securing the manifolds,
– the manifolds.
REFITTING
Proceed in the reverse order to removal.
Replace the manifold, taking care to replace it correctly, and the exhaust gas recirculation valve seal.
12-6
FUEL MIXTURE
F9Q ENGINE
Air flowmeter 12
REMOVAL – both airflow sensor mounting screws (6) on the air
filter unit,
Disconnect: – the airflow sensor.
– the battery,
– heater unit connector (1).
Remove the heater unit mounting bolt and three nuts

(2), then remove the unit.
Disconnect:
– airflow sensor connector (3), REFITTING
– turbocharger air intake pipe (4).
Proceed with refitting in the reverse order to removal
Remove:
– air filter unit mounting screws (5), then remove it,
12-7
FUEL MIXTURE
F9Q ENGINE
Air flowmeter 12
TRACK ALLOCATION
Connector for air flowmeter with integrated air

temperature sensor.
Track Description
1 Air temperature
2 Earth
3 5 V reference
4 + battery
5 Air flowmeter signal
6 Earth
Air temperature sensor resistance (between tracks 1

and 2): ≈ approximately 2170 Ω at 20 °C.
12-8
TURBOCHARGING
F9Q ENGINE
Pressure regulating valve 12
The diaphragm (A) of the pressure regulation valve is The solenoid valve, closed in the rest position, is
controlled by a solenoid valve (B) which is managed by supplied after the engine is started following a delay
the injection computer. This solenoid valve varies the according to the coolant temperature.
vacuum according to the engine operating range,
which enables the turbocharging pressure to be
regulated.
X Timed period (seconds)

Y Temperature (°C)
The pressure regulation valve is open in rest position.

The engine operates as normally aspirated.
12-9
TURBOCHARGING
F9Q ENGINE
Turbocharger pressure adjustment 12
TURBOCHARGER PRESSURE CONTROL VALVE Calibration value
(WASTEGATE)
NOTE: Vacuum value

Rod movement (mm)
The limiter valve functions in the opposite way to (mbar)
conventional assemblies.
120 between 1 and 4
The absence of control pressure limits the 400 between 10 and 12
turbocharging pressure.
> 450 Rod at stop
Check that there are no leaks between the vacuum
pump and the control valve.
On the vehicle itself
Calibration pressure check
It may be necessary to adjust the wastegate rod length
Operation on the vehicle. (A) (if the pressure is not within tolerance) when
checking the calibration pressure.
Loosen the lock nut (1).
Use a magnetic base fitted with a gauge which should

be positioned at the end of the wastegate rod
(inserted as close as possible to the centre line of the
wastegate). Carry out the adjustment by tightening or loosening the
adjusting wheel (2) half a turn at a time until the correct
A vacuum is applied gradually to the wastegate using calibration pressure is obtained.
pressure gauge Mot. 1014.
NOTE:
Check the calibrating pressure after retightening the
locknut (1).
Confirm the repair with a road test, checking

parameters Wastegate opening cyclic ratio and
Turbocharging pressure on the diagnostic tools.
12-10
TURBOCHARGING
F9Q ENGINE
Turbocharger 12
TIGHTENING TORQUES (in daNm)
Turbocharger mounting nut 2.4 ± 1
Oil inlet union on the turbocharger

2.4 ± 4
Engine oil supply connection 2.6 ± 0.2
Oil return union bolt 1.2 ± 0.1
Catalytic converter mounting nuts on
the turbocharger 2.6 ± 0.2
REMOVAL
NOTE: – both exhaust system mounting nuts (6) and allow it to

To loosen the turbocharger mounting nuts on the rest on the engine sub-frame.
exhaust manifold, it helps to spray some unlocking fluid
onto the nuts while they are still warm, just before
removal.
Remove the engine undertray.
Disconnect:
– airflow meter connector (3),
Remove:
– air filter unit mounting screws (5), then remove it,
12-11
TURBOCHARGING
F9Q ENGINE
Turbocharger 12
Remove: Remove:
– the catalytic converter mounting stays (1) and (2), – turbocharger oil supply pipe (5),
– the nuts (3) securing the catalytic converter to the – turbocharger oil return pipe (6),
turbocharger, – three turbocharger mounting nuts (7),
– the catalytic converter. – the turbocharger.
Disconnect:
– wastegate diaphragm control pipe (4),
– the turbocharger air intake and outlet pipes.
12-12
TURBOCHARGING
F9Q ENGINE
Turbocharger 12
REFITTING
Special precautions
For refitting operations, use the reverse procedure to
removal. ● Before refitting, check that the turbocharger
bearings are correctly greased. To do this,
IMPORTANT: activate the starter motor having first
It is essential to replace the leather seal on the disconnected the high pressure regulator
turbocharger oil inlet union and the oil return pipe seal. connector (to prevent the engine from starting)
(clear the computer memory). Sufficient oil should
IMPORTANT: arrive via the oil pressure pipes (place a container
Before starting the engine, leave the pressure regulator underneath). If this is not the case, change the
connector on the high pressure pump disconnected. lubrication pipe.
Then run the starter motor until the oil pressure warning ● Ensure that no foreign bodies enter the turbine or
light goes out (do this for a few seconds). compressor during the refitting operation.
Reconnect the regulator, preheat and start the engine. ● If there has been a fault in the turbocharger, check
Run the engine at idle speed and check that there are that the air-to-air intercooler is not full of oil. If the
no leaks at the oil connections. air-to-air intercooler is full of oil, it must be
Clear the fault and check the turbocharging pressure removed, flushed with a cleaning agent and then
solenoid valve sensor. left to drain properly.
● Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
12-13
TURBOCHARGING
F9Q ENGINE
Air-to-air intercooler 12
REMOVAL
Remove the retaining clip screw (1).
Disconnect:
– air-to-air intercooler air intake pipe (2),
– air-to-air intercooler air outlet pipe (3),
REFITTING
Refitting is the reverse of removal.
Remove:
– air-to-air intercooler mounting bolts (4),
– air-to-air intercooler.
12-14
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DIESEL EQUIPMENT
F9Q ENGINE
Specifications 13
Engine
Vehicle Gearbox Cubic Emission

Bore Stroke Compression
Type Suffix capacity control
(mm) (mm) ratio
(cm3) standard
XLOC PK5 and

F9Q 760 80 93 1870 19 / 1 EU 00
XLOB PK6
ENGINE SPEED (rpm) FUME OPACITY
Maximum - full Homologation Maximum -

Idle speed Maximum - no load
load value maximum
800 ± 50 rpm 4160 ± 150 rpm 3700 ± 100 rpm 1.7 m-1 (50%) 3 m-1 (70%)
Description Make/Type Special notes
High-pressure pump BOSCH CR / CP3 Pressure from 250 to 1350 bar
Booster pump (low-pressure) BOSCH EKP3 Pressure 2.5 bar maximum

Flow: 80 to 100 l/h minimum
Diesel pressure sensor BOSCH Screwed to the injection rail

Resistance: tracks 1,2 and 1,3 = 4,3 MΩ
tracks 2, 3 = 1050 Ω
Injectors BOSCH Solenoid injector

Resistance: < 2 Ω
Maximum pressure 1600 bar
Pressure regulator Incorporated in the high-pressure pump (not

- removable)
Resistance: approximately 5 Ω at 20 °C
Injection computer BOSCH EDC 15 128-track computer
Accelerator pedal sensor HELLA Dual track potentiometer

Track 1 resistance: 1200 ± 480 Ω
Track 2 resistance: 1700 ± 680 Ω
Pre/postheating unit NAGARES BED/7 With pre/post-heating function controlled by the

injection computer
Engine speed sensor MGI Resistance: 800 ± 80 Ω at 20 °C
13-1
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F9Q ENGINE
Specifications 13
Preheater plugs BERU or CHAMPION Resistance: 0.6 Ω connector disconnected
Air intake temperature sensor SIEMENS Incorporated in the air flowmeter

Resistance = approximately 2170 Ω at 20 °C
Diesel temperature sensor MAGNETTI Resistance = approximately 2050 Ω at 25 °C

MARELLI and
ELTH
Atmospheric pressure sensor - Incorporated into the computer
Camshaft sensor ELECTRICIFIL Hall effect sensor
Turbocharging pressure DELCO Resistance: 4 kΩ across tracks A and C

sensor Resistance: 5 kΩ across tracks B and C
Resistance: 9 kΩ across tracks A and B
Turbocharger control solenoid BITRON Resistance: 16.5 ± 1 Ω at 25 °C

valve
Air flowmeter SIEMENS Air flowmeter with integrated air temperature

sensor
Track 1: air temperature
Track 2: earth
Track 3: 5 V reference voltage
Track 4: + battery
Track 5: airflow signal
Track 6: earth
Exhaust gas recirculation PIERBURG/SIEBE Track resistance: 8 ± 0.5 Ω at 20 °C (tracks 1 and 5)

system solenoid valve Sensor resistance: 4 ± 1.6 kΩ at 20 °C (tracks 2
and 4)
13-2
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F9Q ENGINE
Specifications 13
Turbocharger ALLIED SIGNAL Wastegate setting:

(fixed geometry turbo)
120 mbar for rod travel between 1 and 4 mm
400 mbar for rod travel between 10 and 12 mm
> 450 mbar with rod at end of travel
Thermoplungers - Resistance: 0.45 ± 0.05 Ω at 20 °C
Engine coolant temperature ELTH Resistance: 2252 ± 112 Ω at 25 °C

sensor
13-3
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F9Q ENGINE
Special notes 13
The Common Rail high-pressure injection system is designed to deliver a certain quantity of diesel fuel to the
engine at a precisely determined moment.
DESCRIPTION
The system consists of:

– a low-pressure pump (1) (located in the fuel tank),
– a fuel filter (2),
– a priming valve (3),
– a high-pressure regulator (4) mounted on the pump (it is forbidden to separate the regulator from the pump. If there
is a fault in one component, both must be replaced),
– a high-pressure pump (5),
– an injection rail (6) fitted with a diesel fuel pressure sensor and a pressure limiter (7),
– four solenoid injectors,
– various sensors,
– an injection computer.
Dismantling the interior of the high-pressure pump and the injectors is prohibited.
13-4
DIESEL EQUIPMENT
F9Q ENGINE
Special notes 13
OPERATION
The Common Rail high-pressure direct injection system is a sequential diesel injection system (based on the
multipoint injection system 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 low-pressure pump (also known as the booster pump) feeds the high-pressure pump via the fuel filter during
the starting phase only.
The high-pressure pump generates the high pressure sent to the injector rail. The high-pressure regulator located on
the pump modulates the value of the high pressure via the computer. The rail supplies each injector through a steel
pipe.
The computer:
– determines the value of injection pressure necessary for the engine to operate correctly 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
start,
– 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 the type of injector),
– the normal hydraulic flow of the injector (determined by the type of injector),
– the high-pressure rail pressure controlled by the computer.
THE CLEANLINESS AND SAFETY ADVICE SPECIFIED IN THIS DOCUMENT MUST BE FOLLOWED DURING
ANY WORK CARRIED OUT ON THE HIGH-PRESSURE INJECTION SYSTEM.
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DIESEL EQUIPMENT
F9Q ENGINE
Special notes 13
POST-REPAIR CHECK
Re-prime the circuit. To do this, turn the low-pressure pump over by switching on the ignition several times, or turn
the low-pressure pump over with the diagnostic tool using the Actuator Commands menu.
After any operation, check that there are no diesel fuel leaks. Run the engine at idle speed until the engine
cooling fan starts up, then accelerate several times with no load.
IMPORTANT: the engine must not be run with diesel fuel containing more than 10% diester.
The system injects the diesel fuel into the engine at a pressure of up to 1350 bar. Before carrying out any
work, check that the injector rail is depressurized.
It is absolutely vital that you observe the tightening torque:

– of the high-pressure pipes,
– of the cylinder head injector,
– of the pressure sensor.
When the high-pressure pump, injectors and high pressure supply, output and return unions are removed
or repaired, all openings should be fitted with new blanking plugs of the correct size to prevent
contamination entering.
When replacing the high-pressure pipe, follow the method below:

– remove the high-pressure pipe,
– fit anti-contamination plugs,
– loosen the high-pressure rail,
– fit the high-pressure pipe,
– torque-tighten the union at the injector side,
– torque-tighten the union at the high-pressure rail side,
– torque-tighten the high-pressure rail mountings,
– torque-tighten the pump/rail pipe (pump side first).
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Special notes 13
Dismantling the interior components of the pump is prohibited.
The fuel return pipe fitted to the injectors must be replaced when it is removed.
The diesel temperature sensor cannot be removed. It is part of the fuel return rail.
Loosening a High-pressure pipe connection when the engine is running is prohibited.
It is forbidden to remove the pressure regulator from the pump (type CP3).
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DIESEL EQUIPMENT
F9Q ENGINE
Cleanliness 13
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 to or destruction of the high-pressure injection system,
– a component seizing or leaking.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) should get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter through 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 hairs,
– ambient air,
– etc.
IMPORTANT: it is not possible to clean the engine using a high-pressure washer because of the risk of damaging
connections. Furthermore, moisture may collect in the connectors and cause 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 available from the Parts Stores). 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 the resealable plastic bags for storing removed parts. There is less risk of parts stored in this
way being exposed to contamination. The bags must be used only once, and after use they must be thrown away.
● Make sure that lint-free towelettes are to hand. Towelette part number: 77 11 211 707. The use of conventional
cloth or paper wipes is prohibited. They are not lint-free and may contaminate the fuel circuit of the system. Each
lint-free cloth should only be used once.
13-8
DIESEL EQUIPMENT
F9Q ENGINE
Cleanliness 13
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
● Use new thinner for each operation, (used thinner contains impurities). Pour it into a clean receptacle.
● For each operation, use a clean brush 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 them 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. They must not, under any circumstances, be reused.
● Close the resealable bag, even if it has to be reopened shortly afterwards. Ambient air carries impurities.
● All components removed from the injection system must be stored in a hermetically sealed plastic bag once 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.
In fact, these elements are liable to cause the entry of impurities into 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.
13-9
DIESEL EQUIPMENT
F9Q ENGINE
Cleanliness 13
13-10
DIESEL EQUIPMENT
F9Q ENGINE
Location of components 13
1 Diesel fuel filter with heater

2 Camshaft sensor
3 Air flowmeter with air temperature sensor
4 Exhaust gas recirculation valve
5 Thermoplunger unit
6 Turbocharger regulation solenoid valve
7 Turbocharging pressure sensor
8 Injection computer
9 Impact sensor
10 Preheating unit
11 Coolant temperature sensor
12 Engine speed sensor
13 Solenoid injector
14 High-pressure pump
13-11
DIESEL EQUIPMENT
F9Q ENGINE
1 High-pressure pump
2 Common injection rail
3 Injector
4 Pressure regulator
5 Pressure sensor
6 Fuel temperature sensor
7 Pressure limiter
13-12
DIESEL EQUIPMENT
F9Q ENGINE
8 Cylinder marking sensor 12 Exhaust gas recirculation system valve

13 Thermoplunger unit
14 Turbocharger regulation solenoid valve

9 Priming catalytic converter 15 Turbocharger pressure sensor
10 Turbocharger 16 Preheating unit
11 Airflow sensor with integrated temperature sensor
13-13
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F9Q ENGINE
17 Fuel filter 19 Injection computer
18 Impact sensor 20 Accelerator potentiometer
13-14
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F9Q ENGINE
Injection warning light 13
Vehicles using the high-pressure diesel fuel system are fitted with two injection warning lights. These warning lights
are used during the preheating phase and when there is an injection fault.
PRINCIPLE FOR WARNING LIGHTS COMING ON
● The 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 control).
● When there is an injection fault (severity level 1), the fault warning light which is also the preheating warning light
comes on permanently, indicating the need to consult a Renault Dealer. These faults are:
– internal computer fault,
– engine immobiliser fault,
– engine speed fault (vehicle does not start),
– accelerator potentiometer fault,
– air flowmeter fault,
– vehicle speed sensor fault,
– exhaust gas recirculation valve fault,
– turbocharger regulation solenoid valve fault,
– turbocharging pressure sensor fault,
– Top Dead Centre sensor and camshaft sensor synchronisation fault.
● When there is a serious injection fault (level 2), the warning light with the symbol of an engine and the word STOP
flashes to indicate that the vehicle must be stopped immediately. These faults are:
– internal computer fault,
– injector fault,
– computer supply voltage fault,
– rail pressure sensor fault,
– rail pressure regulator fault,
– Top Dead Centre sensor and camshaft sensor synchronisation fault.
● If the engine overheats, the warning light with the engine symbol and the word STOP remains lit.
13-15
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F9Q ENGINE
Immobiliser function 13
This vehicle is fitted with an engine immobiliser system which is controlled by a key recognition system.
REPLACING AN INJECTION COMPUTER
Injection computers are supplied without a code, but they can all be programmed with one.
If a computer is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine
immobiliser function must be ensured.
To do this, switch on the ignition for a few seconds without starting the engine, then switch it off. With the ignition off,
the engine immobiliser function comes into operation after approximately 10 seconds (the red engine immobiliser
warning light flashes).
SPECIAL NOTES ON TESTING THE INJECTION COMPUTER
WARNING:
These vehicles have a special injection computer which does not operate unless it is coded.
Consequently, it is strongly recommended not to carry out tests using computers borrowed from the stores or from
another vehicle, to prevent coding and uncoding problems which could render the computers useless.
13-16
DIESEL EQUIPMENT
F9Q ENGINE
Injection/air conditioning programming 13
THIS VEHICLE IS FITTED WITH A VARIABLE DISPLACEMENT COMPRESSOR
There is no air conditioning computer on this type of engine. The injection computer controls the compressor clutch
according to the request for the compressor to operate (Air conditioning function requested by the driver), which
can be interrupted at any moment by the coolant pressure sensor.
The tracks used for the air conditioning function are:

– one wire on track A F4 of the computer which controls the air conditioning compressor clutch,
– one wire on track A G4 of the injection computer. This wire carries the request for the compressor to start operating.
When the air conditioning function is selected, the idle speed does not change; it is
800 rpm.
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the injection computer prevents the compressor from operating.
Engine starting program
The compressor is prevented from operating for 2 seconds after the engine has started.
Recovery of output when the vehicle starts moving
If the potentiometer position is greater than 45%, and the vehicle speed is below 15 mph (25 km/h), the compressor
is cut off.
Anti-stall protection
During vthrottle-off, if the engine speed is below 675 rpm, the compressor clutch is disengaged. It is re-engaged
when the engine speed exceeds this figure.
Thermal protection program
The compressor does not come into operation when the coolant temperature is greater than + 102 °C.
13-17
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F9Q ENGINE
Idle speed correction 13
IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
X: Engine speed in rpm.

Y: Coolant temperature in °C
CORRECTION ACCORDING TO ELECTRICAL LOAD
The purpose of this adjustment is to compensate for the drop in voltage due to a power consumer being switched on
when the battery is not charged sufficiently. To achieve this, the idle speed is increased, which increases the speed
of rotation of the alternator, and this increases the battery voltage.
The lower the voltage, the more significant the correction. Correction of the engine speed is therefore variable. It
begins when the voltage drops to below approximately 12 V. Idle speed may reach a maximum speed of 900 rpm.
IDLE SPEED CORRECTION WHEN THE POTENTIOMETER IS FAULTY
If the idle speed is held at 1250 rpm. if the accelerator pedal potentiometer is faulty.
If the signal from the accelerator pedal position potentiometer and the brake switch signal are inconsistent, the
speed is changed to 1250 rpm.
IDLE SPEED CORRECTION WHEN DRIVING
The travelling idle speed is modified according to the gear engaged in the gearbox:
– in 1st and 2nd gear, the idle speed is 825 rpm,
– for other gears the speed is 870 rpm.
IDLE SPEED LIMITATION WHEN STATIONARY
If the vehicle is stationary with a gear engaged (clutch pedal depressed), then the maximum engine speed is limited
to 3000 rpm.
13-18
DIESEL EQUIPMENT
F9Q ENGINE
Pre/postheating control 13
The pre/postheating function is controlled by the 2) Starting the engine
preheating unit.
The plugs remain supplied while the starter is being
PRE/POSTHEATING OPERATING PRINCIPLE activated.
1) Switching on the preheating

3) Engine running, postheating
a) Variable preheating
During this phase, the plugs are supplied
The length of time that the warning lights are on continuously according to the coolant temperature.
and the heater plugs supply depends on the
coolant temperature and the battery voltage.
For idle speed without pressing the accelerator pedal.
X Time in seconds
Y Coolant temperature in °C X Time in seconds
Y Coolant temperature in °C
In all cases the preheating warning light cannot
light up for more than 10 seconds.
b) Fixed preheating
After the warning light goes out the plugs remain

supplied for a fixed period of 10 seconds.
13-19
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F9Q ENGINE
Preheater plugs 13
The preheating plug resistance is 0.6 Ω (connector
disconnected).
TIGHTENING TORQUE (in daNm)
Pre-heater plugs 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 impurities

entering the cylinder.
Loosen and remove the plugs.
REFITTING
Proceed in the reverse order to removal.
Ensure that no contamination enters the cylinder

during this operation.
13-20
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F9Q ENGINE
Thermoplunger 13
The four thermoplungers are located on a water unit Control strategy
mounted on the engine lifting bracket.
When the thermoplungers are operating the idle speed
The purpose of the system is to reheat the coolant. is brought to 825 rpm.
The thermoplungers are supplied with 12 V by three Thermoplungers cannot operate:

relays. One relay controls two thermoplungers, the two – preheating,
other relays control one thermoplunger each. This – post-heating,
enables control of one, two, three or four – if the engine speed is below 700 rpm,
thermoplungers as required. – heated windscreen on.
The resistance of the thermoplungers is: If the conditions mentioned above apply, the
0.45 ± 0.05 Ω at 20 °C. thermoplungers are controlled according to a mapping
related to the air and coolant temperature.
X Coolant temperature in °C
Y Air temperature in °C
Non-shaded area: thermoplunger not supplied

Shaded area: thermoplunger supplied
13-21
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F9Q ENGINE
Thermoplunger 13
If the battery voltage is > 13.5 V
If not Then
Thermoplungers not supplied One thermoplunger is supplied
If after 20 seconds the battery

voltage is > 13.5 V
If not Then
Thermoplungers not supplied Two thermoplungers supplied

voltage is > 13.5 V
If not Then
Thermoplungers not supplied Three thermoplungers supplied

voltage is > 13.5 V
If not Then
Thermoplungers not supplied Four thermoplungers are supplied if

the battery voltage is > 13.5 V and in
the conditions mentioned above
13-22
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F9Q ENGINE
Low pressure pump (booster pump) 13
SPECIAL TOOLING REQUIRED
Mot. 1397 Fuel pump securing nut
IMPORTANT: Disconnect:
During all operations on the fuel tank or fuel supply – anti-splashback pipe (1),
circuit, it is vital to: – fuel tank filler neck (2).
– refrain from smoking or bringing incandescent
objects close to the work area,
– protect yourself against diesel fuel splashes when
the pipes are removed (due to residual pressure).
REMOVAL
WARNING: before removing any components, take

precautions to trap fuel running out of the pipes (do not
clamp pipes, this could damage them).
Remove the fuel tank filler pipe access flap.
Place a component jack under the tank to hold it.
13-23
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F9Q ENGINE
Remove the fuel tank mounting bolts (3).
Remove the pump mounting nut (7) using tool

Mot.1397.
Lower the tank slightly to be able to gain access to the
fuel pipes and the electrical wiring. Allow any fuel in the sender unit to drain, then remove
the pump-sender assembly, taking care not to damage
Disconnect: the float.
– pump electrical connector (4),
– fuel return pipe (5),
– fuel outlet pipe (6). NOTE: if it is anticipated that several hours will elapse
between removal and refitting of the pump-sender
assembly, screw the nut back on the fuel tank to
prevent any distortion.
Remove the fuel tank and drain it if necessary.
13-24
DIESEL EQUIPMENT
F9Q ENGINE
REFITTING
Replace the sealing gasket.
Refit the pump/sender assembly, positioning the mark

on the sender unit (8) opposite the three raised lines
(9) on the tank.
Refit the nut and tighten to a torque of 6 daNm.
After tightening, check that the mark (8) on the pump/

sender assembly does in fact line up with the marks
(9) on the tank.
For the other refitting operations, proceed in the

reverse order to removal.
Re-prime the circuit. To do that, turn the low-pressure

pump over by switching on the ignition several times,
or turn the low-pressure pump over with the diagnostic
tool using the Actuator Commands menu.
13-25
DIESEL EQUIPMENT
F9Q ENGINE
Fuel filter 13
The fuel filter is located in the engine compartment. It Unscrew the filter cover (4) and remove the filter
is contained in a removable cartridge. This cartridge cartridge.
contains a diesel fuel heater.
To replace the filter it is therefore necessary to remove

the whole unit.
REMOVAL
FOLLOW THE CLEANLINESS INSTRUCTIONS

CLOSELY
WARNING: watch out for the residual pressure and

the quantity of diesel fuel remaining in the pipes.
Disconnect from the filter:

– the diesel fuel heater connector (1),
– the fuel supply pipe to the engine (2),
– the pipes (3) coming from the tank,
Remove the filter by unclipping it from its support. REFITTING
Take care to line up the mark on the cover and the

mark on the bowl correctly.
It is vital to respect the position of the connections to

the filter.
Be careful not to squeeze or damage the pipes.
IMPORTANT: re-prime the system by switching on the

ignition several times, or turn the low-pressure pump
over with the diagnostic tool using the Actuator
Commands menu.
From time to time it is necessary to bleed the water

trapped in the diesel fuel filter via the bleed plug (5).
13-26
DIESEL EQUIPMENT
F9Q ENGINE
Checking diesel pressure and flow 13
It is possible to check the pressure and flow in the low-pressure fuel circuit.
The low pressure is provided by the booster pump (electric pump fitted in the fuel tank which feeds the high-pressure
pump during starting phases).
Mot. 1311-01
or Fuel pressure test kit
Mot. 1328
Mot. 1311-03 I adapter for fuel pressure test
kit
EQUIPMENT REQUIRED
2000 ml graduated cylinder
LOW PRESSURE CHECK (BOOSTER PUMP) FLOW TEST (BOOSTER PUMP)
Fit an I adapter, Mot. 1311-03, to be able to connect Make the pump flow into a 2000 ml graduated cylinder.
the fuel pressure test kit Mot. 1311-01 to the outlet (2) Turn on the ignition to run the pump. The pump is
of the fuel filter. supplied for 10 seconds if the engine is not started.
Turn over the fuel pump with the diagnostic tool or by The flow read should be 80 to 100 l/h minimum.
direct feed to the pump or by switching on the ignition.
WARNING: it is forbidden to measure the pressure
Read the pressure, which should be 2.5 bar and flow of the high-pressure pump.
maximum.
13-27
DIESEL EQUIPMENT
F9Q ENGINE
High-pressure pump 13
DISMANTLING THE PUMP INTERNALS IS
PROHIBITED
Mot. 1054 TDC setting pin

Mot. 1383 Tool for removing and refitting
the high-pressure pipes
Mot. 1200-02 Pump pulley retaining tool
Mot. 1525 Pulley extractor
Mot. 1525-01 Extractor claws for F9Q
Mot. 1367 Engine support bar
Mot. 1367-02 Engine support tool
EQUIPMENT REQUIRED
Low torque wrench
TIGHTENING TORQUE (in daNm and/or °)
High-pressure pipe 2.5 ± 0.2
High-pressure pump mounting 3 ± 0.3
Rear pump support mounting 3 ± 0.3
High-pressure pump pulley nut 1.5 then 60 ± 10°
Injection rail mounting bolt 2.2 ± 0.2
WARNING: before carrying out any work, connect

the diagnostic tool to the injection computer and check
that the injection rail is not pressurized.
Make a note of the fuel temperature.
13-28
DIESEL EQUIPMENT
F9Q ENGINE
– radiator grille mounting screws (6),
– radiator grille.
CLOSELY
REMOVAL
Disconnect:
– the battery,
– heater unit connector (1).
Remove:
– heater unit bolt and three nuts (2),
– heater unit.
Disconnect the headlight units.
Remove:
– both headlight unit mounting bolts (7),
– the headlight units.
Disconnect:
– airflow sensor connector (3),
Remove:
– air filter unit mounting bolts (5),
– the air filter unit,
13-29
DIESEL EQUIPMENT
F9Q ENGINE
Remove: – bolt through the bumper (11),
– bonnet catch (8), – front upper cross member central mounting bolts
– upper bumper mounting bolts (9), (12), then the reinforcing strut,
– air/air heat exchanger air inlet and outlet pipes, – cooling radiator mounting bolts (13),
– computer shield mounting bolt (14),
– front upper cross member mounting bolts (15),
– upper cross member by pivoting it round the bumper.
– air/air heat exchanger air inlet and outlet pipes (10),
13-30
DIESEL EQUIPMENT
F9Q ENGINE
Disconnect: – High-pressure pipes using tool Mot. 1383, then fit
– pressure regulator (1), plugs,
– pressure sensor (2),
– fuel temperature sensor (3).
Move the electrical wiring loom aside.
– rail mounting bolts (4),

– the rail,
– rear pump support mounting bolts (5),
– the rear pump support.
Remove:
– diesel fuel supply and return pipes, then fit plugs,
13-31
DIESEL EQUIPMENT
F9Q ENGINE
Set the engine to Top Dead Centre using pin Place the pulley retaining tool Mot. 1200-02 in position
Mot. 1054. on the pulley.
Put the engine support tools Mot. 1367 and Remove:

Mot. 1367-02 in position. – High-pressure pump gear nut (2).
Remove the suspended engine mounting.
– High-pressure pump mounting nuts (3).
Remove:
– timing cover screws (1),
– the timing cover.
13-32
DIESEL EQUIPMENT
F9Q ENGINE
Position the F9Q extractor claws for Mot. 1525-01,
then the pulley extractor Mot. 1525.
Extract the pump by tightening the thrust bolt (4) of the

pulley extractor.
13-33
DIESEL EQUIPMENT
F9Q ENGINE
REFITTING Refitting the rail and the High-pressure pipes
Leave removal of the protection plugs from any Refit the rail and hand-tighten the mounting bolts
component until last. without tightening them (the rail must be loose).
For refitting operations, proceed in the reverse order to Refit the High-pressure pipes by hand-tightening the
removal. nuts at the pump and injectors end, then the rail end.
NOTE: be careful not to put the High-pressure pipes or Tighten the rail mounting bolts (3) to a torque of
the rear pump support under any strain. 2.2 daNm.
To do this: Torque-tighten the High-pressure pipes to 2.5 daNm,

tightening the nuts at the pump and injectors end first,
then the rail end.
Refitting the rear pump support
Refit the rear pump mounting and hand-tighten the

mounting bolts so as to bring the mounting into contact
with the cylinder head and the pump.
Torque-tighten the rear pump support mounting bolts

to 3 daNm, tightening bolt (1) on the pump first, then
bolts (2) on the cylinder head.
13-34
DIESEL EQUIPMENT
F9Q ENGINE
The diesel fuel return pipe (4) must be replaced every
time it is removed.
Refit the suspended engine mounting (refer to the

procedure in Section 19).
The remaining refitting operations are performed in the


Commands menu.
13-35
DIESEL EQUIPMENT
F9Q ENGINE
Injector rail 13

EQUIPMENT REQUIRED
Low torque wrench
TIGHTENING TORQUE (in daNm)
Pressure sensor 3.5 ± 0.2
IMPORTANT: before carrying out any work, connect

the diagnostic tool, establish dialogue with the injection
computer and check that the injection rail is no longer
pressurized.
13-36
DIESEL EQUIPMENT
F9Q ENGINE
Injector rail 13
CLOSELY
REMOVAL
Disconnect:
– heat exchanger air intake pipe (2),
Disconnect:
– pressure regulator (6),
– pressure sensor (7),
– fuel temperature sensor (8).
Move the electrical wiring loom aside.

Remove:
– the air filter unit.
13-37
DIESEL EQUIPMENT
F9Q ENGINE
Injector rail 13
Remove: REFITTING
– diesel fuel supply and return pipes, then fit plugs,
Leave removal of the protection plugs from any
component until last.
Refit the rail and hand-tighten the mounting bolts

without tightening them (the rail must be loose).
Refit the High-pressure pipes by hand-tightening the

nuts at the pump and injectors end, then the rail end.
Tighten the rail mounting bolts (3) to a torque of

2.2 daNm.
Torque-tighten the High-pressure pipes to 2.5 daNm,

tightening the nuts at the pump and injectors end first,
then the rail end.
– High-pressure pipes using tool Mot. 1383, then fit

plugs,
– rail mounting bolts (9),

– the rail.
13-38
DIESEL EQUIPMENT
F9Q ENGINE
Injector rail 13
time it is removed.


Commands menu.
13-39
DIESEL EQUIPMENT
F9Q ENGINE
Injectors 13
IT IS FORBIDDEN TO DISMANTLE THE INSIDE OF
AN INJECTOR OR TO SEPARATE THE INJECTOR
HOLDER FROM THE NOZZLE.

EQUIPMENT REQUIRED
Low torque wrench
TIGHTENING TORQUES (in daNm)
Injector clamp mounting bolt 2.5 ± 0.5

computer and check that the injection rail is not
pressurized.
13-40
DIESEL EQUIPMENT
F9Q ENGINE
Injectors 13
CLOSELY
NOTE: injectors may be replaced individually.
REMOVAL
Disconnect:
– diesel fuel return pipe, then fit plugs,

Remove:
13-41
DIESEL EQUIPMENT
F9Q ENGINE
Injectors 13
Remove the high-pressure pipe using tool Mot. 1383. REFITTING
Fit anti-pollution plugs. Leave removal of the protection plugs from any
component until last.
Disconnect the injector connector.
Change the washer beneath the injector.
Remove:
– the injector mounting clamp,
– the injector,
– the flame shield washer.
Refit the injector.
Torque-tighten the injector flange bolts to 2.5 daNm.
CLEANING NOTE: be careful not to place the High-pressure pipes

under any strain.
It is absolutely forbidden to use the following when
cleaning the injector:
To do this:
– a wire brush,
– undo the injection rail (the rail should be loose),
– an emery cloth,
– refit the High-pressure pipes by hand-tightening the
– an ultrasonic cleaner.
nuts at the injectors end first,
– tighten the rail mounting bolts to a torque setting of
To clean the nose of the injector, let it soak in
2.2 daNm,
degreaser, then wipe it with a lint-free cloth.
– torque-tighten the High-pressure pipes to 2.5 daNm,
tightening the nuts at the injectors end first.
13-42
DIESEL EQUIPMENT
F9Q ENGINE
Injectors 13
time it is removed.


Commands menu.
13-43
DIESEL EQUIPMENT
F9Q ENGINE
Pressure sensor 13
TIGHTENING TORQUE (in daNm) – turbocharger air intake pipe (4).
Pressure sensor 3.5 ± 0.2 Remove:

computer and check that the injection rail is not under
pressure.
REMOVAL
Disconnect:
13-44
DIESEL EQUIPMENT
F9Q ENGINE
Pressure sensor 13
Disconnect the pressure sensor (6). REFITTING
Replace the seal.
Screw in the sensor and torque-tighten it to 3.5 daNm.
Connect the sensor.


Commands menu.
Remove the pressure sensor (7).
13-45
DIESEL EQUIPMENT
F9Q ENGINE
Accelerator potentiometer 13
GENERAL INFORMATION Track allocation:
The accelerator pedal potentiometer is incorporated in

the accelerator pedal. Its replacement therefore
Track Description
requires replacement of the accelerator pedal.
1 Track 2 earth
REMOVAL 2 Track 1 earth

3 Track 1 signal
Disconnect:
– the battery, 4 Track 1 feed
– the accelerator pedal connector (1).
5 Track 2 feed
Remove: 6 Track 2 signal
– the three pedal mounting bolts (2),
– the pedal.
NOTE: a fault on the accelerator position

potentiometer causes variations in the idle speed or
REFITTING engine operation (see Section 13 Idle speed
correction).
Refitting is the reverse of removal.
13-46
DIESEL EQUIPMENT
F9Q ENGINE
Central coolant temperature management 13
OPERATION
The injection computer uses the coolant temperature

to control:
– the injection system,
– the fan relay:
● the cooling fan is activated at low speed then at
high speed if the coolant temperature exceeds
90 °C and stops when the temperature falls below
95 °C,
● the fan unit can be controlled by the air
conditioning.
COOLANT TEMPERATURE WARNING LIGHT
The warning light is controlled by the computer via the

multiplex network.
It lights up when the coolant temperature exceeds

115 °C and goes out when the temperature falls below
110 °C.
The coolant temperature sensor (1) (injection and
coolant temperature indicator on the instrument panel)
is a three-track sensor.
Two tracks for the coolant temperature signal to the

computer (tracks B E1 and B K3).
This system allows the engine cooling fan to be

controlled by the injection computer. It consists of a
single temperature sensor used for the injection, the
engine cooling fan, the temperature indicator and the
temperature warning light on the instrument panel.
13-47
DIESEL EQUIPMENT
F9Q ENGINE
Computer 13
GENERAL INFORMATION
The injection computer is located behind a sheet metal

shield under the expansion bottle.
REMOVAL
Remove the expansion bottle mounting screw (1) and

move it out of the way.
Disconnect:
– the turbocharger regulation solenoid valve (2),
– the turbocharging pressure sensor (3) and unclip it,
– the preheating unit.
– computer mounting bolts (5) and remove it, having

disconnected it beforehand.
Remove:
– metal shield mounting bolts (4) and remove it from
above,
REFITTING
Proceed with refitting in the reverse order to removal.
If the computer has been replaced, carry out

programming of the immobiliser code by following the
procedure described in the Section Immobiliser.
13-48
DIESEL EQUIPMENT
F9Q ENGINE
Computer 13
TRACK ALLOCATION
CONNECTOR A
A3 --- Load potentiometer earth (track 2)

A4 →← CAN L MULTIPLEX LINK (Passenger compartment)
B1 ← Heated windscreen input
B3 --- Load potentiometer earth (track 1)
B4 →← CAN H MULTIPLEX LINK (Passenger
compartment)
C1 ← Load potentiometer signal input (track 1)
C3 →← Fault finding
E1 --- Load potentiometer feed (track 1)
E2 ← Clutch switch input
E4 ← Vehicle speed input
F1 ← Load potentiometer signal input (track 2)
F3 ← Brake switch input
F4 → Air conditioning compressor control output
G4 ← Air conditioning request input
H2 --- Load potentiometer feed (track 2)
CONNECTOR B
B2 --- Exhaust gas recirculation system position

potentiometer earth
B3 ← Plugs fault-finding input
C1 ← Turbocharger pressure sensor signal input
C2 ← Exhaust gas recirculation system position
potentiometer signal output
C3 → Preheating control relay
D1 ← Diesel fuel pressure sensor input
D3 ← Air temperature sensor input
D4 → Feed control relay output
E1 --- Coolant temperature sensor earth
E3 --- + After ignition
F2 --- Exhaust gas recirculation system position
potentiometer supply
F3 → Thermoplunger control relay 2 output
(2 thermoplungers)
G1 --- Fuel temperature sensor earth
G2 --- Air flowmeter feed
G3 ← Engine speed sensor signal
H2 --- Diesel pressure sensor supply
H3 ← Engine speed sensor signal
H4 ← Air flowmeter sensor signal input
J2 --- Turbocharging pressure sensor feed
J3 ← Fuel temperature input
K3 ← Coolant temperature sensor input
L1 → High-pressure regulation valve output
L2 → Turbo regulation solenoid valve output
L3 --- Power earth
L4 --- Power earth
M1 → Exhaust gas recirculation system solenoid valve
control output
M2 --- + After relay
M3 --- + After relay
M4 --- Power earth
13-49
DIESEL EQUIPMENT
F9Q ENGINE
Computer 13
CONNECTOR C
A1 → Booster pump control output

A2 → Low speed fan assembly relay control outlet
A3 --- Air flowmeter earth
A4 --- Turbocharger pressure sensor earth
B3 --- Diesel pressure sensor earth
B4 → High speed fan assembly relay control outlet
C1 --- Camshaft sensor earth
E4 → Thermoplunger control relay 3 output
(1 thermoplunger)
J4 → Thermoplunger control relay 1 output
(1 thermoplunger)
K4 ← Camshaft position sensor signal
L1 → Injector 4 control
L2 --- Injector 3 feed
L3 --- Injector 2 feed
L4 → Injector 2 control
M1 → Injector 1 control
M2 → Injector 3 control
M3 --- Injector 1 feed
M4 --- Injector 4 feed
13-50
113
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Introduction
This document presents the fault finding procedure applicable to computers with part number 82 00 051 603
for F9Q 762 engines, and part number 82 00 051 600 for F9Q 760 engines.
EDC15C3C, Program No. CB, Vdiag No. 0C equipping: Primastar vehicle
To run diagnostics on this system, it is essential to have the following items:
– the wiring diagram of the function for the vehicle concerned,
– The Workshop Repair Manual for the vehicle in question,
– the tools listed under the Special Tooling Required section.
DIAGNOSTIC PROCEDURE:
– Use one of the diagnostic tools for identifying the system fitted on the vehicle (reading the computer type, program
number, Vdiag number, etc.).
– Locate the Fault finding documents corresponding to the system identified.
– Read the information provided in the Introductory section.
– Read the faults in the computer memory and use the Interpretation of faults section of the documentation.
REMINDER: each fault is interpreted for a given 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 stated by the diagnostic tool
is described for its type of storage. The type should be considered when the diagnostic tool is switched on after the
ignition has been turned off then back on.
If a fault is interpreted when it is declared stored, the conditions for applying fault finding procedures are shown 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 as
stored by the diagnostic tool but is only interpreted in the documentation for a present fault.
Carry out the conformity check (appearance of possible faults not yet identified by the system's self-diagnostic
procedure) and implement the associated fault finding procedure according to the results.
– Confirm the repair (customer complaint disappears).
– Implement the diagnostic procedure for each "Customer complaint" according to the "fault finding charts", if the
problem persists.
TOOLING REQUIRED:
Diagnostic tool: Consult II
Bornier part number: Elé. 1613 (necessary to avoid damaging the injection computer connector terminals).
IMPORTANT:
Any fault finding which requires an operation on the direct high pressure injection system
requires a comprehensive knowledge of the cleanliness and safety instructions as set out
in this Workshop Repair Manual, section 13.
13-1
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Fault Interpretation
DF001 COMPUTER
PRESENT 1.DEF : Internal electronic fault.
OR
STORED
1.DEF NOTES None.
If the fault is stored, clear the fault from the computer memory.
Switch off the ignition, then switch it on again to initialise the computer.
If the fault reappears, replace the engine management computer.
If necessary, modify the configuration of the new computer to match the equipment options present on the
vehicle.
If the fault is present, replace the engine management computer.

vehicle.
Deal with any other possible faults. Clear the faults from the computer memory.
AFTER REPAIR Switch the ignition off and carry out a road test followed by a check with the diagnostic
tool.
13-2
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF002 COOLANT TEMPERATURE SENSOR CIRCUIT

PRESENT CC.0 : Short circuit to earth
OR CO.1 : Short circuit or open circuit to + 12 V
STORED 1.DEF : Coolant operating temperature not attained
Conditions for applying the fault finding procedure to stored faults:

If the fault is declared present after:
– the fault has been cleared
– and the engine has been running for 1 minute.
NOTES
Special notes
Use bornier Elé. 1613 for all operations on the engine management computer
connectors.
Use a workshop temperature sensor to compare the temperatures.
CC.0 NOTES None.
Check the coolant temperature sensor connectors.

Check the connectors on the engine management computer.
Repair if necessary.
Measure the resistance of the coolant temperature sensor between terminals 2 and 3 of its connector.
Replace the sensor if the Negative Temperature Coefficient is not approximately:
2252 Ω ± 112 at 25°C.
811 Ω ± 39 at 50°C.
283 Ω ± 8 at 80°C.
Ensure insulation against earth of the connection between:
Engine management computer, connector B track2 K3 track 3 coolant-temperature-
sensor connector.
Ensure continuity of the connection between:
Engine management computer, connector B track3 E1 track 2 coolant-temperature-
sensor connector,
CO.1 NOTES None.

Measure the resistance of the coolant temperature sensor between terminals 2 and 3 of the connector.
2252 Ω ± 112 at 25°C.
811 Ω ± 39 at 50°C.
283 Ω ± 8 at 80°C.
Check the continuity and insulation relative to + 12 V on the connections between:

Engine computer, connector B track E1 Track 2 coolant temperature sensor
connector
Engine management computer, connector B track K3 Track 3 coolant temperature sensor
connector
AFTER REPAIR Switch off the ignition and carry out a road test followed by a check with the diagnostic
tool.
13-3
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF002
CONTINUED
Conditions for applying the fault finding procedure to

stored faults:
The fault is declared present after:
1.DEF NOTES – a delay of 3.3 minutes with the engine running.
Special notes:
Use a workshop temperature sensor to compare the values.

Compare the engine temperatures indicated on the instrument panel and by the diagnostic tool "parameter"
screen with those indicated by the "workshop" temperature sensor.
–If there is a significant difference, replace the engine temperature sensor.
or
Measure the resistance of the coolant temperature sensor between terminals 2 and 3 of its connector.
2252 Ω ± 112 at 25°C.
811 Ω ± 39 at 50°C.
283 Ω ± 8 at 80°C.
Check the continuity and insulation against earth of the connection between: (connectors disconnected)
Engine management computer, connector B track K3 Track 3 coolant temperature sensor
connector
Check the continuity and insulation relative to + 12 V on the connection between (connectors disconnected):
Engine management computer, connector B track E1 Track 2 coolant temperature sensor
connector
Measure the line resistance of the following connections:

Track E1, connector B computer Track 2 coolant temperature sensor connector
Track K3, connector B computer Track 3 coolant temperature sensor connector
Carry out the necessary operations if the resistance is abnormally high.
With the engine cold, check the closed position of the thermostat. Start of opening: 83°C.
Check the level and leaktightness of the coolant circuit, see section 19 of the Workshop Repair Manual.
Carry out the necessary repairs.
tool.
13-4
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF012 BATTERY VOLTAGE

PRESENT 1.DEF : Voltage too low
OR 2.DEF : Voltage too high
STORED

– starting and a delay of 30 seconds with the engine running.
NOTES
Special notes:
If necessary, perform a complete check of the charge circuit using the Consult II
diagnostic tool.
1.DEF NOTES None.
Carry out the operations necessary to obtain the correct computer supply:
9 V < operating voltage < 14.5 V.
– Using a multimeter, check the battery voltage directly at the terminals, then compare with the value displayed
by the diagnostic tool in Parameters menu PR004.
If there is no difference:
– Recharge and test the battery and replace it if it is faulty.
– Next check the charge circuit.
If there is a difference:
– Check the condition of engine fuse F2 (corrosion, poor contact at terminals, etc.).
– Check the tightness and the condition of the battery terminals.
– Make sure there is no interference resistance on the power supply to the engine management computer:
Engine fuseholder (F2) tracks M2 and M3 of connector A of the engine management computer
Earths tracks L3, L4, M4 of connector A of the engine management computer
2.DEF NOTES None.
Carry out the operations necessary to obtain the correct computer supply:
9 V < operating voltage < 14.5 V.
– Check the charging circuit.
tool.
13-5
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF015 IMMOBILISER
OR
STORED

NOTES
Apply the fault finding strategy if the fault is either present or stored.
1.DEF NOTES None.
If the fault is stored, clear the fault from the computer memory.
vehicle.
vehicle.
tool.
13-6
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
AIR FLOW SENSOR CIRCUIT

DF019
PRESENT CO.0 : Open circuit or short circuit to earth, engine running
OR CC.1 : Short circuit to + 12 V, engine running
STORED 1.DEF : Sensor supply fault
2.DEF : Signal inconsistency

If the fault reappears as stored after:
– the engine has been running at varying speeds for 5 minutes.
NOTES
Special notes:
connectors.
Priority in the event of a combination of faults:

In the event of the simultaneous presence of fault DF022:
CO.0 NOTES
Air temperature sensor circuit CO.1, check the connection
of the air flowmeter connector.
Check the air flowmeter connectors.

Check the connectors on the engine management computer. Repair if necessary.
Ensure continuity and insulation against earth of the connection between:

Engine management computer, connector B track H4 Track 5 of the air flowmeter connector.
Check the presence of + 5 V on track 3 of the air flowmeter connector.
Ensure insulation as follows:

– between tracks 5 and 6 of the air flowmeter connector,
– between tracks 2 and 5 of the air flowmeter connector.
If the fault persists after these checks, replace the air flowmeter.
CC.1 NOTES None.

Check insulation against + 12 V on the connection between:
Engine management computer, connector B track H4 Track 5 air flowmeter connector
Check the continuity of the following connections:
Engine management computer, connector B track L3 Track 6 of the air flowmeter
connector
Engine management computer, connector B tracks L3, L4 and M4 Battery earth
Engine management computer, connector C track A3 Track 2 of the air flowmeter
connector
Engine management computer, connector B tracks M2 and M3 Track 4 of the air flowmeter
connector
If the fault persists after these checks, replace the air flowmeter.
tool.
13-7
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF019
CONTINUED 1

1.DEF NOTES Deal with the DF091: Sensor feed voltage no. 1 fault as a
priority if it is present or stored.

Check the continuity and insulation relative to + 12 V on the connection between:

Engine management computer, connector B track G2 Track 3 air flowmeter connector
Check the insulation between tracks 3 and 4 of the air flowmeter connector.

Check the following insulations:
– between tracks 3 and 6 of the air flowmeter connector,
– between tracks 3 and 2 of the air flowmeter connector.
Check the presence of + 12 V after relay on track 4 of the air flowmeter connector.
Check for the presence of earth on tracks 2 and 6 of the air flowmeter connector.
tool.
13-8
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF019
CONTINUED 2

stored faults:
– starting and a rise in temperature at idle speed exceeding
60°C followed by a delay of 40 seconds
or
– if it reappears as stored after the fault has been cleared,
2.DEF NOTES
the engine started, the ignition switched off, followed by
the completion of power-latch and the ignition being
switched off.

Deal with the DF077 EGR valve 1.DEF or 2.DEF fault as a
prioriaty if it is declared present.

Check the continuity and insulation relative to + 12 V and earth on the connection between:
Engine management computer, connector B track H4 Track 5 air flowmeter connector
Ensure the continuity and insulation relative to + 12 volts of the connection between:
Engine management computer, connector C track A3 Track 2 air flowmeter connector
Check the presence of + 12 V after relay on track 4 of the air flowmeter connector.
Check continuity of the connection between earth and track 6 of the air-flowmeter connector.
Make sure there are no foreign bodies on the flowmeter grille.

Ensure that the air inlet circuit is tight.
Check the oil-vapour recycling circuit (excess oil).
Carry out the required operations.
tool.
13-9
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF022 AIR TEMPERATURE SENSOR CIRCUIT

OR CO.1 : Open circuit or short circuit to + 12 V
STORED

– the engine has been running for 2 minutes.
NOTES
Special notes:
connectors.
CC.0 NOTES None.
Check the air temperature sensor connections (flowmeter).

Ensure insulation against earth of the connection between:

Engine management computer, connector B track D3 Track 1 of air temperature sensor
connector, (flowmeter)
Check the presence of: + 5 V on track 3 of the air flowmeter connector.
Measure the Negative Temperature Coefficient air temperature sensor resistance between tracks 1 and 2 of
the air flowmeter:
Replace the air flowmeter if the Negative Temperature Coefficient is not approximately:
3714 Ω ± 161 at 10°C.
2448 Ω ± 90 at 20°C.
1671 Ω ± 59 at 30°C.
Priorité dans le traitement en cas de cumul de défaut:

In the event of simultaneous presence of fault "DF019: air
CO.1 NOTES
flowmeter 2.DEF", check that the flowmeter connector is
properly mated.
Check the air temperature sensor connections (flowmeter).

Check the continuity and insulation relative to + 12 V on the following connections:

Engine management computer, connector B tracks D3 Track 1 air temperature sensor
connector
Engine management computer, connector C tracks A3 Track 2 air temperature sensor
connector
Measure the Negative Temperature Coefficient between tracks 1 and 2 of the air flowmeter:
Replace the air flowmeter if the Negative Temperature Coefficient is not approximately:
3714 Ω ± 161 at 10°C.
2448 Ω ± 90 at 20°C.
1671 Ω ± 59 at 30°C.
tool.
13-10
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF040 AFTER IGNITION FEED

PRESENT 1.DEF : Inconsistency after initialisation
OR
STORED
1.DEF NOTES None.
Check after ignition power supply to the engine management computer on connector B in track E3.
If necessary, check:
– the condition of the engine fuseholders F2 and F4 (oxidation, crimping of wires at the terminals and
condition of terminals on the fuse side),
– the integrity of the ignition switch,
– the engine management computer connectors.
If the fault persists:

– Clear the fault from the computer memory.
– Switch off the ignition, then switch it on again to initialise the computer.
– If the fault reappears, replace the engine management computer.
vehicle.
tool.
13-11
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF048 LOW SPEED FAN ASSEMBLY CIRCUIT

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

– the fault memory has been cleared and
– actuator command AC011: Low speed fan assembly relay
NOTES
Special notes:
connectors.
CC.1 NOTES None.
Perform a check on the connectors of low speed fan relay socket "R10" in the engine fuse and relay box.
Measure the resistance of the low-speed fan relay coil:

Replace the relay if the resistance is not approximately 65 Ω ± 5 at + 20°C
Remove the low speed relay and check the insulation relative to + 12 V on the connection between:
Engine management computer, connector C track A2 Track 2 low speed fan relay socket
CO.0 NOTES None.
Perform a check on the connectors of low speed fan relay socket "R10" in the engine fuse and relay box.
Measure the resistance of the low-speed fan relay coil:

Replace the relay if the resistance is not approximately 65 Ω ± 5 at + 20°C
Ensure the continuity and insulation against earth of the connection between:
Engine management computer, connector C track A2 Track 2 of the low speed fan
assembly relay socket
Check the presence of 12 V after relay on track 1 of the low speed fan assembly relay socket.
tool.
13-12
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF049 HIGH SPEED FAN ASSEMBLY CIRCUIT

STORED

– actuator command "AC012: High speed fan assembly relay".
NOTES
Special notes
connectors.
CC.1 NOTES None.
Perform a check on the connectors of high-speed fan relay socket R9 in the engine fuse and relay box.
Measure the resistance of the high-speed fan relay coil:

Replace the relay if the resistance is not approximately 60 Ω ± 5 at + 20°C.
Remove the high speed relay and check the insulation relative to + 12 V on the connection between:
Engine management computer, connector C track B4 Track 2 of the high speed fan
CO.0 NOTES None.
Perform a check on the connectors of high-speed fan relay socket R9 in the engine fuse and relay box.
Measure the resistance of the high-speed fan relay coil:

Replace the relay if the resistance is not approximately 60 Ω ± 5 at +20°C.
Engine management computer, connector C track B4 Track 2 of the high speed fan
Check the presence of 12 V after relay on track 1 of the high speed fan assembly relay socket.
tool.
13-13
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF061 HEATER PLUG CIRCUIT

PRESENT 1.DEF : Heater plug(s) faulty or in open circuit
OR
STORED

– actuator command AC010: Preheating relay.
NOTES
Special notes:
connectors.
1.DEF NOTES None.
Check the preheating unit connectors.

Check the connections on all the heater plugs.
Ensure that the engine is earthed.

Check the resistance of heater plugs: replace any plug in which the resistance is not 0.6 ± 0.1 at 20°C.
Ensure the continuity of the following connections:
– Preheating unit track 1 Cylinder 3 heater plug,
– Preheating unit track 7 Cylinder 2 heater plug.
Check that fuse no. 1 (70A) on the engine fuse and relay box is intact.
Check the presence of + 12 V battery on track 3 of the heater plug relay.
Check the continuity of the connection between:
Engine management computer, connector B track B3 Track 9 preheating unit connector.
If the fault persists, replace the preheating unit.
tool.
13-14
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF067 FUEL PRESSURE SENSOR CIRCUIT

OR CO.1 : Open circuit or short circuit to + 12 V

NOTES Special notes:

connectors.
IMPORTANT: It is forbidden to carry out an ohmmeter check on the pressure sensor.
CC.0 NOTES None.
Check the fuel pressure sensor connectors.

Check the insulation against earth on the connection between:

Engine management computer, connector B track D1 Track 2 fuel pressure sensor connector
Check continuity of the connection between:
Engine management computer, connector B track H2 Track 3 fuel pressure sensor connector
If the problem persists, replace the rail pressure sensor.
CO.1 NOTES None.

Check the fuel pressure sensor connectors. Repair if necessary.
Check the continuity and insulation relative to + 12 V on the connection between:

Engine management computer, connector B track B3 Track 1 fuel pressure sensor connector
If the problem persists, replace the rail pressure sensor.
tool.
13-15
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF067
CONTINUED

priority if it is present.

Check the continuity and the absence of interference resistance on the following connections:
Engine management computer, connector B track D1 Track 2 fuel pressure sensor
connector
Engine management computer, connector B track H2 Track 3 fuel pressure sensor
connector
Engine management computer, connector C track B3 Track 1 fuel pressure sensor
connector
If all these connections are correct, check presence of a power supply to the fuel pressure sensor:
+5V Track 3 of rail pressure sensor connector
Earth Track 1 of rail pressure sensor connector
If the feeds are correct, replace the fuel pressure sensor.
tool.
13-16
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
CAMSHAFT SENSOR / ENGINE SPEED CONSISTENCY

DF070
PRESENT 1.DEF : Frequency of camshaft sensor signal too high
OR 2.DEF : Engine speed inconsistency
STORED 3.DEF : Tooth-to-tooth dynamic consistency of engine speed sensor
4.DEF : Inconsistent camshaft signal
Conditions for applying the fault finding strategy to the stored fault.
– starter action for 10 seconds, or
– the engine has been running for one minute.
NOTES
Special notes:
connectors.

1.DEF NOTES Deal with fault DF012: Battery voltage as a priority if it is
declared present.
Check presence of power supply between tracks 1 and 3 of camshaft sensor connector:
12 V after relay Track 3
Earth Track 1
Ensure earthing of the engine block.
Check the state of the sensor (temperature rise). Replace it if necessary.
2.DEF NOTES None.
Check the engine speed sensor connectors.

Check the resistance of the engine speed sensor between sensor tracks A and B.
Replace the sensor if the resistance is not approximately: 800 Ω ± 80 Ω.
Engine management computer, connector B track G3 Track A of the engine management
computer
Engine management computer, connector B track H3 Track B of the engine speed sensor
Check fastening, air gap and condition (overheating) of the sensor. Replace if necessary.
tool.
13-17
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF070
CONTINUED
Conditions for applying the fault finding strategy to the

stored fault.
3.DEF NOTES The fault reappears after:
– it is cleared and the engine is started followed by the
engine running for one minute.

Ensure that the engine block is earthed.

Engine management computer, connector B track G3 track A of the engine management
computer
Engine management computer, connector B track H3 track B of the engine speed sensor
Check the resistance of the engine speed sensor between sensor tracks A and B.
Replace the sensor if the resistance is not approximately: 800 Ω ± 80 Ω at 20°C.
Carry out a conformance check on the flywheel (where applicable check the form of the engine speed signal
using an oscilloscope, broken tooth, etc.). Carry out the necessary repairs.
4.DEF NOTES None.
Check the camshaft sensor connections.


Engine management computer, connector C track K4 Track 2 of the camshaft sensor
connector
Engine management computer, connector C track C1 Track 1 of the camshaft sensor
connector
Check the presence of 12 V after relay on track 3 of the camshaft sensor connector.

Check the tension of the timing belt.
Check pinion/key assembly on the camshaft.
Check the timing adjustment.
tool.
13-18
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF071 PEDAL SENSOR CIRCUIT TRACK 1

PRESENT CO.0 : Open circuit or short circuit to earth
OR CC.1 : Short circuit to + 12 V
Special notes:
NOTES Use bornier Elé. 1613 for all operations on the engine management computer
connectors.

In the event of the simultaneous presence of the DF073:
CO.0 NOTES
Pedal sensor circuit track 2 CO.0 fault, check that the
pedal sensor connector is fully plugged in.
Check the pedal sensor connections.

Check the continuity and insulation against earth on the connection between:
Engine management computer, connector A track C1 Track 3 pedal sensor connector
Also ensure the insulation of this connection against the following connections:
Engine management computer, connector A track B3 Track 2 pedal sensor connector
Engine management computer, connector A track A3 Track 1 pedal sensor connector
Engine management computer, connector A track E1 Track 4 pedal sensor connector
Measure the resistance of the pedal sensor track 1 between tracks 2 and 4.
Replace the sensor if the resistance is not approximately: 1.2 ± 0.48 kΩ at + 20°C.
CC.1 NOTES None.

Check insulation relative to + 12 V on the connection between:

Engine management computer, connector A track B3 Track 2 pedal sensor connector.
Measure the resistance of the pedal sensor track 1 between tracks 2 and 4.
Replace the sensor if the resistance is not approximately: 1.2 ± 0.48 kΩ at + 20°C.
tool.
13-19
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF071
CONTINUED

1.DEF NOTES As a priority, deal with fault DF091: Sensor supply voltage
No. 1 if the fault is present or stored.

Check the continuity and absence of interference resistance on the following connections:
Check the insulation between the following two connections:
Also check the insulation against + 12 V.
If the fault persists, go to the accelerator pedal sensor conformity check.
tool.
13-20
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
FUEL PRESSURE SIGNAL

DF072 1.DEF : Measured pressure too high
PRESENT 2.DEF : Measured pressure too low
OR 3.DEF : OCR of rail pressure regulating solenoid valve too high
STORED 4.DEF : Regulating solenoid valve jammed closed
5.DEF : Regulating solenoid valve jammed open
Conditions for applying the fault finding procedure to the stored fault.
– the engine has been running at idle speed for 2 minutes.
Special notes:
NOTES
connectors.
IMPORTANT: It is forbidden to carry out an ohmmeter check on the pressure

sensor.

1.DEF As a priority, deal in priority with the DF091: Sensor power
NOTES
5.DEF supply No. 1 or DF012: Battery voltage faults if one of
these two faults is present or stored.

Check the fuel pressure solenoid valve connectors.
Check the insulation against earth of the connection between:

Engine management computer, connector B track L1 Track 2 fuel pressure solenoid valve
connector
With the connector disconnected, check the insulation against 5 V on the connection between:
Engine management computer, connector B track D1 Track 2 rail pressure sensor
connector
Perform an AC006: Fuel pressure solenoid valve actuator command. A light whistling sound should be
heard from the fuel pressure regulator. If it cannot be heard, check the presence of + 12 V after relay on
track 1 of the fuel pressure sensor solenoid valve connector.
If the problem persists, go to the fault finding procedure for the interpretation of parameter: PR083.
tool.
13-21
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF072
CONTINUED
2.DEF
3.DEF NOTES None.
4.DEF

Check the fuel pressure solenoid valve connectors.
Check the presence of 12 V after relay on track 1 of the rail pressure regulating solenoid valve.
Check the continuity and absence of interference resistance on the following connections:
connector
At idling speed, warm engine (coolant temperature > 75°C), view parameter PR083: Pressure in rail.
If the value displayed is not 275 ± 30 bar, go on to perform the fault finding procedure for the interpretation of
parameters "PR083".
tool.
13-22
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
PEDAL SENSOR CIRCUIT TRACK 2

DF073
OR CC.1 : Short circuit or + 12 V
2.DEF : Consistency between track 1 and track 2
– successive cycles of full load and no load on the accelerator pedal.
NOTES
Special notes:
connectors.

In the event of the simultaneous presence of the DF071:
CO.0 NOTES
Pedal sensor circuit track 1 CO.0 fault, check that the
pedal sensor connector is fully plugged in
Check the connectors on the pedal sensor.


Engine management computer, connector A track F1 Track 6 pedal sensor connector
Also check the insulation of this connection against earth and against the following connections:
Measure the resistance of the pedal sensor - track 2, between tracks:
1 and 5 1.7 ± 0.68 kΩ at + 20°C
Replace the sensor if the resistance is outside permitted tolerance values.
CC.1 NOTES None.


Engine management computer, connector A track F1 track 6 pedal sensor connector
Ensure the presence of earth on track 1 of the pedal sensor connector.
If the fault persists, replace the pedal sensor.
tool.
13-23
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF073
CONTINUED

1.DEF NOTES As a priority, deal with the DF092: Sensor supply voltage
No.2 fault if it is present or stored.

Check the continuity and insulation against + 12 V on the connections between:

Engine management computer, connector A track H2 Track 5 pedal sensor connector
Ensure the insulation against earth of the connections between:
If the fault persists, replace the pedal sensor.
2.DEF NOTES None.

Measure the resistance of pedal sensor track 1, across tracks 2 and 4 of the pedal sensor connector.
Replace the sensor if the resistance is not approximately: 1.2 ± 0.48 KΩ.
Measure the resistance of pedal sensor track 2, between tracks 1 and 5 of the pedal sensor connector.
Replace the sensor if the resistance is not approximately: 1.7 ± 0.68 KΩ.

Engine management computer, connector A track F1 Track 6 pedal sensor connector
If the fault persists, go on to perform the accelerator-pedal sensor correctness check.
tool.
13-24
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
TURBOCHARGER PRESSURE SENSOR

DF074
PRESENT OC.0 : Open circuit or short circuit to earth
2.DEF : Inconsistency with atmospheric pressure
Special notes:
connectors.
NOTES
– the engine has been started or after a road test.
CO.0 NOTES None.
Check the turbocharger pressure sensor connectors.

Check the continuity and insulation against earth of the connection between:
Engine management computer, connector B track C1 Track B turbocharger pressure sensor
connector.
Also check the continuity of the connection between:
Engine management computer, connector B track J2 Track C turbocharger pressure sensor
connector
If the fault remains present, replace the turbocharger pressure sensor.
CC.1 NOTES None.

Check the continuity and insulation against + 12 V on the connection between:

connector.
Also check the continuity of the connection between:
Engine management computer, connector B track A4 Track A turbocharger pressure sensor
connector
If the fault remains present, replace the turbocharger pressure sensor.
tool.
13-25
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF074
CONTINUED



Engine management computer, connector B track J2 Track C turbocharger pressure sensor
connector
Also check the insulation on this connection against the earth and + 12 V and against the following
connections:
connector
Engine management computer, connector C track A4 Track A turbocharger pressure sensor
connector
Engine management computer, connector C track A4 Track A turbocharger pressure sensor
connector
Also check the insulation of this connection against + 12 V and against the connection between:
connector
2.DEF NOTES None.

Check the continuity and absence of interference resistance on the connections between:
connector
Check fitting of the sensor and the condition of its seal.
Check that there are no leaks in the induction circuit: unions, hoses, sleeves, exchanger, turbocharger.
Ensure there is no oil in the air inlet circuit.
Check the efficiency of the turbocharger.
If the problem persists, carry out the interpretation of commands diagnostic procedure AC004. If the wastegate
is not faulty, replace the turbocharger pressure sensor.
tool.
13-26
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF075 ATMOSPHERIC PRESSURE SENSOR

PRESENT 1.DEF : Supply voltage too low
OR 2.DEF : Supply voltage too high
STORED

NOTES Deal with the DF091: Sensor feed voltage no. 1 fault as a priority if it is present or
stored.

1.DEF
NOTES Deal with the DF091: Sensor feed voltage no. 1 fault as a
2.DEF
If the fault is stored, clear the fault from the engine management computer memory.
vehicle.

vehicle.
tool.
13-27
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
EGR VALVE
DF077
OR OC.0 : Open circuit or short circuit to earth
STORED 1.DEF : Negative loop deviation
2.DEF : Positive loop deviation

– the fault has been cleared from the memory and
– actuator command AC007: EGR valve.
NOTES
Special notes:
connectors.
CC.1 NOTES None.
Check the connections of the exhaust gas recirculation valve.

Measure the resistance of the exhaust gas recirculation valve between tracks 1 and 5.
If the resistance is not approximately 8 Ω ± 0.5 at + 20°C, replace the exhaust gas recirculation valve.
Engine management computer, connector B track M1 Track 5 exhaust gas recirculation valve
connector
CO.0 NOTES None.

Engine management computer, connector B track M1 Track 5 of the exhaust gas recirculation
valve connector
Check the presence of + 12 V after relay on track 1 of the exhaust gas recirculation valve connector.
tool.
13-28
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF077
CONTINUED
1.DEF
NOTES None.
2.DEF

Check leaktightness of the air intake circuit and the exhaust gas recirculation circuit.
If the problem persists, carry out the interpretation of commands diagnostic procedure: AC007.
tool.
13-29
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
WASTEGATE
DF078
STORED 1.DEF : Positive deviation in turbocharging regulation
2.DEF : Negative deviation in turbocharging regulation

The fault reappears as stored after:
– the fault memory has been cleared and actuator command AC004: Wastegate, or
– if the fault becomes present during a road test.
NOTES
Special notes:
connectors.
CC.1 NOTES None.
Check the wastegate connectors.


Engine management computer, connector B track L2 Track 1 wastegate connector.
Check the resistance of the wastegate (turbocharger pressure limitation valve) between tracks 1 and 2.
Replace the wastegate if the resistance is not approximately: 16.5 Ω ± 1.6 at + 25°C / (22.1 Ω ± 2.2 at + 110°C).
CO.0 NOTES None.

Check the insulation against earth of the connection between:

Engine management computer, connector B track L2 Track 1 wastegate connector
Check the presence of + 12 V after relay on track 2 of the wastegate connector.
Replace the wastegate if the resistance is not approximately: 16.5 Ω ± 1.6 at + 25°C / (22.1 Ω ± 2.2 at + 110°C).
tool.
13-30
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF078
CONTINUED 1

1.DEF NOTES Deal with the DF074: turbocharger pressure sensor fault
as a priority if it is declared present.

Check the presence of 12 V after relay on track 2 of the wastegate connector.
Replace the wastegate if the resistance is not approximately: 16.5 Ω ± 1.6 at + 25°C / 22.1 Ω ± 2.2 at + 110°C
If the fault persists, this indicates that the pressure measured by the computer exceeds that set by the
wastegate management system.
Check integrity of the wastegate (jamming/seizing: open).
Check wastegate movement (jamming/seizing: closed).
Check the setting of the wastegate control rod (Workshop Repair Manual section 12: Pressure regulator
valve).
tool.
13-31
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF078
CONTINUED 2

2.DEF NOTES Deal with the DF074: turbocharger pressure sensor fault

Replace the wastegate if the resistance is not approximately: 16.5 Ω ± 1.6 at + 25°C / 22.1 Ω ± 2.2 at + 110°C.
If the fault persists, this indicates that the pressure measured by the computer is lower than that set by the
wastegate management system.:
– Check integrity of wastegate valve (jamming/seizing: closed)
– Check the condition and sealing of the air inlet circuit.
– Check the leaktightness of the vacuum system, from the vacuum pump up to the wastegate control LDA
via the solenoid valve (or flap valve).
– Check the efficiency of the vacuum pump.
– Check the setting of the wastegate control rod (Workshop Repair Manual section 12: Pressure
regulator valve ).
– Check wastegate movement (jamming/seizing: open).
– Check the turbocharger.
tool.
13-32
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF079 THERMOPLUNGER RELAY No. 3
STORED
Special notes:
connectors.

NOTES
– the engine has been started, after the engine has been running for 30 seconds at
idle speed, with heated windscreen not selected and the engine temperature at
starting less than 70°C, or
– if it reappears after being cleared followed by actuator command: AC002.
CC.1 NOTES None.
Check the connectors on the additional heater 3 relay socket in the engine fuse and relay box.
Check the integrity of the additional heater 3 relay socket in the engine fuse and relay box:
– Insulation between tracks 3 and 5 of the relay.
– Measure the resistance of the relay coil, between tracks 1 and 2.
– replace the relay if the resistance is not approximately 65 ± 5 Ω at + 20°C.
Engine management computer, connector C track E4 Track 2 of the additional heater
no. 3 relay socket in the engine fuse
and relay box
Also check the insulation of this connection against the following connections:
Additional heater no. 3 in the engine fuse and relay box track 1 + 12 V after relay
Additional heater no. 3 in the engine fuse and relay box track 3 + 12 V battery
CO.0 NOTES None.
Check the connectors on the "additional heater 3" relay socket in the engine fuse and relay box.
Measure the resistance of the "additional heater 3" relay coil, between its tracks 1 and 2:
–replace the relay if the resistance is not approximately 65 ± 5 Ω at + 20°C.
Engine management computer, connector C track E4 Track 2 of the additional heater no. 3
relay socket in the engine fuse and
relay box
Check the presence of + 12 V after igntion on track 1 of the additional heater no. 3 relay socket.
tool.
13-33
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF081 PREHEATING RELAY CIRCUIT

PRESENT CC.1 : Short circuit to +12 V
STORED

– actuator command AC010: Preheating relay.
NOTES
Special notes
connectors.
CC.1 NOTES None.

Engine management computer, connector B track C3 Track 8 preheating unit connector
CO.0 NOTES None.

Engine management computer, connector B track C3 Track 8 preheating unit connector
Check the presence of 12 V battery on track 3 of the preheating unit connector (via F01; 70A)
tool.
13-34
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF082 LOW PRESSURE PUMP RELAY CIRCUIT
STORED

– actuator command AC005: Low pressure pump relay control.
NOTES
Special notes:
connectors.
CC.1 NOTES None.
Check the low pressure pump relay socket connections R3 in the engine fuse and relay box.
Remove the low pressure pump relay and check the insulation against + 12 V on the connection between:
Engine management computer, connector C track A1 Track 2 low pressure pump relay socket
High pressure pump relay socket in the engine fuse and relay box track 1 +12 V after ignition
Low pressure pump relay socket on the engine fuse and relay box track 3 +12 V battery
Check the integrity of the "low-pressure pump" relay in the engine fuse and relay box:
Measure the resistance of the relay coil, between tracks 1 and 2.
Replace the relay if the resistance is not approximately 85 ± 5 Ω at + 20°C.
CO.0 NOTES None.
Perform a check on the connectors of low-pressure pump relay socket R3 in the engine fuse and relay box.
Engine management computer, connector C track A1 Track 2 low pressure pump relay
socket
Check the presence of + 12 V after relay on track 1 of the low pressure pump relay.
Measure the resistance of the low pressure pump relay coil between its tracks 1 and 2.
Replace the relay if the resistance is not approximately 85 ± 5 Ω at + 20°C.
tool.
13-35
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF083 FUEL PRESSURE SOLENOID VALVE CIRCUIT

STORED 1.DEF : Consistency after switching off the ignition

NOTES – actuator command AC006: Fuel pressure solenoid valve control.
Special notes:
Use bornier Elé. 1613 for all operations on the computer connector.
CC.1 NOTES None.
Check the fuel pressure solenoid valve connections.

With the fuel pressure solenoid valve connector disconnected, check the insulation against + 12 V on the
connection between:
Engine management computer B track L1 Track 2 fuel pressure solenoid valve connector
Measure the resistance of the fuel-pressure solenoid valve across tracks 1 and 2:
Replace the solenoid valve if the value is not approximately: 5 Ω ± 05 Ω at 20°C.
CO.0 NOTES None.

Measure the resistance of the fuel-pressure solenoid valve across tracks 1 and 2:
Replace the solenoid valve if the value is not approximately: 5 Ω ± 0.5 Ω at 20°C.
connector
Check the presence of + 12 V after relay on track 1 of the fuel pressure solenoid valve.
tool.
13-36
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF083
CONTINUED

1.DEF NOTES Deal with the DF088 Consistency of flywheel signal fault


Engine management computer, connector B track H3 Track B engine speed sensor
Engine management computer, connector B track G3 Track A engine speed sensor
Measure the line resistance of the connection between:
Engine management computer, connector B track L1 Track 2 of the fuel pressure solenoid
valve
Measure the resistance of the fuel pressure solenoid valve between tracks 1 and 2:
Replace the solenoid valve if the value is not approximately: 5 Ω ± 0.5 Ω at 20°C.
If the problem persists, carry out the interpretation of commands correctness check: AC006.
tool.
13-37
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF088 FLYWHEEL SIGNAL INCONSISTENCY

PRESENT 1.DEF : Overspeed detected
OR
STORED

– the fault has been cleared,
– the engine has been started followed by acceleration to over 2500 rpm.
NOTES
Special notes:
connectors.
This fault appears following an engine overspeed of

1.DEF NOTES
> 5000 rpm

Check the insulation against + 12 V and the earth on the following connections:
Engine management computer, connector B track H3 Track B engine speed sensor
Engine management computer, connector B track G3 Track A engine speed sensor
Measure the resistance of the engine speed sensor between tracks A and B of the sensor.
Replace the sensor if the resistance value is not approximately 800 Ω ± 80 at 20°C.
tool.
13-38
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF089 INJECTION CONTROL CAPACITOR VOLTAGE

PRESENT 1.DEF : Voltage too high
OR 2.DEF : Voltage too low
STORED

stored faults:
1.DEF
NOTES The fault is declared present after:
2.DEF
– the engine has been running for one minute.
vehicle.

vehicle.
tool.
13-39
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF090 ANALOGUE TO DIGITAL CONVERTER

OR
STORED
1.DEF NOTES None.
vehicle.

vehicle.
tool.
13-40
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF091 SENSOR SUPPLY VOLTAGE No. 1

STORED

The fault reappears as stored after:
– The fault has been cleared and
– the engine has been running for 1 minute.
NOTES
Special notes:
connectors.
1.DEF NOTES None.
Check the connectors of the following sensors:

– pedal sensor,
– fuel pressure sensor,
– air flowmeter,
– exhaust gas recirculation valve position sensor,
– turbocharger pressure sensor.
Display parameter PR090: Sensors no.1 supply voltage. If this voltage is below 4.9 V, disconnect the
connectors on all the sensors referred to above one by one.
– If the voltage returns to normal (wait a few seconds between each disconnection so that the computer can
take the measurement), replace the faulty sensor (or repair the faulty connection).
Clear the faults created by the multiple disconnections.
– If the voltage is still below 4.9 V when all these sensors are disconnected, check that there is no short circuit
in these sensor supply lines:
– Disconnect all the sensors referred to above and the computer-side connectors and check the insulation
between:
tracks 2 and 4 of the pedal sensor connector;
tracks 1 and 3 of the fuel pressure sensor connector;
tracks 2 and 3 of the air-flowmeter connector.
tracks 2 and 4 of the exhaust gas recirculation valve position sensor connector,
tracks A and C of the turbocharger pressure sensor connector.
If all the insulation is correct, replace the engine management computer.
vehicle.
tool.
13-41
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF091
CONTINUED
2.DEF NOTES None.

– pedal sensor,
– fuel pressure sensor,
– air flowmeter,
– exhaust gas recirculation valve position sensor,
– turbocharger pressure sensor.
Display parameter PR090: Sensors no.1 supply voltage. If this voltage is above 5.1 V, disconnect all the
sensor connectors referred to above one by one:
– If the voltage returns to normal, replace the faulty sensor (or repair the faulty connection) (wait a few seconds
between each disconnection so that the computer can take the measurement).
Clear the faults created by the multiple disconnections.
– If the voltage is still above 5.1 V with all these sensors disconnected, check that there is no short circuit to
+ 12 V on these sensor supply lines (+ 5 V):
– Disconnect all the sensors referred to above and the connectors on the computer side and check the
insulation against + 12 V on tracks:
– 4 of the pedal sensor connector;
– 3 of the fuel pressure sensor connector;
– 3 of the air flowmeter connector;
– 2 of the exhaust gas recirculation valve position sensor connector,
– C of the turbocharger pressure sensor connector.
If all these tracks are insulated against + 12 V, replace the engine management computer. If necessary, modify
the configuration of the new computer to match the equipment options present on the vehicle.
tool.
13-42
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C

STORED

The fault reappears after:
– The fault has been cleared and
NOTES
Special notes:
connectors.
1.DEF NOTES None.

– pedal sensor,
– Refrigerant pressure sensor.
Display parameter PR091: Sensor no.2 supply voltage. If the value of this voltage is below 4.9 V, disconnect
the sensor connectors referred to above one by one and display PR091 again.
– If the voltage returns to normal (wait a few seconds after each disconnection so the computer can take the
measurement), replace the faulty sensor (or repair the faulty connection).
– If the voltage is still below 4.9 V, with all these sensors disconnected, check that there is no short circuit on
these sensor supply lines.
– Disconnect all the sensors referred to above and the computer-side connectors and check the insulation
between:
tracks 1 and 5 of the pedal sensor connector;
tracks A and B of the refrigerant pressure sensor connector.
If these checks reveal a short circuit, perform the necessary repairs.
If these checks do not reveal a short circuit, replace the engine management computer.
vehicle.
tool.
13-43
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF092
CONTINUED
2.DEF NOTES None.

– pedal sensor,
– refrigerant pressure sensor.
Display parameter PR091: Sensor no.2 supply voltage. If the value of this voltage is above 5.1 V, disconnect
the sensor connectors referred to above one by one and display PR091 again;
– If the voltage returns to normal (wait a few seconds after each disconnection so the computer can take the
measurement), replace the faulty sensor (or repair the faulty connection).
– If the voltage is still above 5.1 V with all these sensors disconnected, check that there is no short circuit to
+ 12 V on these sensor supply lines (+ 5 V):
– Disconnect all the sensors referred to above and the connectors on the computer side and check the
insulation against + 12 V on tracks:
– 5 of the pedal sensor connector.
– B of the refrigerant pressure sensor connector.
If these checks reveal a short circuit to + 12 V, perform the necessary repairs.
If these checks do not reveal a short circuit, replace the engine management computer.
vehicle.
tool.
13-44
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF093 MICROCONTROLLER
OR 2.DEF : Inconsistency
STORED
1.DEF
NOTES None.
2.DEF
If the fault is present or stored, clear the fault from the engine management computer memory.
Switch off the ignition, then switch it on again to initialise the computer. Carry out a road test.
vehicle.
tool.
13-45
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF094 THERMOPLUNGER RELAY No. 1

STORED

– the engine has been started, after the engine has been running at idle speed for
30 seconds, with heated windscreen not selected and the engine temperature at
NOTES
– if it reappears after being cleared followed by actuator command: AC301.
Special notes:
connectors.
CC.1 NOTES None.
Check the connectors on the "additional heater 1" relay in the engine fuse and relay box.
Check the integrity of the "additional heater 1" relay in the engine fuse and relay box:
– Insulation between tracks 3 and 5 of the relay (at rest position).
– Measure the resistance of the relay coil, between tracks 1 and 2:
–replace the relay if its resistance is not approximately: 64 Ω ± 5 at +20°C.
Engine management computer, connector C track J4 Track 2 additional heater 1 relay socket in
the engine fuse and relay box.
Also check the insulation of this connection against following connections:
Additional heater no. 1 relay socket in the engine fuse and relay box, track 1 + 12 V after relay
Additional heater no. 1 relay socket in the engine fuse and relay box, track 3 + 12 V battery
CO.0 NOTES None.
Check the connectors on the "additional heater 1" relay in the engine fuse and relay box.
Check the presence of + 12 V after ignition on track 1 of additional heater 1 relay socket. Measure the
resistance of the relay coil, between tracks 1 and 2:
–replace the relay if its resistance is not approximately: 64 Ω ± 5 at + 20°C.
Engine management computer, connector C track J4 Track 2 additional heater 1 relay socket
in the engine fuse and relay box.
tool.
13-46
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C

PRESENT 1.DEF : Vehicle speed too high
OR 2.DEF : Vehicle speed signal frequency too high
STORED 3.DEF : Inconsistency between engine speed and air flow

If the fault becomes present:
– during a road test at a speed above 2000 rpm.
NOTES
Special notes:
connectors.
Condition for appearance of fault 1.DEF: if speed is

1.DEF NOTES
> 200 km/h for 10 seconds .
Check the condition of the sensor, if the body shows any deformation due to overheating, replace the sensor.
Perform a road test and compare the speed indicated by the diagnostic tool (Parameters menu) with that
shown on the instrument panel:
– If these two values do not coincide,
Check the following continuity (obtain the appropriate wiring diagram):
Engine management computer connector A track E4 / speed sensor track B1 / track 13 black connector
on instrument panel.
If continuity is ensured between these three points, replace the engine management computer.
vehicle.
– If these two values coincide, perform the following checks:
Check the insulation against the earth and against + 12 V on the following connection:
Engine management computer, connector A track E4 Track B1 vehicle speed sensor
connector
Ensure the presence of earth on track B2 of the vehicle speed sensor.
Check the presence of + 12 V on track A of the vehicle speed sensor.
If the fault persists, remove the speed sensor and check the condition of the sensor drive pinion. If necessary
replace the sensor.
tool.
13-47
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF095
CONTINUED
Condition for appearance of 3.DEF:

If the computer detects a speed signal lower than 10 km/h
but the fuel flow and engine speed show a higher speed.
2.DEF Special notes:
NOTES
3.DEF If the road test highlights a clutch problem (slipping), consult
Workshop Repair Manual Section 2 and correct the
problem. After the repair, follow the general notes for DF095
before applying the fault-finding procedure.
Check the vehicle speed sensor connectors.

Check the condition of the sensor, if the body shows any deformation due to overheating, replace the sensor.
Check the integrity of fuse F4 in the engine fuse and relay box.
Check the presence of 12 V after ignition on track A of the vehicle speed sensor.
Ensure the presence of earth on track B2 of the vehicle speed sensor.
Check the continuity of the following connection:
Engine management computer, connector A track E4 Track B1 vehicle speed sensor
connector
Also check the insulation against the earth and against + 12 V on the same connection.
The speed sensor supplies a signal which is shared by four control units: The injection control unit, the radio,
the video display and the instrument panel.
To eliminate a possible fault caused by one of these elements, disconnect them one by one (except the
injection control unit) and perform a road test between each disconnection.
– If the fault is not present during the road test after one of the disconnections, this means that the control unit
in question was causing an electrical fault.
If this is the case, clear the fault, carry out a final road test to confirm the source of the fault and if the
fault does not reappear, replace the unit found to be faulty
– If the fault persists, remove the vehicle speed sensor and check condition of the pinion, its rod and the
connection to the sensor itself.
Replace the pinion or sensor if necessary.
tool.
13-48
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF097 CLUTCH CONTACT INFORMATION

PRESENT 1.DEF: Inconsistent vehicle speed
OR
STORED

If the fault becomes present:
– during a road test exceeding 60 mph (100 km/h).

NOTES Deal with the DF095: Vehicle speed signal fault as a priority if it is declared present
or stored.
Special notes:
connector.
1 - Perform a check on the connectors of the clutch switch.

Display state ET012: Clutch switch signal. Press the clutch pedal and note whether this state becomes
active:
If it becomes active,
– Reset the engine management computer. Switch the ignition back on, road test the vehicle and then take a
fault reading. If the fault reappears, go to step 2.
If it does not become active,
– Ensure that the switch is correctly adjusted.
– Check the continuity and insulation against earth of the connection between:
Engine management computer, connector A track E2 Track A1 clutch switch
– Ensure the presence of earth on track B3 of the clutch switch.
– Check the operation of the clutch switch:
– Closing of the contact between tracks A1 and B3 when the clutch pedal is depressed.
– Opening of the contact between tracks A1 and B3 when the clutch pedal is released.
– Replace the switch if necessary.
2 - If the fault persists:

– Clear the fault from the computer memory.
– Switch off the ignition, then switch it on again to initialise the computer.
– Carry out a road test.
– If the fault reappears, replace the engine management computer.
vehicle.
tool.
13-49
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
MAIN RELAY
DF098 1.DEF : Relay cut-out too soon
STORED 2.DEF : Relay cut-off too late
Conditions for applying the fault finding procedure:

NOTES – the fault has been cleared and
– the ignition is switched off with loss of dialogue and
– the ignition is switched on again and dialogue is re-established.
1.DEF NOTES None.
Check the connectors on R2 main relay socket in the engine fuse and relay box.
Check that the battery terminals (+ and -) are tight and in good condition.

Main relay R2 track 5 tracks M2 and M3, connector B of the engine management computer
Main relay R2 track 2 Track D4, connector B of the engine management computer
Check the condition of the F2 fuse connections on the engine fuse and relay box (crimping of the wires on the
terminals and condition of the terminals).
Check the condition of the engine management computer earth connections: tracks L3, L4, M4, connector B
of the engine management computer.
Check the conformity of the impact sensor.
If the fault persists after these checks, replace main relay R2.
2.DEF NOTES None.
Check the connectors on main relay R2 in the engine fuse and relay box.
Check the insulation against earth for the following connection:

Main relay R2 track 2 Track D4, computer connector B
Check the conformity of the main relay (relay removed).
– Insulation of contacts across tracks 3 and 5.
– Measure the resistance of the coil across tracks 1 and 2:
– Replace the relay if the resistance is not approximately 60 Ω ± 5 at + 20°C.
Check the integrity of the impact sensor.
If the fault persists after these checks, replace the main relay R2.
tool.
13-50
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF099 CYLINDER INJECTOR CIRCUIT 1

PRESENT 1.DEF : Overcurrent on injector energising current
OR 2.DEF : Undercurrent on the injector energising current
STORED

If the fault reappears as present following:
– starting the engine.
NOTES
Special notes:
connectors.
1.DEF NOTES None.
Check the connections for injector no. 1.

Measure the resistance of injector no. 1:

Replace the injector if the resistance between tracks 1 and 2 is not: 0.33 Ω at + 20°C / 2 Ω max.
Engine management computer, connector C track M1 Track 2 injector no. 1 connector
Check insulation against earth on the following connection:

Engine management computer, connector C track M3 Track 1 of the connector to the no. 1
injector
If the fault persists, replace the injector.
2.DEF NOTES None.


Measure the resistance of injector no. 1:
tool.
13-51
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C

STORED

If the fault reappears as present following:
– starting the engine.
NOTES
Special notes:
connectors.
1.DEF NOTES None.

Measure the resistance of injector no. 2.

Engine management, computer C track L4 Track 2 injector no. 2 connector
Engine management, computer C track L3 Track 1 injector no. 2 connector
Check insulation against earth on the following connection:
Engine management computer, connector C track L3 Track 1 of injector no. 2 connector
2.DEF NOTES None.


Engine management computer, connector C track L4 Track 2 injector no. 2 connector
tool.
13-52
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C

PRESENT 1.DEF :Overcurrent on injector energising current
OR 2.DEF :Undercurrent on the injector energising current
STORED

If the fault becomes present after:
– the engine is started.
NOTES
Special notes:
connectors.
1.DEF NOTES None.


Check the insulation against earth on the following connection:
2.DEF NOTES None.


tool.
13-53
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C

STORED

If the fault reappears as present after:
– the engine is started.
NOTES
Special notes:
connectors.
1.DEF NOTES None.


Ensure insulation against earth for the following connection:
Engine management computer, connector C track M4 Track 1 of the injector no. 4 connector
2.DEF NOTES None.


tool.
13-54
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF104 THERMOPLUNGER No. 2 RELAY

STORED

– the engine has been started, after the engine has been running at idle speed for
30 seconds, with heated windscreen not selected and the engine temperature at
NOTES – if it reappears after being cleared followed by actuator command: AC302
Special notes:
connectors.
The no. 2 thermoplunger relay powers thermoplungers 2 and 3 in parallel.
CC.1 NOTES None.
Check the connectors on additional heater2 relay in the engine fuse and relay box.

Engine management computer, connector B track F3 track 2 additional heater 2 relay socket
Additional heater 2 relay socket, track 1 + 12 V after relay
Additional heater 2 relay socket, track 3 + 12 V battery
Check the integrity of the additional heater 2 relay:
– Measure the resistance of the relay coil, between tracks 1 and 2:
– Replace the relay if the resistance is not approximately: 82 Ω ± 5 at + 20°C.
CO.0 NOTES None.
Check the connectors on the additional heater 2 relay in the engine fuse and relay box.
Check continuity and insulation against earth of the connection between:

Engine management computer, connector B track F3 Track 2 additional heater 2 relay socket
Check the presence of + 12 V after relay on track 1 on additional heater 2 relay socket
– Measure the resistance of the additional heater 2 relay coil, between its tracks 1 and 2:
– Replace the relay if the resistance is not approximately: 82 Ω ± 5 at + 20°C.
tool.
13-55
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF105 STABILISED VOLTAGE REGULATOR

STORED
vehicle.

vehicle.
tool.
13-56
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
A.C. RELAY CONTROL CIRCUIT, COLD LOOP

DF111 1.CC.1 : Short circuit to + 12 V on the compressor relay control line
PRESENT 1.CO.0 : Open circuit or short circuit to earth of the compressor relay control line.
OR 1.DEF : Refrigerant pressure sensor voltage too low
STORED 2.DEF : Refrigerant pressure sensor voltage too high
3.DEF : Refrigerant pressure sensor supply fault

– the fault has been cleared and actuator command AC003: Air conditioning
suppression command is issued or
NOTES – the engine is started followed by a request for air conditioning.
Special notes:
connectors.
CC.1 NOTES None.
Check the connections on the compressor control relay socket.

Remove the compressor relay and check the insulation against + 12 V on the connection between:
Engine management computer, connector A track F4 Track A2 compressor control relay
socket
Check the resistance of the air conditioning compressor control relay coil:
Replace the relay if the resistance is not 88 Ω ± 10 Ω.
CO.0 NOTES None.
Check the connections on the compressor control relay socket.

Engine management computer, connector A track F4 Track A2 compressor control relay
socket
Check the presence of 12 V after relay on track 1 of the compressor control relay socket.
Check the resistance of the air conditioning compressor control relay coil:
Replace the relay if the resistance is not 88 Ω ± 10 Ω.
tool.
13-57
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
DF111
CONTINUED
1.DEF
NOTES None.
2.DEF
Check the refrigerant pressure sensor connections.

Check the continuity (and absence of interference resistance) on the following connections:
Engine management computer, connector B track F1 Track A refrigerant pressure sensor
connector
Engine management computer, connector B track A3 Track B refrigerant pressure sensor
connector
Engine management computer, connector B track G4 Track C refrigerant pressure sensor
connector
If the fault persists, check conformance of the air conditioning circuit.
1.DEF: Underpressure in the refrigerant fluid circuit;
2.DEF: Overpressure in the refrigerant fluid circuit.

priority if it is present.
Check the refrigerant pressure sensor connections.

Check the continuity (and absence of interference resistance) on the following connections:
Engine management computer, connector B track F1 Track A refrigerant pressure sensor
connector
Engine management computer, connector B track A3 Track B refrigerant pressure sensor
connector
Engine management computer, connector B track G4 Track C refrigerant pressure sensor
connector
With the connectors disconnected, check insulation values between these same connections.
tool.
13-58
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
FLOW AT SELF-TEST AFTER IGNITION SWITCHED OFF

DF141 1.DEF : Inconsistency with engine speed
STORED

Deal with any other fault that is present or stored as a
priority.
Conditions for application of the fault finding
procedure:
– the fault has been cleared,
– followed by several power latch* phase ends, each
preceded by an engine start and acceleration to
1.DEF NOTES > 2000 rpm cycle.
* Information regarding the notes: This fault is detected
when the ignition is switched off, during the power latch
phase. Moreover, this detection is based on a "counting"
strategy and is therefore not performed at each ignition
switch-off. If it is detected during a power latch, it will not
necessarily be detected during the next. After a fault is
cleared, then, several power latches should be performed,
each preceded by one cycle with the engine running (see
above), to attempt to make the fault reappear.
Conditions for appearance of the fault: this fault appears if the engine speed does not drop below a certain
value (˜ 300 rpm) in a very short time (t < 1.5 seconds) after the ignition is switched off. It is therefore necessary
to eliminate all mechanical, hydraulic or other causes which keep the engine running after it has been switched
off.
It is therefore necessary to eliminate all causes which could keep the engine running after the ignition is
switched off.
Check that there is not an excess of engine oil, and correct the oil level if required.
Check that there are no leaks in the injector pipes (see injector fault finding in the Help section).
Perform the necessary operations, clear the fault and then carry out the instructions again.
If the fault persists, replace the engine management computer. If necessary, modify the configuration of the
new computer to match the equipment options present on the vehicle.
tool.
13-59
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Conformity check
Do not refer to this conformity check until you have checked that there is no fault with
NOTES the diagnostic tool.
Test conditions: engine stopped, ignition on.
Parameter or state Symbol on display and

Order Function Fault finding
Check or action notes
ET001: Computer +after state: ACTIVE

ignition In the event of a problem,
1 Battery voltage refer to fault finding
PR004: Computer supply 12.4 < X < 12.8 V procedure PR004
voltage
ET003: Engine status: INACTIVE

immobiliser The computer is locked! In the event of problems,
2 Immobiliser refer to the engine
ET133: Code state: YES
immobiliser diagnostic
programmed The computer has a code stored
in memory!
Any phase difference

between the camshaft
sensor and the TDC
sensor causes clearing of
Synchronisation DF070.
state: STANDBY, then
(between
becomes "Complete" If starting is impossible:
3 camshaft sensor ET157: synchronisation
once the engine is the status becomes
and engine speed
started. "UNDERWAY" while the
sensor)
starter motor is running,
and will only become
"performed" if the engine
starts.
E027T: Pre/postheating status: ACTIVE as soon If ET011 is "ACTIVE" at

relay command as the ignition is switched the same time as ET027,
on and until the end of a plug has failed or the
4 Pre/postheating pre-postheating diagnostic connection of
ET011: pre-postheating status: ACTIVE as soon the pre-postheating unit is
signal as pre-postheating is in open circuit.
completed + appearance of DF061.
status: ACTIVE, as soon

as the ignition is switched
on.
This function ensures
ET105: Low-pressure Becomes: INACTIVE, as
5 Boosting pump priming of the low-
pump relay control soon as the engine is
pressure circuit
running, or after 10
seconds if the engine
does not start.
13-60
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
Test conditions:engine stopped, ignition on.

ET012: Clutch switch state: DEPRESSED or

6 Switches signal RELEASED, depending None
ET154: Brake pedal on actions on the pedals
– Engine overheating The coolant temperature

warning light: warning is lit when the
Indicator lights controlled coolant temperature is
– Preheating + electronic > 110°C, and turns off
failure warning light by the engine computer
Instrument panel via the multiplexed when the temperature
7 drops below 105°C again.
warning lights network: as soon as the
ignition is switched on In the event of problems,
and for a few seconds perform the fault finding
procedure for the
instrument panel
PR090: Sensor supply 4.9 V < X < 5.1 V

voltage No. 1
8 Supply voltage None
PR091: Sensor supply 4.9 V < X < 5.1 V
voltage No. 2
In the event of a problem,

PR002: Coolant X = Engine temperature
refer to fault finding
temperature ± 5 °C
strategy PR002

Temperature X = vehicle external
9 PR003: Air temperature refer to fault finding
sensors temperature ± 5 °C
strategy PR003

X = Engine temperature
PR001: Fuel temperature refer to fault finding
± 10 °C
strategy PR001
PR016: Atmospheric In the event of a problem,

X = Atmospheric pressure
pressure refer to diagnostic PR016
10 Inlet pressures
PR082: Turbocharger In the event of a problem,
X ≅ Atmospheric pressure
pressure refer to diagnostic PR082
13-61
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
Test conditions:engine stopped, ignition on.
Parameter or state Symbol on display

Check or action and notes
RCO signal:
– Exhaust gas PR095: Exhaust gas In the event of a
recirculation recirculation valve opening X = 5% problem, go to fault
valve cyclic ratio X≅1V finding procedure
PR088: Copy exhaust gas AC007.
11 recirculation valve position
– Wastegate In the event of a

PR094: Turbocharger problem, go to fault
X = 5%
wastegate opening cyclic ratio finding procedure
AC004.
Diesel pressure PR083: Manifold pressure 0 < X < 4 bars If the engine has just
been stopped, wait a
PR202: Regulated fuel flow few seconds to obtain
rate X ≅ 25000 mm3/s
12 this value. In the event
Fuel flow of a problem, consult the
PR033: Fuel flow 10 < X < 80 mm3/ fault finding procedure
stroke for PR083
ACCELERATOR PEDAL NO
LOAD
PR008: Pedal potentiometer X = 0.71 V

Important:
voltage track 1
approximately every
PR005: Pedal load X = 0% 5 seconds the computer
performs a test to set
PR092: Pedal load X = 0% PR009 at 0 V.
(circuit No. 1) This corresponds to
normal operation.
PR093: Pedal load X = 0%
(circuit No. 2)
PR009: Pedal potentiometer X = 0.35 V If only one track

voltage track 2 responds after the pedal
Accelerator pedal is depressed, change
13 the pedal sensor.
sensor
ACCELERATOR PEDAL If the voltages shown
FULL LOAD does not correspond to
+ or - 0.3 V, replace the
pedal sensor.
voltage track 1

In the event of pedal
PR092: Pedal load X = 100% sensor failure, the
(circuit No. 1) engine speed is frozen
at 1200 rpm (for return
to workshop).
(circuit No. 2)

voltage track 2
13-62
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
Only perform this conformity check if a full check using the diagnostic tool revealed no
NOTES faults.
Test conditions: warm idling engine, without electric consumer.

PR 006: Engine speed 800 rpm ± 50
PR002: Coolant
higher than 80ºC
temperature
PR062: Engine speed

14 Engine speed 800 rpm ± 50. None
reference
PR035: Idling-speed X = 0 rpm ± 50

correction (Depending on increase
or decrease in the tool
configuration menu)
PR083: Manifold pressure X = 275 bar ± 30

(approximately 1350 bar
at most when at full load)
In the event of a problem
15 Diesel pressure PR086: Manifold-loop consult the fault finding
X ≅ 0 bar
deviation procedure PR083.
ET105: Low-pressure pump

state: INACTIVE
relay control
FLOW RATES:
– Fuel PR202: Regulated fuel flow X ≅ 1210 mm3/s

rate
PR033: Fuel flow X ≅ 5 mm3/ stroke None

16 PR075: Idling speed fuel X ≅ 5 mm3/ stroke
flow reference
– Air PR050: Air flow X ≅ 34 kg/h at 800 rpm,

measurement (approx. 390 kg/h under
None
load in the case of a full
load)
RCO signal:
– Exhaust gas PR095: Exhaust gas X ≅ 33% In the event of a problem,

recirculation recirculation valve opening go to fault finding
17 valve cyclic ratio procedure AC007.
– Wastegate PR094: Wastegate opening X ≅ 85% In the event of a problem,

cyclic ratio go to fault finding
procedure AC004.
13-63
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
Test conditions: warm idling engine, without electric consumer.

If necessary consult the Workshop Repair Manual, Section 13: Injection/air conditioning strategy.
If the injection computer allows compressor operation
ET102: Air conditioning state: ACTIVE In the event of

requested anomalies, refer to the
heating/ventilation
status: ACTIVE diagnostics
Becomes inactive if the
refrigerant pressure If the refrigerant
ET037: Low-speed fan unit > 22 bar pressure is > 22 bars,
relay control the fan assembly is
triggered at high speed
until the pressure falls
below 20 bars again.
status: ACTIVE In the event of a fan unit

ET038: High-speed fan unit
only if the refrigerant problem, go to command
relay control
pressure > 22 bar AC011 or AC012
Air conditioning
18
(selected) ET116: Air conditioning state: ACTIVE
compressor relay control.
PR006: Engine speed 800 rpm
If the injection computer does not allow compressor

operation
ET102: Air conditioning state: ACTIVE

requested
ET037: Low-speed fan unit state: INACTIVE

relay control
ET116: Air conditioning state: INACTIVE

compressor relay control.
PR006: Engine speed X = 800 rpm
13-64
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
Test conditions: engine stopped, ignition on.

PR002: Coolant If PR002 ≥ at 93°C In the event of a problem

temperature then on the fan, go to
ET038: High speed fan = command AC012
assembly relay control state: ACTIVE
When the temperature
Engine cooling (with air conditioning) The fan must run at high
drops to 88°C again, the
19 or speed
fan assembly cuts out
ET037: Low speed fan
(the command state
assembly (without air
becomes: INACTIVE).
conditioning)
If necessary, refer to Workshop Repair Manual section 13: Centrally managed

coolant temperature
Electrically heated ET186: Heated state: ACTIVE

20 windscreen windscreen None
(selected) PR006: Engine speed 1,000 rpm
ET106: Thermoplunger Command statuses:

relay control No. 1 ACTIVE or INACTIVE,
depending on
ET107: Thermoplunger If necessary, refer to
authorisation of the
relay no. 2 control Workshop Repair Manual
21 Thermoplungers injection computer
section 13:
ET108: Thermoplunger Thermoplungers.
relay no. 3 control 825 rpm
PR006: Engine speed
13-65
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
Test conditions: engine stopped, ignition on. ET003 Inactive.
Symbol on display and

Order Function Description Fault finding
notes
In the event of a problem:

AC301: No.1
consult fault finding
thermoplunger relay
procedure AC301.
AC302: No.2 You should hear the relay In the event of a problem:
22 Thermoplungers thermoplunger relay activate (two sequences of consult fault finding
~ 1 second ) procedure AC302.

AC303: No.3
thermoplunger relay
procedure AC002.
Air conditioning One should hear the relays In the event of problems,
AC003: Air conditioning
23 compressor and compressor being consult fault finding
inhibition
control actuated (ten sequences) procedure AC003.
During entry of the

command, maintain a
vacuum pressure of
Turbocharging approx. 600 mbar at the
24 AC004: Wastegate consult fault finding
solenoid valve valve inlet to hear it
procedure AC004.
operating and check
operation of the wastegate
diaphragm.
One should hear the relay

being actuated and the In the event of problems,
AC005: Low pressure
25 Boosting pump pump running (one consult fault finding
pump relay command
sequence of approx. procedure AC005.
15 seconds)
AC006: Solenoid valve

Fuel pressure control of fuel pressure Place your hand on the
26 consult fault finding
regulator (or flow regulation valve to feel it operating
procedure AC006.
solenoid valve)
13-66
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
Test conditions: engine stopped, ignition on. ET003 Inactive.

AC007: Exhaust gear In the event of a problem:

Exhaust gas Place your hand on the
27 recirculation valve consult fault finding
recirculation valve valve to feel it operating
command procedure AC007.
Any plug fault should

Place a clamp-on clear fault DF061.
ammeter on track 3 (on
the red 5 mm2 wire) of the Locate the faulty plug by
AC010: Preheating placing the clamp-on
28 Preheating relay preheating relay and
relay ammeter directly on the
check that the current
consumption is approx. power supply wires of
80 A. each plug: approx.
20A/ plug
AC011: Low speed fan You should hear the relay

unit relay activating and observe
that the fan unit is running
at low speed (only if the
procedure AC011.
vehicle is equipped with air
conditioning)
29
AC012: High speed fan You should hear the relay
unit relay activating and observe
that the fan unit is running
at high speed (only if the
procedure AC012.
vehicle is equipped with air
conditioning)
(For vehicles without air conditioning, only the AC011 command is operational. It causes the fan to run at high
speed)
13-67
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Parameter interpretation
FUEL TEMPERATURE
PR001:
IMPORTANT: In the event of a relatively low outside temperature, the difference

between the fuel temperature and the engine temperature after cold starting may be
greater than 30°C.
No faults should be present or stored.
Perform this fault finding procedure after an inconsistency is displayed in the
NOTES
Parameter menu.
Special note:
– Use a temperature sensor to compare the values displayed on the diagnostic tool.
– Use bornier Elé. 1613 for all operations on the engine management computer
connector.
Check for the absence of interference resistance on the following lines:

– between track J3, connector B of the computer and track 1 of the temperature sensor connector,
– between track G1, connector B of the computer and track 2 of the temperature sensor connector.
Repair.
Check that the sensor follows the "resistance as a function of temperature" (NTC) calibration curve correctly.
3820 Ω ± 282 at 10°C
2050 Ω ± 100 at 25°C
810 Ω ± 47 at 50°C.
Compare the value displayed by the diagnostic tool with the value shown by a temperature sensor (placed on
the return circuit).
Replace the sensor if it deviates (if a sensor deviates, it is often due to an electric shock).
AFTER REPAIR Repeat the conformity check.
13-68
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
COOLANT TEMPERATURE
PR002:

Perform this fault finding procedure after an inconsistency is displayed in the
Parameter menu.
NOTES Special note:
– Use a temperature sensor to compare the values displayed on the diagnostic tool.
connector.
Check that the cooling circuit is topped up and properly bled. Carry out the required operations.

– between track E1, connector B of the computer and track 2 of the temperature sensor connector.
– between track K3, connector B of the computer and track 3 of the temperature sensor connector.
Repair.
2252 Ω ± 112 at 25°C / 811 Ω ± 39 at 50°C / 283 Ω ± 8 at 80°C.
Compare the value displayed on the instrument panel with that shown by the diagnostic tool, and if they do not
correspond, compare with the value shown by a temperature sensor (placed in the expansion bottle). Replace
the sensor if there is a significant difference.
Replace the sensor if it deviates (if a sensor deviates, it is often due to an electric shock).
13-69
EDC15C3C - Bosch
DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
AIR TEMPERATURE
PR003:

Perform this fault finding procedure after noting an inconsistency in the parameter
menu.
NOTES
Special note:
– Use a temperature sensor to compare the values displayed on the tool.
connector.
Check that there are no foreign bodies on the air flowmeter grille. Clean if necessary.

– between tracks D3, connector B of the computer and track 1 of the temperature sensor connector,
– between tracks A3, connector C of the ECU and track 2 of the temperature-sensor connector
Repair.
3714 Ω ± 161 at 10°C / 2448 Ω ± 90 at 20°C / 1671 Ω ± 59 at 30°C.
Compare the value displayed by the diagnostic tool with the value shown by a temperature sensor (placed on
the flowmeter grille via the air filter outlet).
Replace the sensor (integrated into the air flowmeter) if it deviates (a sensor which deviates is often the result
of an electric shock).
13-70
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DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
COMPUTER SUPPLY VOLTAGE

PR004

NOTES Perform this fault finding procedure after noting an inconsistency in the parameter
menu.
Ignition on
If the voltage is lower than the minimum recommended, the battery is discharged or unserviceable:
– Recharge and teste the battery, check the charge circuit to detect the source of the problem, if necessary
replace the battery.
If the voltage is above the recommended level, the battery is overcharged:

Check that the charging voltage is correct with and without electrical consumers.
At idle speed
If the voltage is lower than the minimum recommended, the charging voltage is too low, or the battery is
unserviceable:
– Check the electrolyte level, recharge the battery and perform a test.
– If the battery is not faulty, check the charging circuit to find the source of this problem.
If the voltage is above the maximum recommended level, the charging voltage is too high:
The alternator regulator is faulty. Rectify this fault.
13-71
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DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
ATMOSPHERIC PRESSURE SENSOR

PR016
Perform this fault finding procedure after noting an inconsistency in the parameter
NOTES
menu.
The atmospheric pressure sensor is inside the engine management computer, and no repairs are possible.
Simply check that the computer's air vent is not clogged.
If the parameter is not correct, reset the computer. Check parameter PR016 with the engine running and with
the engine stopped but the ignition on.
If the value read is not correct, replace the computer.
vehicle.
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Program No.: CB
Vdiag No.: 0C
TURBOCHARGER PRESSURE
PR082

NOTES Perform this fault finding procedure after an inconsistency is displayed in the
Parameter menu or after a customer complaint (lack of performance, fumes, etc.).
Check the turbocharger pressure.:

– While stationary, with the engine idling + full load for 3 seconds (up to 4170 rpm) the tool should indicate a
turbocharger pressure of: ~ 1850 hPa for F9Q 760 / F9Q 762 engines
– During a road test, with the engine idling + full load for 3500 rpm, the tool should indicate a turbocharger
pressure of: ~ 1995 hPa for F9Q 760 engines
~ 1850 hPa for F9Q 762 engines
If the turbocharger pressures are not in conformance, check that the sensor is operating correctly by
proceeding as follows:
Remove the hose from the turbocharger pressure sensor at the inlet manifold end and connect it to a vacuum
pump. Then check the values displayed by the diagnostic tool, in the "parameters" screen, against the pressure
and vacuum values given by your vacuum pump.
Maximum pressure to apply: 2200 hPa or 2.2 bar.
Minimum pressure to apply: 400 hPa or 0.4 bar.
– In the event of a deviation > 100 hPa or 0.1 bar (depending on precision of the pump pressure
gauge). Check that there is no interference resistance on the signal line and on the sensor supply
lines. Replace the sensor if the electric connections are not faulty.
– If there is no deviation, check:
– the leaktightness of the hose connecting the sensor to the inlet nozzle, and the tightness of its
collars,
– the leaktightness of the admission circuit: unions, hose, sleeves, exchanger, turbocharger.
– Perform the interpretation of commands fault finding procedure: AC004: Wastegate.
– Ensure there is no oil in the air inlet circuit.
– Check the efficiency of the turbocharger.
– Ensure there is no back-pressure at the exhaust.
13-73
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DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
RAIL PRESSURE
PR083

NOTES Perform this diagnostic after detecting an inconsistency in the parameters menu or
following a customer complaint (starting problem, lack of power, injection noise, etc.).
It is strictly forbidden to carry out an ohmmeter check on the rail pressure sensor.
Normal rail pressure value according to operating conditions:
Idling - 275 bars ± 30 for F9Q 760 and F9Q 762 engines
During full load (3 seconds) - 1480 bar max. for F9Q 760 engines
- 1100 bar max. for F9Q 762 engine
If the pressures do not conform and there is an engine operating fault (starting fault, injection noise, inadequate
performance, irregular engine operation), perform the following checks:
1 Make sure there is no interference resistance on the connections between:
Engine management computer, connector B track H2 Track 3 rail pressure sensor
Engine management computer, connector B track D1 Track 2 rail pressure sensor
Engine management computer, connector C track B3 Track 1 rail pressure sensor
2 Make sure the low-pressure diesel circuit is primed (max. 2.5 bar) at the outlet of pump EKP13
(submerged in the tank), regulated by the anti-return valve between 0.2 and 0.5 bar at the high pressure
pump inlet).
3 Check filter condition: pressure difference of at most 0.3 bar between the diesel fuel filter inlet and
outlet.
4 Check that there are no leaks on the high pressure circuit (visual checks, odours, etc.): pump, regulation
solenoid valve, pipes, rail unions, injectors, etc.
5 Check the operation of the pressure regulator (AC006 fault finding procedure).
6 Ensure correct operation of the injectors (return leakage too high, clogging, sticking: see injector fault
finding procedure).
13-74
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Program No.: CB
Vdiag No.: 0C
REFRIGERANT FLUID PRESSURE

PR192

NOTES Perform this fault finding procedure after an inconsistency is displayed in the
Parameter menu or after a customer complaint (no air conditioning, etc.).
Display PR192 from the Parameter or Function menu of your diagnostic tool:
Start the engine, maintain a speed of 1500 rpm and turn on the air conditioning:
– if the pressure is above normal, continue to stage no. 2.
– if the pressure does not increase or remains lower than normal, go to the command menu on your diagnostic
tool and check the operation of the compressor and its relay by running command AC003. In the event of a
problem, apply the relevant fault finding procedure.
If the compressor and relay are not faulty: Check the conformity of the refrigerant pressure sensor by
comparing* the value shown on the diagnostic tool (PR192) with the value given by the pressure gauges
on an air conditioning station.
* IMPORTANT: the tool displays the absolute pressure, if the high pressure gauge on your charge station
displays the relative pressure, there will be a normal deviation between the two values, approximately equal to
atmospheric pressure.
If the values do not match, (gap > ± 1.5 bar), ensure the continuity and absence of interference resistance
on the connections between:
Engine management computer, connector B track F1 Track 1 refrigerant pressure sensor
Engine management computer, connector C track A3 Track 2 refrigerant fluid pressure
sensor
Engine management computer, connector B track G4 Track 3 refrigerant fluid pressure
sensor
If the computer/refrigerant pressure sensor connections are not faulty, replace the refrigerant
pressure sensor (see section 62 of the Workshop Repair Manual).
If the values coincide, the sensor is not faulty, continue to stage no. 2
Stage no. 2Perform a complete fault finding check on the air conditioning.
13-75
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Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Interpretation of commands
AIR CONDITIONING INHIBITION

AC003

NOTES Perform this diagnostic after detecting an anomaly in the command menu or following
a problem with the air conditioning compressor.
If the compressor does not engage when command AC003 is issued, carry out the following checks:
If the compressor
relay does not
operate
Check the continuity of the following connection:

Engine management computer, connector A, track F4 Track 2 Compressor relay socket R6
Check fuse F2 and the power supplies of the compressor relay socket:
Compressor relay socket R6 track 1 12 V after relay
Compressor relay socket R6 track 3 12 V battery.
Check the resistance of the compressor clutch coil: 3.5 Ω ± 0.5.
If all these checks are OK, check operation of the compressor relay by the engine management computer in
the following way:
Remove the compressor relay, put a 50 to 100 Ω resistor on the mounting in place of the relay coil (tracks 1
and 2), reconnect the voltmeter terminal (-) on track 2 of the relay socket and the (+) voltmeter terminal on
track 1 of the relay socket:
Clear the fault and run command AC006;
– If the voltmeter does not display the battery voltage (ten sequences), replace the engine management
computer. If necessary, modify the configuration of the new computer to match the equipment options
present on the vehicle.
– If the voltmeter displays the battery voltage (ten sequences), replace the compressor relay.
If the compressor
relay operates
Check the air conditioning compressor clutch resistance: 3.5 Ω ± 0.5.

Check the continuity and insulation relative to earth of the following connection:
Compressor relay socket "R6", track 5 Track A compressor connector
Check the presence of earth on track B of the compressor connector.
Check fuse F3 (15A) and its holder and terminals.
Check power supply of the compressor relay socket: track 3 12 V battery
Check the conformance of compressor diode No. 10 in the engine fuse/relay box.
13-76
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Program No.: CB
Vdiag No.: 0C
TURBOCHARGING LIMITATION VALVE

AC004
Carry out this fault finding procedure following interpretation of an unresolved fault, or
NOTES following handling of the interpretation of PR082 and/or following a customer complaint
(lack of power, smoke, etc.).
In the event of a problem on the braking assistance (SERVOFREIN), first check that the vacuum pump
operates correctly and check the conformity of its unions and wastegate.
IMPORTANT: When performing this command, a vacuum pressure (600 mbar) must be maintained at the inlet
of the solenoid valve, in order to hear it operate and verify the simultaneous operation of the wastegate flap.
If, when this command is executed, no flap movement is observed:
– Check the resistance of the wastegate (turbocharger pressure limitation valve) between its tracks1 and 2.
Replace the wastegate if the resistance is not approximately: 16.5 Ω ± 1.6 at + 25°C / 22.1 Ω ± 2.2 at
+ 110°C.
– Make sure there is no interference resistance on the connections between:
Engine management computer, connector B track L2 Track 1 of the turbocharger pressure
regulator
12 V after relay Track 2 of the turbocharger pressure
regulator
– Check the leaktightness of the vacuum circuit, from the vacuum pump to the wastegate control diaphragm
(to check the operation of the wastegate diaphragm and its flap, operate it directly with a vacuum pump).
– Check the setting of the wastegate rod (Workshop Repair Manual section 12: Wastegate).
– Check the upper and lower stops of the wastegate flap.
13-77
EDC15C3C - Bosch
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Program No.: CB
Vdiag No.: 0C
LOW PRESSURE PUMP RELAY

AC005
No faults should be present or stored

NOTES Perform this diagnostic after detecting a malfunction in the command menu or following
a customer complaint (starting problem).
Reminder: the low-pressure pump is used for priming the high-pressure pump. As soon as the engine speed
exceeds 300 rpm or the high pressure reaches approx. 250 bar, the relay command is deactivated.
If relay "R3" is not actuated, (by command AC005): Carry out a check of the connectors of relay socket "R3".
If the problem persists, check that relay R3 is operated by the engine management computer as follows:
– Disconnect relay R3, put a 50 to 100 Ω resistor on the relay socket in place of the coil and connect the
voltmeter as follows:
Positive terminal on + 12 V battery
Negative terminal on track 2 of relay socket "R3".
– Delete the fault.
– Run command AC005,
– If the voltmeter does not display the battery voltage (a sequence of approximately 10 seconds), replace the
computer. If necessary, modify the configuration of the new computer to match the equipment options
present on the vehicle.
– If the voltmeter indicates the battery voltage correctly, replace relay "R3".
If the relay is actuated, but the low-pressure pump does not work, check with the help of the wiring diagram:
– the battery + power supply for track 3 of relay socket "R3";
– the continuity of the connection between track 5 of relay socket "R3" and track 1 of the low-pressure pump
motor connector;
– the conformity of low-pressure pump relay "R3" (and its mounting);
– the conformity of the low pressure pump (insulation, etc.),
– the continuity of the connection between track 2 of the low-pressure pump motor connector and earth.
13-78
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Program No.: CB
Vdiag No.: 0C
FUEL PRESSURE SOLENOID VALVE

AC006
(pressure regulator)
Perform this diagnostic after detecting an anomaly in the command menu, or following
interpretation of an unresolved fault, or following a customer complaint.
NOTES
Special note: a suspected problem with the pressure regulator (or flow regulator)
requires the pump/regulator unit to be replaced.
Check the resistance of the pressure regulator between tracks 1 and 2.

– If the resistance is not approximately: 5 Ω ± 0.5 at 20°C. Replace the pump/pressure regulator unit.
– Make sure there is no interference resistance between:
Engine management computer, connector B track L1 Track 2 of the pressure regulator connector.
12 V after relay Track 1 of the pressure regulator connector.
Check the operation of the computer output stage by measuring the solenoid valve Opening Cyclic Ratio while
executing its command. During the 24 seconds of this command, the valve receives ten cycles from two successive
Opening Cyclic Ratios which can be measured in the following ways:
By voltmeter: With the solenoid valve connected, link the voltmeter's earth lead to track 2 of the fuel pressure
solenoid and the positive lead to track 1, clear any fault from the fuel pressure solenoid valve, then execute
command AC006:
The voltmeter should display two successive voltages approximately equal to the battery voltage and
the current Opening Cyclic Ratio, i.e. successively: ~ 3.15 V for an Opening Cyclic Ratio of 25% then
~ 9.45 V for an Opening Cyclic Ratio of 75% (ten cycles).
By oscilloscope on 5 V/div calibre and a base time of 1 ms/div: with the solenoid valve connected, connect the
oscilloscope to the battery earth and the positive touchpoint on track 2 on the fuel pressure solenoid valve, clear
a possible fault on the fuel pressure solenoid valve, then initiate command AC006:
The oscilloscope should display a square signal of 12.5 V amplitude at a frequency of 185 Hz (with an Opening
Cyclic Ratio which switches from 25 to 75% successively).
If the measurement does not indicate any control, or a fixed direct current, replace the engine management
computer, if necessary modify the configuration of the new computer against the options presented on the vehicle.
If the solenoid valve, its connection and its management are in conformance, go on to the next stage:
With the engine running at a different speed, display PR202: Regulated fuel flow:
– If this value falls without a noticeable decrease in the rail pressure, this may indicate seizure or jamming of the
flow solenoid valve (jammed open).
In this case, and in the case of overpressure in the rail:
Check operation of the injectors: see Help section
on the pressure sensor: Interpretation of PR083 fault finding procedure,
If these two checks do not indicate any fault, replace the pump/regulator assembly.
– If this value increases without a noticeable increase in the rail pressure, this may indicate sticking or jamming of
the pressure solenoid valve (jammed shut).
In this case, and in the case of underpressure in the rail:
Ensure correct operation of the "parameter interpretation diagnostic PR083 pressure sensor, check 1".
Make sure that the low-pressure diesel circuit is primed (max. 2.5 bar) at the outlet of pump EKP13 (submerged
in the tank), regulated by the anti-return valve between 0.2 and 0.5 bar at the high pressure pump inlet).
Check the leaktightness of the low pressure and high pressure diesel circuit (visual checks, odours, etc.): pump
body, pressure regulator, pipes, rail unions and injectors, etc. Perform the necessary repairs.
Check tension of the high pressure pump drive belt.
Check the operation of the injectors: Injector fault finding, see Help section.
– If the checks are correct, replace the pump/regulator unit.
13-79
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Program No.: CB
Vdiag No.: 0C
EGR VALVE
AC007
Perform this fault finding procedure following unresolved fault DF077 (1.DEF or 2.DEF)
NOTES
or following a customer complaint (poor performance, smoke, etc.).
Stage no. 1:
–If its resistance is not approximately 8 Ω ± 0.5 at + 20°C, replace the exhaust gas recirculation valve.
Make sure there is no interference resistance on the connections between:
Engine ECU, connector B track M1 Track 5 exhaust gas recirculation valve connector
12 V after relay Track 1 exhaust gas recirculation valve connector
Check the operation of the computer output stage by measuring the exhaust gas recirculation valve Opening
Cyclic Ratio while executing the command. During the 24 seconds of this command, the valve receives ten
cycles of two successive Opening Cyclic Ratios, which can be measured in the following ways:
– By oscilloscope on 5 V/div calibre and a base time of 2 ms/div: with the exhaust gas recirculation valve
connected, connect the oscilloscope earth to the battery earth and the positive touchpoint on track 5 of the
exhaust gas recirculation valve, clear any possible exhaust gas recirculation valve fault, then initiate
command AC007.
The oscilloscope should display a square signal of 12.5 V amplitude at a fréquency of 140 Hz, (with an
Opening Cyclic Ratio ranging from 25 to 75%).
– Or with a voltmeter: with the exhaust gas recirculation valve connected, connect the voltmeter earth
braiding on track 2 of the exhaust gas recirculation valve and the positive braid to
track 1, clear any possible exhaust gas recirculation valve fault, then initiate command AC007; the voltmeter
should display two successive voltages approximately equal to the product of the battery voltage and the
current Opening Cyclic Ratio, i.e. successively: 3.15 V for an Opening Cyclic Ratio of 25% then 9.45 V for
an Opening Cyclic Ratio of 75% (10 cycles).
If the oscilloscope (or the voltmeter) does not indicate any control, or a fixed direct current, replace the engine
management computer. If necessary, modify the configuration of the new computer to match the equipment
options present on the vehicle.
If the exhaust gas recirculation valve, its connection and its automation are not faulty, continue to the next
stage:
Stage no. 2
Disconnect the connector and remove the exhaust gas recirculation valve:
– If removal reveals that the valve is blocked (e.g.: valve in open position), replace the exhaust gas
recirculation valve.
– Otherwise, reconnect the connector, clear the fault and run command AC007:
The valve receives two successive Opening Cyclic Ratio cycles: 25% and 75%.
Then check:
– The movement of the valve when the command is executed, (2.25 mm ± 0.1 for an Opening Cyclic Ratio of
25% and 6.75 mm ± 0.3 for an Opening Cyclic Ratio of 75%).
– There is no clearance between the exhaust gas recirculation valve and its control stalk as well as the general
condition (clogging, hard point, etc.).
– Valve closing when the command is completed.
If during command AC007, no movement of the exhaust gas recirculation valve is noticed, or if these checks
reveal an irreparable blockage or seizing, replace the exhaust gas recirculation valve.
13-80
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
LOW SPEED FAN ASSEMBLY RELAY

AC011

NOTES Perform this fault finding procedure after detecting an anomaly in the commands menu
or following an engine cooling or air conditioning fault.
REMINDER: if the vehicle is not fitted with air conditioning, there is no low speed fan assembly relay; in that
case it is replaced by the fan assembly relay "R9". In this case, command AC011 triggers fan operation at high
speed and the procedure to be complied with in case of problems is the procedure for command AC012.
If relay "R10" is not actuated (when command AC011 is run):

Check the "R10" relay socket connections.
If the problem persists, check that relay "R10" is controlled by the engine management computer as follows:
– Disconnect relay "R10", put a 50 to 100 Ω resistance on relay socket "R10", in place of the coil and connect
a voltmeter as follows:
Negative terminal on track 2 of the "R10" relay socket.
– Clear the fault and initiate the "AC011" command.
If the voltmeter does not display the battery voltage (ten sequences of 1 second), replace the computer.
vehicle.
If the voltmeter displays the battery voltage (ten sequences of 1 second), replace relay "R10".
If relay "R10" activates, but there is still a coolant temperature or air conditioning warning fault, use the wiring
diagram to check:
– the conformance of fan fuse "F03";
– presence of + battery supply on track 3 of the low speed fan unit relay socket, "R10",
– the conformity of relay "R10",
– the continuity of the connection between track 5 of relay socket "R10" and track 1 of the low-speed resistor;
– the conformity of the low-speed resistor (resistance and connections);
– the continuity of the connection between track 2 of the low speed resistor connector and track 1 of the fan
connector;
– the condition of the fan;
– the continuity of the connection between track 2 of the fan connector and earth.
13-81
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
HIGH-SPEED FAN ASSEMBLY

AC012

NOTES Perform this fault finding procedure after detecting a fault in the commands menu or
following a problem of engine cooling.
REMINDER: if the vehicle is not fitted with air conditioning, this command is not operational. Fan operation at
high speed is in that case triggered by command AC011 and the procedure to be complied with in case of
problems is as follows:
If relay "R9" is not activated (when command AC012 is executed):

Check the "R9" relay socket connections.
If the problem persists, check that relay "R9" is operated by the engine management computer as follows:
– Disconnect relay "R9", fit a 50 to 100 Ω resistor on the "R9" relay socket in place of the coil and attach a
Negative terminal on track 2 of "R9" relay socket
– Clear the fault and initiate the "AC012" command.
If the voltmeter does not display the battery voltage (ten sequences of 1 second), replace the computer.
vehicle.
If the voltmeter displays the battery voltage (ten sequences of 1 second), replace relay. "R9".
If relay "R9" activates, but there is still a coolant temperature warning fault, use the wiring diagram to check:
– the conformance of fan fuse "F03";
– presence of + battery supply on track 3 of the high speed fan unit relay socket, "R9",
– the conformity of relay "R9",
– the continuity of the connection between track 5 of relay socket "R9" and track 1 of the fan connector,
– the conformity of the fan assembly,
– the continuity of the connection between track 2 of the fan connector and earth.
13-82
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
THERMOPLUNGER RELAY No. 1

AC301

Perform this fault finding procedure in the event of the function not working properly,
NOTES
indicated in the command menu or in the event of a passenger compartment heating
or demisting fault.
If relay "R7" is not actuated when command AC301 is run:

Check the connectors of additional heater No. 1 relay socket "R7".
– Disconnect relay "R7", put a 50 to 100 Ω resistor on the relay socket in place of the coil and connect the
Negative terminal on track 2 of relay socket "R7"
– Clear the fault.
– Run command AC301.
If the voltmeter does not display the battery voltage (two sequences of 1 second), replace the computer.
vehicle.
If the voltmeter does display the battery voltage (two sequences of 1 second), replace relay "R7".
If relay "R7" activates, but there is still a passenger compartment heating or demisting fault, use the wiring
diagram to check:
– the conformance of fuse "F01" (70A);
– the presence of + 12 V battery on track 3 of relay socket "R7",
– the conformance of relay "R7";
– the continuity between track 5 of relay socket "R7" and the supply lug of thermoplunger 1;
– the conformity of the thermoplunger resistance: 0.45 Ω ± 0.05 at 20°C,
– the presence of earth at the plenum chamber (thermoplunger mounting).
Also check the level of the cooling circuit and that there are no leaks.
13-83
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
THERMOPLUNGER No. 2 RELAY

AC302

NOTES or demisting fault.
Special note:
The "No. 2 thermoplunger relay", supplies thermoplungers 2 and 3 in parallel.
If relay "R8" is not activated when command AC302 is executed:

Battery negative terminal on track 2 of relay socket "R8".
– Delete the fault.
– Begin command AC302.
vehicle.
diagram to check:
– the continuity between track 5 of relay socket "R8" and the supply terminals of thermoplungers 2 and 3,
– the conformity of the thermoplunger resistors: 0.45 Ω ± 0.05 at 20°C,
13-84
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
THERMOPLUNGER No. 3 RELAY

AC002

NOTES
or demisting fault.
If relay "R1" is not activated when command AC002 is executed:

Negative terminal on track 2 of relay socket "R1"
– Clear the fault.
– Run command AC002.
vehicle.
diagram to check:
– the continuity between track 5 of relay socket "R1" and the supply lug of thermoplunger 4;
– the conformity of the thermoplunger resistance: 0.45 Ω ± 0.05 at 20°C.
13-85
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Customer complaints
Before carrying out the steps associated with customer complaints, check for the
absence of faults and the conformity (or otherwise) of the parameters and states, using
If the customer complaint is not eliminated, then proceed according to the
corresponding fault finding chart.
NO COMMUNICATION WITH THE COMPUTER CHART 1
STARTING DIFFICULT OR IMPOSSIBLE CHART 2
INJECTION NOISE CHART 3
POOR PERFORMANCE CHART 4
IRREGULAR ENGINE OPERATION CHART 5
13-86
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Fault finding chart
CHART 1 No communication with the engine management computer
Check the conformity of the vehicle type and the domain selected on your tool.
Make sure that the tool is not faulty by trying to establish dialogue with a computer on another vehicle.
In the engine fuse and relay box, check the correctness of:
→ fuses F2 and F4,
→ the injection computer supply relay, marked "R2":
65 Ω ± 5 Ω between tracks 1 and 2
infinite resistance between tracks 3 and 5 (contact open)
resistance < 0.3 Ω between tracks 3 and 5 (contact closed)
Check the conformity of the impact sensor (inertia sensor) at rest (before impact): continuity between tracks 1
and 3.
Place bornier Ele 1613 on the engine harness on the computer side, and verify conformance of the power
supplies:
Engine management computer, connector B track E3 + After ignition
Engine management computer, connector B tracks L3, L4 and M4 Earth
by shunting tracks 3 and 5 of relay socket "R2":
Engine management computer, connector B tracks M3 and M2 + Battery (after relay)
Ensure continuity of the connection between:
Engine management computer, connector B track D4 Track 2 relay socket "R2"
Check the supply to the diagnostic socket:

→ + before ignition on track 16 / + after ignition on track 1 / earth on tracks 4 and 5
Ensure the continuity of the following connection:
Engine management computer, connector A track C3 Diagnostic socket track 7 (line K)
If the tool is not faulty, try to communicate with another computer on the same vehicle.
If you cannot communicate with another computer on the same vehicle, it may be that a faulty computer is
causing interference on line K. To locate it, proceed by elimination by successively disconnecting the following
computers (depending on the equipment): air conditioning, air bag, ESP and ABS, UCH, instrument panel,
central communication unit, proximity sensor. Try to make communication between each disconnection.
→ If you still can't enter into communication, disconnect all the above-mentioned computers, as well
as the engine management computer, and check insulation against + 12 V and against earth of
track 7 of the diagnostic socket.
If you can enter into communication with another computer on the same vehicle: replace the engine
management computer. If necessary, modify the configuration of the new computer to match the equipment
options present on the vehicle.
AFTER REPAIR Perform a road test followed by a check with the diagnostic tool.
13-87
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
Starting problems
CHART 2
(no starting or difficulty starting the engine)
Before analysing this customer complaint, check for absence of faults, and conformity
NOTES (or otherwise) of parameters and statuses, using the diagnostic tool.
If the customer complaint is not resolved, perform the following checks:
See next impossible

Is starting difficult or impossible?
page
difficult
Check the engine earths.

Make sure the engine speed reaches 250 rpm when the starter motor is operated, displayed in the parameter
screen.
Ensure that the correct fuel is being used.
Check that the low pressure diesel circuit is primed (presence of air bubbles upstream of the pump; if there are
numerous such bubbles, look for the air leak).
Check the supercharging pressure at the high-pressure pump inlet, namely: 0.2 to 0.5 bar.
Check operation of pre-heater plugs (absence of DF061 fault).
Check condition of diesel fuel filter (measurement of the pump pressure upstream and downstream of the
filter).
Ensure the tightness of the high-pressure circuit - pump, pipes, unions (visual check + odours).
Check the condition of the air filter (clogging).
Check the position of the exhaust gas recirculation valve (blockage, mechanical seizing, see interpretation of
commands: AC007).
Check the consistency of the coolant temperature sensor signal (compare the value given by the tool with that
given by a thermometer).
Ensure correct operation of the injectors (return leakage too high, clogging, sticking: see injector fault finding
procedure).
Check compression values:
1: according to current consumption in the starting phase (Compression test menu on the
CONSULT II tool).
2: in the event of unbalanced fuel consumption, use a compression meter to complete the
measurements.
13-88
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
Starting impossible
CHART 2
(or vehicle starts and stalls immediately)
Correct From the "STATUS" menu on your diagnostic tool, verify the
conformance of the immobiliser system: "ET003" should be "inactive",
"ET110" should be "YES".
Incorrect
Refer to the immobiliser Check the position and conformance of the impact switch.
fault finding procedure. Check the presence of 12 Volts after relay on tracks M2 and M3 of
connector B on the engine management computer.
Check the battery charge as well as the condition and tightness of the
terminals and the engine earth connections.
Check the engine fuses (+ mountings, wires and terminals).
Check the conformance of the main relay (+ mountings, wires and
terminals).
Check the engine speed sensor mounting.
Check the absence of fault: DF070; camshaft sensor/engine speed
consistency.
Make sure the engine speed reaches 250 rpm when the starter motor
is operated, displayed in the parameter screen.
Ensure the presence and conformity of fuel in the tank.
test
YES Activate the starter motor:
Does the pressure rise normally in the rail?
high pressure ≅ 170 bar at approx. 250rpm
NO
Make sure of correct
operation of the injectors Make sure the low-pressure diesel circuit is primed.
(no internal leaks, Check the condition of the fuel filter (measurement of the LP pump
gumming or jamming) pressure upstream and downstream of the filter).
Check the engine Check the leaktightness of the high-pressure circuit - pump, pipes,
compression. unions (visual checks + smells).
Ensure correct operation of the pressure sensor (interpretation of
parameters: PR083)
Make sure that the pressure regulator is not jammed/seized.
Check the injectors (refer to the injector fault finding procedure in the
Help section).
13-89
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
CHART 3 Injection noise
REMINDER: A just-audible knocking noise under low load conditions between 1800 and 2500 rpm is a
characteristic of the normal operating noise for this engine. No intervention is therefore recommended. This
noise should disappear as the engine is revved up.
If occurring following cold-starting:

Ensure correct operation of the preheating function.
Check the consistency:
– of the fuel and engine temperatures; fault finding procedure PR002 and PR001
– of the rail pressure signal; diagnostic PR083
If the fault persists, carry out an injector fault finding procedure.
If you hear the noises at idling speed:

Check the condition of the injector connectors and contact, and the pressure regulator.
Ensure the correct fuel is being used.
Check that there is no air in the low pressure fuel circuit.
Ensure supply to the fuel heater.
Check the condition of the air filter.
Check the position of the exhaust gas recirculation valve (interpretation of commands: AC007).
Check the consistency of the airflow signal.
If the fault persists, perform the fault finding procedure on the injectors, then the high pressure pump.
If occurring at all engine speeds,
Check the condition of the injector connectors and contacts, and the pressure regulator.
Ensure the correct fuel is being used.
Check the consistency and stability of the rail pressure signal (PR083 fault finding procedure).
If occurring at transient engine speeds:

In road testing, when changing gear, view the PR202 parameter; if the value varies, without having any major
influence on the rail pressure, this may indicate seizure of the flow controller. In this case, refer to diagnostic
AC006.
13-90
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
CHART 4 Poor performance
NO
Is the poor performance accompanied by smoke?
If yes: check whether the wastegate or its solenoid valve are jammed in open
position (use fault finding procedure AC004).
NO Is the poor performance il accompanied by smoke at full load?
If yes: check whether the exhaust gas recirculation valve is jammed in open
position. Use fault finding procedure AC007.
Does the engine rotate on all cylinders?
If no: check the operation of the injectors (injector fault finding procedure Help
section).
Check the conformity of the pedal sensor, atmospheric pressure sensor and exhaust gas recirculation valve.
Check the level of clogging of the air filter.
Make sure there are no foreign bodies on the grille of the flowmeter and in the air inlet section (e.g., detachment
of the internal lining of a hose).
Check:
– the condition of the intercooler (clogging),
– the leaktightness of the admission circuit between flowmeter and turbocharger,
– the tightness of the oil vapour rebreathing circuit,
– the flow regulator (jamming or seizing; use fault finding procedure AC006),
– the wastegate and its solenoid valve (jamming or seizing),
– the absence of leaks in the low pressure and high pressure diesel circuit,
– the turbocharger efficiency.
– Check consistency of the following signals: flowmeter, coolant temperature sensor, turbocharger pressure
sensor, fuel-temperature sensor.
– Check the engine compression.
– Make sure there is no back-pressure at the exhaust.
13-91
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DIESEL INJECTION
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Program No.: CB
Vdiag No.: 0C
CHART 5 Irregular engine operation
If, when changing gears, the vehicle jerks or builds up engine speed (with loss of engine braking), check
conformance of the clutch sensor and if need be carry out the DF097 procedure: Step 1.
Ensure that the correct fuel is being used.
– Make sure the low-pressure circuit is primed (no air in the circuit).
– Check conformance of rail pressures: 250 bar at idling speed and 1350 bar under load with foot hard down
on the accelerator.
– Check conformity of the air flow: 30 to 36 kg/h air flow at 800 rpm,
390 kg/h under load at full load.
If this is not the case, check the leaktightness of the inlet circuit and ensure that there are no foreign bodies on
the flowmeter grille.
Check the operation of the turbocharging function (refer to AC004).
– Check the injectors: with engine running at idling speed, disconnect the injectors one after the other:
If disconnecting one of the injectors does not cause a change in operation, it indicates a fault (electrical or
mechanical). After eliminating the connections as the possible cause of the fault, replace the faulty injector.
Clear the faults caused by the multiple disconnections, then perform a conformity check.
Check the engine compression values.
13-92
EDC15C3C - Bosch
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13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Help
INJECTOR FAULT FINDING PROCEDURE
STAGE no. 1: check for electrical conformity

If you perform this fault finding procedure following an unresolved fault (DF099 to DF102), go directly to step 2.
Otherwise, carry out the following checks:
– Resistance between tracks 1 and 2 of each injector: 0.33 Ω at 20°C /2 Ω max.
– Continuity, absence of interference resistance and insulation on the following connections:
Engine management computer, connector C track M1 Track 2 of of injector no. 1 connector
Engine management computer, connector C track M3 Track 1 of injector no. 1 connector
Engine management computer, connector C track M2 Track 2 of the connector for injector no. 3
Engine management computer, connector C track L2 Track 1 of the connector for injector no. 3
Engine management computer, connector C track L1 Track 2 of the injector no. 4 connector,
Engine management computer, connector C track M4 Track 1 of the injector no. 4 connector
STAGE no. 2: check the balance of the injector return flow
From the "parameters" menu of your diagnostic tool, check conformance of the fuel pressure at 800 rpm, at approx.
2000 rpm, then after switching off the engine. Failure of one or more injectors can result in either an overpressure
or an underpressure in the rail:
Fit tappings on the injector returns towards the measuring cylinders, start the engine and check the flow balance,
first at 800 rpm then at ˜ 2000 rpm:
In the event of overpressure in the rail:
Replace the injector for which the return indicates no leak or a smaller leak than for the other returns,
In the event of under-pressure in the rail:
Replace the injector whose return shows a stronger leak than the others.
The gradual fall in pressure in the rail, when the engine is switched off, is obtained by discharge of the high
pressure towards the injector return circuits (about 2 minutes to fall below 2 bar). It is therefore possible to carry
out the same procedure for checking flow balance after the engine has been switched off, or, better still, after timing
(obtaining a high rail pressure, with the engine stopped, due to a sudden engine switch-off).
STAGE °2: check on leaktightness of the injector nozzle
If the engine starts:
With the engine running, disconnect the injectors one after the other.
Replace the injector which causes no variation in operation when it is disconnected. (this also applies to
blocked closed injectors). Clear the faults that are caused by these multiple disconnections, and then road
test the vehicle to confirm repair.
If the engine does not start:
Check the level and condition of the engine oil (contamination by diesel oil).
If the preceding check indicates pollution, remove the injectors to pinpoint which one is leaking. (If one of
the four nozzles is wet and the other three are dry, the injector with the wet nozzle is leaking). Replace
the faulty injector.
For removal of injectors, refer to the method defined in the Workshop Repair Manual, Section 13.
13-93
EDC15C3C - Bosch
DIESEL INJECTION
13
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762 Fault finding - Glossary
F9Q 760 and 762 engine speed (60 and 74 kW):
Idling, warm engine 800 rpm
Idling + heated windscreen 1000 rpm
Idling + thermoplungers 825 rpm
Fast idling in the event of accelerator pedal sensor failure: 1200 rpm
Maximum engine speed, no load 3000 rpm
High pressure pump CP3 from 275 to 1350 bar
Boosting pump 2.5 bar max. / flow rate 80 to 100 litres/h. minimum
Anti-return valve and low pressure controller Calibration: from 0.2 to 0.5 bar
Pressure sensor screwed on rail
Injector 0.33 Ω at 20°C / 2 Ω max
Flow regulator (on high-pressure pump) R = 5 Ω at 20°C (not removable)
Injection computer 128 tracks
Accelerator pedal sensor R track 1 = 1200 Ω ± 480
R track 2 = 1700 Ω ± 680
Heater plug R = 0.6 Ω (consumption at start of preheating 20A)
Air temperature sensor R = 3714 Ω ± 161 at 10°C / 2448 Ω ± 90 at 20°C / 1671 Ω ± 59 at 30°C
Diesel oil temperature sensor R = 3820 Ω ± 282 at 10°C / 2050 Ω ± 100 at 25°C / 810 Ω ± 47 at 50°C
Engine coolant temperature sensor R = 2252 Ω ± 112 at 25°C / 811 Ω ± 39 at 50°C / 283 Ω ± 8 at 80°C
Engine speed sensor R = 800 Ω ± 80 at 20°C
Camshaft sensor Hall-effect sensor
Turbocharger pressure sensor Power supply 5 ± 0.25 V / pressure from 0 to 2.5 bar.
Wastegate control solenoid valve R = 16.5 Ω ± 1 to 25°C
Air flowmeter Track 1: air temperature signal Track 4: + 12 V battery
Track 2: - flowmeter Track 5: air flow signal
Track 3: + 5 V flowmeter Track 6: Earth
Exhaust gas recirculation valve R between tracks 1 and 5 (coil): = 8 Ω ± 0.5 at 20°C
Thermoplungers R = 0.45 Ω ± 0.05 at 20°C
(R = resistance)
13-94
114
ANTI-POLLUTION
F9Q ENGINE
Oil vapour rebreathing 14
CIRCUIT DIAGRAM
A Oil vapour rebreathing pipe for the bottom of engine
1 Engine B Oil vapour rebreathing pipe for the top of engine.

2 Oil decanter
3 Air filter unit C Oil decanter.
4 Inlet manifold
D Oil vapour rebreathing pipe linked to the inlet pipes.
INSPECTION
To ensure the correct operation of the anti-pollution

system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
14-1
ANTI-POLLUTION
F9Q ENGINE
Exhaust gas recirculation 14
CIRCUIT DIAGRAM
1 Engine
2 Injection computer
3 Inlet manifold
4 Exhaust manifold
5 Exhaust gas recirculation solenoid valve
6 Coolant temperature sensor
REMOVING THE VALVE
The exhaust gas recirculation valve is an interference fit with the inlet
manifold.
To make it easier to replace, it is preferable to remove the manifolds.
AIM OF THE EXHAUST GAS RECIRCULATION CIRCUIT
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content
of the exhaust gases.
The injection computer allows gas to pass by controlling a solenoid valve.
14-2
ANTI-POLLUTION
F9Q ENGINE
Exhaust gas recirculation 14
OPERATING PRINCIPLE
The valve is controlled by an Opening Cyclic Ratio

(OCR) signal emitted by the injection computer. The
Opening Cyclic Ratio signal adjusts the opening of
the valve and consequently the quantity of exhaust
gas directed back to the inlet manifold.
OPERATING CONDITIONS
The parameters controlling activation of the exhaust

gas recirculation solenoid valve are the following:
– coolant temperature,
– air temperature,
– atmospheric pressure,
– accelerator pedal position,
– engine speed,
– air flow,
– injection flow rate,
– turbocharging pressure. If there is a fault in:
– the coolant temperature sensor,
Exhaust gas recirculation is cut off if: – the air temperature sensor,
– the battery voltage is below 9 V, – the atmospheric pressure sensor,
– engine speed is below 600 rpm. the exhaust gas recirculation solenoid valve is fed for
– engine speed is greater than 3000 rpm. 40 seconds on each return to idle speed if the air
– mapping (engine speed/load) exceeds a given temperature is greater than 15 °C.
threshold,
– vehicle speed is less than 7.5 mph (12 kph), and
engine speed is less than 1000 rpm
– after running for 18 minutes if the air temperature
stays between 10 °C and 30 °C.
The exhaust gas recirculation valve is not controlled

after engine start-up depending on coolant
temperature mapping.
X Time
Y Coolant temperature (°C)
1 Solenoid feed
2 Sensor feed
4 Sensor earth
5 Solenoid earth
6 Sensor output
14-3
117
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Introduction
GENERAL APPROACH TO FAULT FINDING
To carry out a fault finding test on the SAGEM 2000 Vdiag 08 injection system, the
following elements are required:
– The wiring diagram of the function on the vehicle concerned.
– Consult II diagnostic tools.
– Multimeter.
– Test bornier Elé. 1590.
1 Use one of the diagnostic tools to identify the system fitted on the vehicle (reading the computer family
- SAGEM 2000 Vdiag 08).
NOTE:
If dialogue cannot be established with the computer, go straight to the Customer complaints section and refer to
FAULT FINDING CHART 1 No dialogue with the computer.
2 Locate the Fault finding documents corresponding to the system identified.
3 Read the faults stored in the computer memory and use the Fault interpretation section of the
documents.
Reminder: the interpretation of a fault should be considered when using the diagnostic tool after the engine
has been switched off and on again.
There are two types of fault interpretation, faults present and faults stored in memory.
– If the fault is declared "Present":
run the diagnostic directly.
– If the fault is declared "Stored":
follow the notes for application to a stored fault.
If the fault is not returned as "present", run the diagnostic but do not replace components.
In both cases, complete the fault finding procedure by performing the "After repair" section.
17-1
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Introduction
4 Performance of the conformance check (appearance of possible malfunctions not yet declared by the
system's self diagnosis procedure) and application of the relevant fault finding techniques according to
results.
5 Validation of the repair (elimination of the sections on "Customer complaints" and "Fault finding chart").
6 Use of the sections on "Customer complaints" and "Fault finding chart", if the problem persists.
IMPORTANT
Do not drive the vehicle until you have checked that the computer is clear of any fault relating to the throttle
unit.
CHARACTERISTICS OF THE BORNIER

The Elé. 1590 bornier comprises a 112-track base fixed to a printed circuit carrying 112 coppered areas
numbered from 1 to 112.
Using the wiring diagrams, it is easy to identify connections or other parts needing to be checked.
IMPORTANT
– Any checks using bornier Elé. 1590 should only be performed with the battery disconnected.
– The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 V be
applied to the test points.
17-2
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Interpretation of faults
DF002 THROTTLE POTENTIOMETER CIRCUIT

PRESENT DEF : Unidentified electrical fault
OR
STORED
IMPORTANT:
Do not drive the vehicle until you have checked that the computer is clear of any
fault relating to the throttle unit.
NOTES If faults DF125 and DF126 are present, deal with these as a priority.

– a change in engine speed.
Check the cleanliness, connection and condition of the connections on the throttle potentiometer.
Replace the connectors if necessary.

Disconnect the computer. Check the cleanliness and condition of the connectors.
Connect the bornier in place of the computer and check the insulation, continuity and absence of
interference resistance on the following connections:
Computer track G4, connector B Throttle position potentiometer
Computer track D3, connector B Throttle position potentiometer
(See the connector track numbers in the corresponding wiring diagram)
Check the cleanliness of the throttle, and correct rotation of the throttle valve.
Check that tracks 1 and 2 of the throttle potentiometer correctly follow their curves of resistance (see
values in the Help section).
Repair or replace the throttle unit if necessary.
If the fault has still not disappeared, deal with the other faults and then proceed to the conformity
check.
If the throttle unit has been replaced, reinitialise the programming (RZ008).
Follow the instructions to confirm repair:
– If the fault is present, continue to deal with the fault.
AFTER REPAIR
– If the fault is stored in memory, ignore it.
Deal with any other possible faults.
Clear the fault memory.
17-3
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF003 AIR TEMPERATURE SENSOR CIRCUIT

OR OBD : OBD (On Board Diagnostic) fault
STORED

– Tripping of the fan with the engine running
Check the cleanliness, connection and condition of the sensor and the
DEF connector.

Connect the bornier in place of the computer and check the insulation, continuity
and absence of interference resistance on the following connections:
Computer track E3, connector B Air temperature sensor
Computer track E2, connector B Air temperature sensor
Check the resistance of the air temperature sensor (see the values in the
Helpsection).
If necessary replace the sensor.
If the fault has still not disappeared, deal with the other faults and then
proceed to the conformity check.
If the fault had been characterised as "DEF", it may change characterisation and
become "OBD"; this is normal.

AFTER REPAIR – If the fault is present and characterised as "DEF", continue to process the fault.
– If the fault is stored and characterised as "DEF", ignore it.
– If the fault is present or stored and characterised as "OBD", ignore it.
17-4
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF003
CONTINUED
OBD NOTES Run the engine until the fan begins to run.
If the fault's characterisation has become DEF after the instructions have been
followed, the electrical fault has been detected. Accordingly, it should be dealt with
as a fault present and characterised as DEF.
If the fault is still characterised as "OBD" after the instructions have been followed,
the electrical fault has been present several times but is no longer detected.
Accordingly, the circuit must be checked without changing parts which are not clearly
identified as at fault.
This check should be based on the fault finding procedure for the "DEF"
characterisation.

17-5
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF004 COOLANT TEMPERATURE SENSOR CIRCUIT

STORED

– Tripping of the fan with the engine running
DEF connector.

Computer track F2, connector B Coolant temperature sensor
Check the resistance of the air temperature sensor (see the values in the
Helpsection).

17-6
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF004
CONTINUED
characterisation.

17-7
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF005 PRESSURE SENSOR CIRCUIT

STORED

NOTES – the ignition is switched off and dialogue is lost;
– the ignition has been switched on again and dialogue re-established,
– 10 seconds at idle speed.
Check that the manifold pressure sensor is properly fitted

DEF Check that the inlet line is tight, from the throttle to the cylinder.
Verify that no seals are defective.
Check that the fuel vapour absorber bleed is not disconnected or jammed open.
Verify that the manifold air temperature sensor is properly fitted.
Check that the resonator is not cracked.
Check the cleanliness, connection and condition of the sensor and its
connection.
Replace as necessary.
Using a vacuum pump, check the consistency of the manifold pressure.

Check consistency with parameter PR001 in the diagnostic tool.

Computer track H2, connector B Pressure sensor

17-8
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF005
CONTINUED
characterisation.

17-9
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF006 PINKING SENSOR CIRCUIT

STORED

– a road test while the engine is warm and at a high engine speed.
Check the conformity of the fuel in the fuel tank.

DEF
Check the conformity of the spark plugs.
Check that the pinking sensor is tightened.
connector.

Computer track A2 connector B Pinking sensor
Computer track B2 connector B Pinking sensor
Computer track C2 connector B Pinking sensor screening

17-10
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF006
CONTINUED
characterisation.

17-11
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
FUEL PUMP CONTROL RELAY CIRCUIT

DF008
OR CC.1 : Short circuit to +12 V
STORED DEF : Unidentified electrical fault
OBD : OBD (On Board Diagnostic) fault

– the ignition is switched on.
CO.0 Check the supply fuse of the fuel pump relay.

CC.1 Replace the fuse if necessary.
DEF
Check the cleanliness, connection and condition of the petrol pump relay
connector.
Replace the connector if necessary.
Disconnect the relay. Check the condition and cleanliness of the contacts.
With the ignition on, check for the presence of +12 V on track 1 of the fuel pump
relay, connector side.
Check the resistance of the fuel pump relay on tracks 1 and 2 (see the value in the
Help section).
Replace the fuel pump relay if necessary.

and absence of interference resistance on the following connection:
Computer track D1 connector C Fuel pump relay
If the fault had been characterised as "CO.0, CC.1 or DEF", the fault may change
characterisation and become "OBD"; this is normal.

– If the fault is present and characterised as "CO.0, CC.1 or DEF", continue to deal
AFTER REPAIR with the fault.
– If the fault is stored and characterised as "CO.0, CC.1 or DEF", ignore it.
17-12
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF008
CONTINUED
If, after following the instructions, the characterisation has become "CO.0, CC.1 or
DEF", the electrical fault is detected. Accordingly, it should be dealt with as a present
fault and characterised as "CO.0, CC.1 or DEF"
This check should be based on the fault finding of the characterisations "CO.0, CC.1
or DEF".

17-13
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF009 ACTUATOR RELAY CONTROL CIRCUIT

OR
STORED

Check the condition and cleanliness of the vehicle's battery and earth leads.
Check the two supply fuses of the actuator relays.

Replace if necessary.
Check the cleanliness, connection and condition of the actuator relay connector.
Check the resistance of the actuator relay across tracks 1 and 2. (See the value in the Help section).
Replace the actuator relay, if necessary.
Check for the presence of 12 V on track 1 of the actuator relay, connector side.

interference resistance on the following connection:
Injection computer track D4, connector B Actuator relay.
check.
Follow the instructions to confirm the repair.

AFTER REPAIR Deal with any other possible faults.
17-14
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
LOW-SPEED FAN ASSEMBLY CIRCUIT

DF010 CO.0 : Open circuit or short circuit to earth
DEF : Unidentified electrical fault
NOTES Deal with fault DF004 first if it is present.
Check the cleanliness, connection and condition of the low-speed fan assembly relay connector.
With the ignition on, check for the presence of + 12 V on track 1 of the relay.
Check the resistance of the low-speed fan assembly relay on tracks 1 and 2 (see the value in the Help
section).
Replace the low-speed fan assembly relay if necessary.

Computer track F1, connector C Low-speed fan relay
check.

AFTER REPAIR
17-15
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF011 FAULT WARNING LIGHT CIRCUIT

NOTES None.
Test the multiplex network.

Refer to the "Multiplex Network" and "Instrument Panel" sections of the Workshop Repair Manual.
Perform fault finding on the "Instrument panel" system if necessary.
AFTER REPAIR None.
17-16
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CANISTER BLEED SOLENOID VALVE CIRCUIT

DF014
Deal with faults DF009 or DF019 first if they are present.
NOTES Conditions for applying the fault finding procedure to stored faults:
CO.0 Check the cleanliness, connection and condition of the fuel vapour absorber
CC.1 bleed solenoid valve connector.
DEF Replace the connector if necessary.
With the ignition on, check for the presence of + 12 V on the fuel vapour absorber
bleed solenoid valve.

Computer track E1, connector C Fuel vapour absorber bleed
valve
Check the resistance of the fuel vapour absorber bleed solenoid valve (see value in
the Help section).
Replace the solenoid valve, if necessary.

17-17
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF014
CONTINUED
fault and characterised as "CO.0, CC.1 or DEF"
or DEF".

17-18
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
FLYWHEEL SIGNAL INFORMATION

DF017
PRESENT 1.DEF : Engine flywheel target fault
OR 2.DEF : Absence of tooth signal
STORED 1.OBD : (On Board Diagnostic) OBD fault: engine flywheel target
2.OBD : OBD fault: absence of flywheel signal
The pressure sensor must not be faulty when performing this fault finding test.

NOTES
1.DEF Check the positioning of the flywheel signal sensor.

2.DEF
Check the cleanliness, connection and condition of the sensor, the cable and its
connector.

Computer track E4, connector B Flywheel signal sensor
Computer track F3, connector B Flywheel signal sensor
Check the resistance of the flywheel signal sensor (see the value in the Help
section).
Check the cleanliness and condition of the engine flywheel.
NOTE:
If the target mounting has been altered, modify the programming.
If the fault had been characterised as "1.DEF or 2.DEF", the fault may change
characterisation and become "1.OBD or 2.OBD"; this is normal.

– If the fault is present and characterised as "1.DEF or 2.DEF", continue to deal with
AFTER REPAIR the fault.
– If the fault is stored and characterised as "1.DEF or 2.DEF", ignore it.
– If the fault is present or stored and characterised as "1.OBD or 2.OBD", ignore it.
17-19
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF017
CONTINUED
1.OBD
NOTES Run the engine until the fan begins to run.
2.OBD
If, after following the instructions, the characterisation has become "1.DEF or
2.DEF", the electrical fault is detected. Accordingly, it should be dealt with as a
present fault and characterised as "1.DEF or 2.DEF".
If the fault is still characterised as "1.OBD" or "2.OBD" after the instructions have
been followed, the electrical fault has been present several times but is no longer
detected.
This check should be based on the fault finding of the characterisations "1 DEF" or
"2.DEF".
If the fault had been characterised as "1.DEF or 2.DEF", the fault may change
characterisation and become "1.OBD or 2.OBD"; this is normal.

– If the fault is present and characterised as "1.DEF or 2.DEF", continue to deal with
AFTER REPAIR the fault.
– If the fault is stored and characterised as "1.DEF or 2.DEF", ignore it.
17-20
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
UPSTREAM OXYGEN SENSOR HEATER CIRCUIT

CO.0 :
Open circuit or short circuit to earth
DF018 CC.1 :
Short circuit to +12 V
PRESENT 1.DEF :
Unidentified electrical fault
OR 2.DEF :
Heating output of oxygen sensor defective
STORED 1.OBD :
(On Board Diagnostic) OBD fault: upstream oxygen sensor heating
output
2.OBD : OBD fault: upstream oxygen sensor heating output
If faults DF009 and DF019 are present, deal with them first.
– running the engine for 10 seconds.
CO.0 Check the cleanliness, connection and condition of the upstream oxygen sensor
CC.1 connector.
1.DEF Replace the connector if necessary.
2.DEF
With the ignition on, check for the presence of + 12 V on track A of the upstream
oxygen sensor connector.

Computer track G1, connector C Upstream oxygen sensor
Check the heating resistance of the upstream oxygen sensor (see the value in the
Help section).
Replace the upstream oxygen sensor if necessary.
If the fault had been characterised as "CO.0, CC.1, 1.DEF or 2.DEF", the fault may
change characterisation and become "1.OBD or 2.OBD"; this is normal.

– If the fault is present and characterised as "CO.0, CC.1, 1.DEF or 2.DEF",
AFTER REPAIR continue to deal with the fault.
– If the fault is stored and characterised as "CO.0, CC.1, 1.DEF or 2.DEF", ignore it.
17-21
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF018
CONTINUED
1.OBD
2.OBD
If, after following the instructions, the characterisation has become "CO.0, CC.1,
1.DEF or 2.DEF", the electrical fault is detected. It should therefore be dealt with as
a present fault and characterised as "CO.0, CC.1, 1.DEF or 2.DEF".
detected.
This check should be based on the fault finding of the characterisations "CO.0, CC.1,
1.DEF or 2.DEF".

17-22
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF019 SUPPLY
PRESENT 1.DEF : + 12 V after actuator relay electrical fault
OR
STORED
Deal with fault DF009 first if it is present.

– the ignition is switched off and dialogue is lost;
– the ignition is switched on and dialogue is established.
Disconnect the actuator relay.

Check the cleanliness, connection and condition of the actuator relay connections.
With the ignition on, check for 12 V on track 3 of the actuator relay.
If 12 V is not present, check the supply fuse (see the relevant section in the Workshop Repair Manual).
Check the insulation and continuity of the wire.
Check the resistance of the actuator relay across tracks 1 and 2. (See the value in the Help section).
Replace the relay if necessary.

Computer track G2, connector C Injection actuator relay
If that does not work, replace the actuator relay.
check.

17-23
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF021 IMMOBILISER
OR
STORED
NOTES None.

Refer to the "Multiplex Network" and "Immobiliser" sections of the Workshop Repair Manual.
Perform fault finding on the "Immobiliser" system if necessary.
AFTER REPAIR None.
17-24
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
COMPUTER
DF022 1.DEF : Computer fault
PRESENT 2.DEF : Computer fault: motorised throttle control
3.DEF : Backup memory area fault
4.DEF : Immobiliser memory area fault
NOTES None.
1.DEF Computer defective or not to specification.

2.DEF Replace the injection computer.
3.DEF Do not replace the injection computer immediately.

4.DEF
Carry out the following procedure:
– Switch the ignition on and establish dialogue with the computer.
– Clear the computer memory.
– Switch the ignition off and wait for loss of dialogue with the computer.
– Switch the ignition on and establish dialogue with the computer.
If the computer fault is still present, carry out this procedure again.
If the computer fault is still present after the fifth attempt at clearing, replace the
injection computer.
AFTER REPAIR Clear the fault memory.
17-25
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
HIGH-SPEED FAN ASSEMBLY CIRCUIT

Check the cleanliness, connection and condition of the high-speed fan assembly relay connector.
Check the resistance of the low-speed fan assembly relay tracks 1 and 2 (see the value in the Help section).
Replace the high-speed fan assembly relay if necessary.

Computer track F2, connector C High-speed fan assembly relay
check.

AFTER REPAIR
17-26
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
COOLANT TEMPERATURE OVERHEATING WARNING LIGHT

DF032
PRESENT CIRCUIT
STORED CC.1 : Short circuit to + 12 V
NOTES None.

AFTER REPAIR None.
17-27
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DOWNSTREAM OXYGEN SENSOR HEATER CIRCUIT

CO.0 :
Open circuit or short circuit to earth
DF038 CC.1 :
Short circuit to + 12 V
PRESENT 1.DEF :
Unidentified electrical fault
OR 2.DEF :
Heating output of oxygen sensor defective
STORED 1.OBD :
(On Board Diagnostic) OBD fault: downstream oxygen sensor heating
output
2.OBD : OBD fault: downstream oxygen sensor heating output
– running the engine for 10seconds.
CO.0 Check the cleanliness, connection and condition of the downstream oxygen
CC.1 sensor connector.
1.DEF Replace the connector if necessary.
2.DEF
With the ignition switched on, check the presence of + 12 V on track A of the
downstream oxygen sensor connector.

Computer track G3, connector C Downstream oxygen sensor
Check the heating resistance of the downstream oxygen sensor (see the value in
the Help section).
Replace the downstream oxygen sensor if necessary.

– If the fault is present and characterised as "CO.0, CC.1, 1.DEF or 2.DEF", continue
AFTER REPAIR to deal with the fault.
17-28
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF038
CONTINUED
1.OBD
2.OBD
If, after following the instructions, the characterisation has become "CO.0, CC.1,
1.DEF or 2.DEF", the electrical fault is detected. It should therefore be dealt with as
a present fault and characterised as "CO.0, CC.1, 1.DEF or 2.DEF".
detected.
This check should be based on the fault finding of the characterisations "CO.0, CC.1,
1.DEF or 2.DEF".

17-29
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CYLINDER 1 INJECTOR CIRCUIT

DF052 CO : Open circuit
The fault is declared present after
CO Check the cleanliness, condition and connection of cylinder injector 1 and its
CC.0 connections.
CC.1 Clean or replace as necessary.
DEF
With the ignition switched on, check for the presence of + 12 V on track 1 of the
injector 1 connector.

Injection computer track L4, connector B Cylinder 1 injector
Check the resistance of cylinder injector 1 (see the value in the Help section).
Replace the injector if necessary.
If the fault had been characterised as "CO, CC.0, CC.1 or DEF", the fault may change

– If the fault is present and characterised as "CO, CC.0, CC.1 or DEF", continue to
AFTER REPAIR deal with the fault.
– If the fault is stored and characterised as "CO, CC.0, CC.1 or DEF", ignore it.
17-30
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF052
CONTINUED
If, after following the instructions, the characterisation has become "CO, CC.0, CC.1,
or DEF", the electrical fault is detected. It should therfore be dealt with as a present
fault characterised as "CO, CC.0, CC.1, or DEF".
This verification should be based on the fault finding of the characterisations "CO,
CC.0, CC.1, or DEF".

17-31
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

CC.0 connections.
DEF
With the ignition on, check for the presence of + 12 V on track 1 of the injector 2
connector.


17-32
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF053
CONTINUED

17-33
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

CC.0 connections.
DEF
connector.


17-34
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF054
CONTINUED

17-35
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

DF055 DEF : Unidentified electrical fault
PRESENT CO : Open circuit
OR CC.0 : Short circuit to earth
STORED CC.1 : Short circuit to + 12 V
CC.0 connections.
DEF
connector.

Injection computer track M2, connector B Cylinder 4 injector

17-36
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF055
CONTINUED

17-37
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF057 UPSTREAM OXYGEN SENSOR CIRCUIT

STORED
If other faults are present, deal with them first.
– a period of 5 minutes of richness regulation (engine running).
Check that the manifold pressure sensor is properly fitted.

DEF Check that the inlet line is tight, from the throttle to the cylinder.
Check that there are no leaks in the fuel vapour absorber bleed circuit.
Check that the throttle air temperature sensor is properly fitted.
Check the condition and fitting of the upstream sensor.

Replace the sensor if necessary.
Check for air leaks on the exhaust system.
If the vehicle is driven frequently in town, decoke the engine.
Check the cleanliness, connection and condition of the upstream oxygen sensor
connections.
With the ignition on, check the presence of + 12 Volts on the upstream oxygen
sensor.

17-38
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF057
CONTINUED

Computer track C1, connector C Oxygen sensor
Computer track B1, connector C Oxygen sensor
If the fault persists, replace the oxygen sensor.
characterisation.

17-39
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF058 DOWNSTREAM OXYGEN SENSOR CIRCUIT

STORED
Deal with fault DF057 first if it is present.

The fault is declared as present in one of the following cases:
NOTES – A road test driving smoothly after the fan has come into operation and the double
richness ratio loop ET027 is active.
– A road test driving smoothly after the fan has come into operation, followed
immediately by a road test on a slope in no load conditions (deceleration phase).
Verify the condition and fitting of the downstream sensor.

DEF Replace the sensor if necessary.
Check the cleanliness, connection and condition of the downstream oxygen

sensor connections.
With the ignition on, check the presence of + 12 V on the downstream oxygen
sensor.

Computer track A2, connector C Oxygen sensor

17-40
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF058
CONTINUED
characterisation.

17-41
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
IGNITION COIL 1 - 4 CIRCUIT

DF061
Deal with faults DF009, DF019 or DF008 first if they are present.
CO.0 Disconnect the connectors from the pencil coils of cylinders 1 and 4.
CC.1 Check the cleanliness and condition of the connections and pencil coils.
DEF Clean or replace as necessary.
Check the primary and secondary resistances of the pencil coils 1 and 4 (see the

Computer track H2, connector C Coil 1
Coil 1 Coil 4
Check the supply fuse of the fuel pump relay.
Check the continuity and insulation of the wiring between coil 4 and the fuel pump
relay (this relay supplies the ignition coils).
Check the electrical resistance of the fuel pump relay (see the value in the Help
section).

17-42
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF061
CONTINUED
Check the cleanliness and condition of the fuel pump relay connections.
Clean or replace as necessary.
Check the insulation and continuity of the line between track 3 of the relay and
supply fuse.
fault characterised as "CO.0, CC.1 or DEF"
or DEF".

17-43
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
IGNITION COIL 2-3 CIRCUIT

DF062
Deal with faults DF009, DF019 or DF008 first if they are present.
CO.0 Disconnect the connectors from pencil coils 2 and 3.

CC.1 Check the cleanliness and condition of the connections and pencil coils.
DEF Clean or replace as necessary.
Check the primary and secondary resistance of the ignition coils on cylinders 2
and 3 (see the values in the Help section).

Computer track H3, connector C Coil 2
Coil 2 Coil 3
Check the continuity and insulation of the line between coil 3 and the fuel pump
relay (this relay supplies the ignition coils).
Check the electrical resistance of the fuel pump relay (see the value in the Help
section).

AFTER REPAIR
with the fault.
17-44
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF062
CONTINUED
Check the cleanliness and condition of the fuel pump relay connections.
Check the insulation and continuity of the line between track 3 of the relay and
supply fuse.
fault characterised as "CO.0, CC.1 or DEF"
or DEF".

17-45
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF064 VEHICLE SPEED SIGNAL

STORED

Check the cleanliness and external condition of the vehicle speed sensor.
DEF Check the cleanliness and condition of the target.
Check the cleanliness, condition and connection of the connections.
Check the electrical resistance of the vehicle speed sensor (see the value in
theHelp section).

Disconnect the computer. Check the cleanliness and condition of the
connectors.
Computer track C3, connector B Vehicle speed sensor
(See the connector track numbers in the corresponding wiring diagram).
If that does not work, replace the sensor.

17-46
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF064
CONTINUED
– If, after following the instructions, the characterisation has become "DEF", the electrical fault is detected.
Accordingly, it should be dealt with as a fault present and characterised as DEF.
– If, after following the instructions, the fault still has its "OBD" characterisation, the electrical fault has been
present several times but is no longer detected.
Accordingly, the circuit must be checked without changing parts which are not clearly identified as at fault.
This check should be based on the "DEF" fault finding of the characterisations.

17-47
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF082 PETROL/LPG CONNECTION

OR
STORED
NOTES None.

Refer to the Multiplex network section in the Workshop Repair Manual.
AFTER REPAIR None.
17-48
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF083 ABS/INJECTION CONNECTION

OR
STORED
NOTES None.

Refer to the Multiplex network section in the Workshop Repair Manual.
AFTER REPAIR None.
17-49
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
OXYGEN SENSOR OPERATING FAULT

DF102 OBD : OBD fault (On Board Diagnostic)
PRESENT 1.OBD : OBD fault detected when running
If faults DF009, DF019, DF018, DF038, DF057 or DF058 are present, deal with
NOTES
them in priority.

Check that the inlet line is tight, from the throttle to the cylinder.
Check that there are no leaks in the fuel vapour absorber bleed circuit.

Replace the sensor if necessary.
Check the cleanliness, connection and condition of the upstream oxygen sensor connections.
With the ignition on, check the presence of + 12 V on the upstream oxygen sensor.

Computer track C1, connector C Oxygen sensor
check.

AFTER REPAIR
17-50
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CATALYTIC CONVERTER OPERATING FAULT

PRESENT 1.OBD : OBD fault present
2.OBD : OBD fault detected when driving
NOTES Deal with the other faults first.
Check sealing of the complete exhaust system.

Check the condition and assembly of the downstream oxygen sensor.
Check the connection and condition. of the downstream oxygen sensor wires and connector.
– Inspect the, condition of the catalytic converter Deformation may be the cause of the fault.
– Visually check for signs of thermic shock. A warm catalytic converter may be damaged if it comes into
contact with cold water.
– Make sure there has been no excessive oil or coolant consumption.
Ask the customer if they have used an additive or other products of this kind. Such products can contaminate
the catalytic converter and damage its performance sooner or later.
This could destroy the catalytic converter.
If the cause of the damage is identified, it is possible to change the catalytic converter.
If you replace the catalytic converter, make absolutely sure that the problem has been solved,
otherwise the new catalytic converter may be damaged.
check.

AFTER REPAIR
17-51
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
POLLUTANT MISFIRES
Deal with the other faults first.

NOTES Refer to states ET093, ET094, ET095 and ET096 to ascertain how many cylinders
are misfiring.
This means that the problem is probably due to a component which can only act on this
cylinder:
Misfiring on one – Injector fault
cylinder – Spark plug fault (check conformance)
– HV cable fault
– Ignition coil fault
Misfiring on all This means that the problem is probably due to a component which can only act on this
cylinders pair of cylinders:
1 and 4
OR
2 and 3
This means that the problem is probably due to a component which can only act on all
Misfiring on all four the cylinders:
cylinders – Check that the correct petrol is used.
– Check condition and conformity of spark plugs.
If the fault is still present, carry out the following checks:

– Check the flywheel sensor.
– Check the condition and cleanness of the flywheel.
– Check the mounting of the flywheel sensor.
– Check the sensor / flywheel air gap
– Check the cylinder compression.
– Check the whole petrol supply circuit.
– Check the whole ignition system.
Ensure that all the faults have been processed.

Clear the stored faults. It is not necessary to clear the programming.
To check the correct state of repair of the system:
– There should be no further electrical faults.
AFTER REPAIR
– Programming should have been carried out.
– The engine should be warm (minimum 75ºC).
– Run at idling speed with all electrical users engaged for 15 minutes.
If the fault reappears, continue the fault finding procedure.
17-52
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DESTRUCTIVE MISFIRE
PRESENT 1.OBD : OBD fault present
2.OBD : OBD fault detected when driving
If faults relating to ignition or the petrol supply circuit are present, deal with them
first.
NOTES
Refer to states ET093, ET094, ET095 and ET096 to ascertain how many cylinders
are misfiring.
This means that the problem is probably due to a component which can only act on this
cylinder:
Misfiring on one – Injector fault
cylinder – Spark plug fault (check conformance)
– HV cable fault
Misfiring on all This means that the problem is probably due to a component which can only act on this
cylinders pair of cylinders:
1 and 4
OR
2 and 3
This means that the problem is probably due to a component which can only act on all
Misfiring on all four the cylinders:
cylinders – Check that the correct petrol is used.
– Check condition and conformity of spark plugs.
If the fault is still present, carry out the following checks:

– Check the flywheel sensor.
– Check the condition and cleanness of the flywheel.
– Check the mounting of the flywheel sensor.
– Check the sensor / flywheel air gap
– Check the cylinder compression.
– Check the complete petrol supply circuit.
– Check the complete ignition system.
Ensure that all the faults have been processed.

Clear the stored faults. It is not necessary to clear the programming.
To check the correct state of repair of the system:
– There should be no further electrical faults.
AFTER REPAIR
– Programming should have been carried out.
– The engine should be warm (minimum 75ºC).
– Run at idling speed with all electrical users engaged for 15 minutes.
If the fault reappears, continue the fault finding procedure.
17-53
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
FUEL SYSTEM OPERATING FAULT

If faults relating to ignition or the petrol supply circuit are present, deal with them
NOTES
first.
Carry out a complete check on the fuel supply system.
Check the cleanliness of the petrol fuel tank if necessary.
check.

AFTER REPAIR
17-54
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
IMMOBILISER CODE NOT PROGRAMMED

DF117
PRESENT

Refer to the "Multiplex Network" and "Immobiliser" sections of the Workshop Repair Manual.
Perform fault finding on the "Immobiliser" system if necessary.
AFTER REPAIR None.
17-55
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF118 REFRIGERANT PRESSURE SENSOR CIRCUIT

OR
STORED

Check the cleanliness, connection and condition of the refrigerant pressure sensor.
Check the electrical resistance of the refrigerant sensor (see value in the Help section).

Computer track J3, connector B Pressure sensor
check.

17-56
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
OBD WARNING LIGHT CIRCUIT

NOTES None.

AFTER REPAIR None.
17-57
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF123 THROTTLE POSITION POTENTIOMETER CIRCUIT TRACK 1

STORED
IMPORTANT: Do not drive the vehicle until you have checked that the computer
is clear of any fault relating to the throttle unit.
NOTES

Computer track G4, connector B Throttle position potentiometer track 1
Check that track 1 of the throttle potentiometer correctly follows its resistive curve (see the values in the
Help section).
Repair or replace the throttle position potentiometer if necessary.
check.
AFTER REPAIR
17-58
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
THROTTLE POSITION POTENTIOMETER CIRCUIT TRACK 2

NOTES

Computer track D3, connector B Throttle position potentiometer track 2
Check that track 2 of the throttle potentiometer correctly follows its resistive curve (see the values in the
Help section).
check.
AFTER REPAIR
17-59
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF125 PEDAL POTENTIOMETER TRACK 1 CIRCUIT

STORED

– switching the accelerator from no load to full load.
Check that the pedal is not mechanically seized.
Check the cleanliness, connection and condition of the pedal potentiometer connector.

Computer track H3, connector A Pedal potentiometer track 1
Computer track G2, connector A Pedal potentiometer track 1
Computer track H2, connector A Pedal potentiometer track 1
Check that track 1 of the pedal potentiometer correctly follows its curve of resistance (see the values in
the Help section).
Replace the pedal potentiometer if necessary.
check.

17-60
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
PEDAL POTENTIOMETER TRACK 2 CIRCUIT


– switching the accelerator from no load to full load.

Computer track F4, connector A Pedal potentiometer track 2
Check that track 2 of the pedal potentiometer correctly follows its curve of resistance (see the values in
the Help section).
check.

17-61
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF129 PEDAL POTENTIOMETER CIRCUIT

PRESENT DEF : Consistency of pedal potentiometer tracks
OR
STORED
Deal with faults DF125 or DF126 first if they are present.

The fault is declared as present in one of the following cases:
NOTES – When the ignition is switched on without depressing the accelerator pedal for the first
10 seconds.
– During gradual switching of the pedal potentiometer from no load to full load
condition.
– During full load condition for 10 seconds.

Computer track H3, connector A Pedal potentiometer
Computer track G2, connector A Pedal potentiometer
Computer track F4, connector A Pedal potentiometer
Check that tracks 1 and 2 of the pedal potentiometer correctly follow their curves of resistance.
(See values in the "HELP" section).
check.

17-62
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF134 INSTRUMENT PANEL CONNECTION

OR
STORED
NOTES None.

Refer, in the Workshop Repair Manual, to the "Multiplex Network" and "Instrument Panel" sections.
AFTER REPAIR None.
17-63
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF135 BRAKE PEDAL SENSOR CIRCUIT

PRESENT 1.DEF : Fault on one of the two brake pedal contacts
OR 2.DEF : Fault on both brake pedal contacts
STORED
It is essential that the ABS is not defective when carrying out this test.
NOTES Fault finding conditions for stored fault:

– a long press on the brake pedal.
Check the cleanliness, connection and condition of the double-contact switch and its connections.

Computer track E4 or G3, connector A Brake pedal switch
Computer track H2, connector B Brake pedal switch
If the fault does not disappear, deal with the other faults then go to the conformity check.

AFTER REPAIR Process any other faults
17-64
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
ACCELERATOR PEDAL / MOTORISED THROTTLE VALVE

DF136 CIRCUIT
PRESENT DEF : Consistency between the position of the pedal and the position of the
OR motorised throttle valve
STORED 1.DEF : Fault on + 5 V supply
2.DEF : Fault on potentiometer power supply No. 1
3.DEF : Fault on potentiometer power supply No. 2
NOTES If faults DF137, DF123, DF124, DF125, DF126, DF129 or DF002 are present, deal
with them first.
Check the cleanliness, connection and condition of the pedal potentiometer and its connections.
Check the cleanliness, connection and condition of the motorised throttle and its connections.
Check that tracks 1 and 2 of the throttle potentiometer correctly follow their curves of resistance (see
Clean or replace the throttle unit if necessary.
Check the electrical resistance of the throttle motor (see the value in the Help section).
Check that the resistances of pedal potentiometer tracks 1 and 2 correctly follow their curves of resistance
(see the values in the Help section).
AFTER REPAIR
17-65
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF136
CONTINUED

Computer track M3, connector B Motorised throttle valve
Computer track G4, connector B Motorised throttle valve potentiometer
Computer track D3, connector B Motorised throttle valve potentiometer
check.
AFTER REPAIR
17-66
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
MOTORISED THROTTLE
DF137
OR 1.DEF : Motorised throttle valve servo control fault
STORED 2.DEF : Motorised throttle valve thrust stop search fault
3.DEF : General motorised throttle valve control fault
NOTES
Check the cleanliness, connection and condition of the connections.


Computer track G4, connector B Motorised throttle valve
Check the cleanliness of the throttle unit and that the throttle rotates correctly.
check.
AFTER REPAIR
17-67
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF168 AIR INTAKE CIRCUIT

PRESENT OBD : OBD fault (On Board Diagnostic)
OR 1.OBD : OBD fault detected when running
STORED
NOTES If faults DF123, DF124, DF125, DF126, DF129, DF136, DF137 or DF002 are
present, deal with them first.

Check that the manifold air temperature sensor is correctly mounted.

17-68
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF233 DIRECTIONAL STABILITY CONTROL

PRESENT
OR
STORED
NOTES None.

Refer to the ABS / ESP and Multiplex network sections in the Workshop Repair Manual.
Carry out fault finding on the ABS and ESP if necessary.
AFTER REPAIR None.
17-69
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Conformity check
Only carry out this conformity check after a full check with the diagnostic tool
NOTES (the values shown in this conformity check are only given as a guide).
Conditions for the application of this check: engine stopped, ignition on.
Parameter or State Fault finding

Order Function Display and notes
check or Action procedure
SUPPLY FUNCTION
ET001: + After ignition ACTIVE In the event of a fault:

computer refer to fault finding
1 Battery voltage procedure
PR004: Computer supply 11.8 < X < 13.2 V
PR004
voltage
SENSOR FUNCTION
Activate the starter motor:
ET060: Flywheel signal with ACTIVE In the event of a fault:

Engine flywheel engine running refer to fault finding
2
signal procedure
PR060
PR002: Coolant Engine temperature In the event of a fault:

Coolant temperature ± 5°C refer to fault finding
3 temperature procedure
sensor PR002
PR003: Air temperature Temperature under In the event of a fault:

Air temperature bonnet ± 5°C refer to fault finding
4 procedure
sensor
PR003
PR016: Atmospheric 1000 mbar ± 3%

pressure (atmospheric
In the event of a fault:
pressure)
Atmospheric refer to fault finding
5
pressure sensor procedure
PR001: Manifold pressure 1000 mbar ± 3% PR001
(atmospheric
pressure)
17-70
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

PEDAL ASSEMBLY FUNCTION
Accelerator pedal released
ET129: Accelerator pedal ACTIVE In the event of a fault:

position: no load refer to fault finding
procedure
ET128: Accelerator pedal INACTIVE
PR112
position: full load
PR112: Measured pedal 15° ± 1°
position
PR120: Pedal no load 15° ± 1°
programming
Accelerator pedal pressed

lightly
6 Accelerator pedal ET129: Accelerator pedal INACTIVE In the event of a fault:

procedure
ET128: Accelerator pedal INACTIVE
PR112
position: full load
Accelerator pedal under full

load
ET129: Accelerator pedal INACTIVE In the event of a fault:

procedure
ET128: Accelerator pedal ACTIVE
PR112
position: full load
PR112: Measured accelerator 80° ± 4°
pedal position
17-71
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

Brake pedal released
ET110: Brake pedal INACTIVE In the event of a fault:

procedure
ET143: Redundant brake INACTIVE
ET110
pedal
ET143
(Confirmation
signal)
7 Brake pedal
Brake pedal depressed
ET110: Brake pedal ACTIVE In the event of a fault:

procedure
ET143: Redundant brake ACTIVE
ET110
pedal
ET143
(Confirmation
signal)
17-72
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

MOTORISED THROTTLE VALVE FUNCTION
Accelerator pedal released
ET111: Throttle valve stops ACTIVE In the event of a fault:

programming switch off the ignition
and wait for the loss
of dialogue.
Switch on the ignition
again.
ET118: Motorised throttle unit INACTIVE In the event of a fault:

in defect mode a fault is declared by
the diagnostic tool
Motorised throttle
8
unit
ET130: Motorised throttle ACTIVE In the event of a fault:
valve closed refer to fault finding
procedure
PR113: Reference position of 15° ± 1°
PR017
the motorised throttle
valve
PR017: Measured valve 15° ± 1°
position
position track 1
position track 2
PR119: Motorised throttle 10° ± 1°
valve lower stop
17-73
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C

MOTORISED THROTTLE VALVE FUNCTION
Accelerator pedal under full

load
ET118: Motorised throttle unit INACTIVE In the event of a fault:

in defect mode a fault is declared by
the diagnostic tool
ET131: Motorised throttle ACTIVE In the event of a fault:

valve open refer to fault finding
8 procedure
Motorised PR113: Reference position of 90° ± 3°
(con- PR017
throttle unit the motorised throttle
tinued)
valve
position
position track 1
position track 2
PR118: Motorised throttle 92° ± 3°
valve upper stop
17-74
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Only carry out this conformity check after a full check with the diagnostic tool (the
NOTES values shown in this conformity check are only given as a guide).

ACTUATOR CONTROLS
AC010: Fuel pump relay The fuel pump should In the event of a fault:
9 Fuel supply be heard operating refer to fault finding
procedure
AC010
AC271: Low-speed fan The fan should be In the event of a fault:

assembly relay heard running at low refer to fault finding
speed procedure
AC271
10 Fan assembly
AC272: High-speed fan The fan should be In the event of a fault:
assembly relay heard running at high refer to fault finding
speed procedure
AC272
AC016: Canister bleed The fuel vapour In the event of a fault:

Fuel vapour solenoid valve absorber solenoid refer to fault finding
11
absorber bleed valve should be heard procedure
operating AC016
AC612: Motorised throttle The motorised throttle In the event of a fault:

Motorised unit valve should be heard refer to fault finding
12
throttle unit operating procedure
AC612
17-75
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
(the values shown in this conformity check are only given as a guide).
NOTES
Conditions for application of the check: Engine warm at idle speed, without
electrical consumers.

ELECTRICAL SUPPLY FUNCTION
ET001: + After ignition ACTIVE In the event of a fault:

PR004: Computer supply 13 < X < 14.5 V
1 Battery voltage procedure
voltage
PR004
SENSOR FUNCTION
ET060: Flywheel signal with ACTIVE In the event of a fault:

engine running refer to fault finding
2 Flywheel signal procedure
ET060
PR016: Atmospheric X = Atmospheric In the event of a fault:

Atmospheric pressure pressure refer to fault finding
3 procedure
pressure sensor PR001: Manifold pressure 280 < X < 360 mbar
PR001
PR015: Anti-pinking X≤5 In the event of a fault:

correction refer to fault finding
4 Pinking sensors procedure
PR013: Medium pinking 30 < X < 60
PR013
signal
17-76
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES

FAN FUNCTION
PR002: Coolant The fan should cut in when In the event of a

temperature the engine coolant fault:
temperature exceeds refer to fault finding
99 °C procedure
ET035
ET035: Low-speed fan ACTIVE
assembly
5 Fan assembly
PR002: Coolant The fan should cut in when In the event of a
temperature the engine coolant fault:
temperature exceeds refer to fault finding
102 °C procedure
ET036
ET036: High-speed fan ACTIVE
assembly
IDLE SPEED REGULATION FUNCTION
ET039: Idle speed ACTIVE In the event of a

regulation fault:
procedure
PR006: Engine speed 725 < X < 775 rpm
ET039
PR041: Idle speed setpoint 725 < X < 775 rpm
PR055: After-Sales idle -16 rpm < X < +16 rpm

speed set point
(Possibility or reducing or
Idle speed increasing the idling speed by
6
regulation means of the commands
parameterised as VP004 and
VP003)
PR040: Idle speed -25 < X < +25 rpm

divergence
PR022: Idling opening 20 % < X < 30 %

cyclic ratio
PR021: Idling opening -6 % < X < 6 %

cyclic ratio adaptive
17-77
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES

RICHNESS REGULATION FUNCTION
ET037: Richness regulation ACTIVE In the event of a fault:

PR009: Upstream sensor 20 < X < 800 mV
procedure
voltage
ET037
Richness
7 PR035: Richness ratio 0 < X < 255
regulation
correction value
OXYGEN SENSOR FUNCTION
ET030: Upstream O2 sensor ACTIVE In the event of a fault:

heating refer to fault finding
procedure
ET030
Upstream
8
oxygen sensor ET157: Upstream sensor ACTIVE In the event of a fault:
state refer to fault finding
procedure
ET157
ET158: Downstream sensor ACTIVE In the event of a fault:

state refer to fault finding
procedure
ET158
Downstream
9
oxygen sensor ET031: Downstream O2 ACTIVE In the event of a fault:
sensor heating refer to fault finding
procedure
ET031
INFORMATION FUNCTION
Switch on the windscreen In the event of a fault:

heating refer to fault finding
Heated procedure
10 ET013: Heated windscreen ACTIVE
windscreen ET013
17-78
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Conditions for application of the check: Road test.

SENSOR FUNCTION
Vehicle under load

1 Pinking sensor refer to fault finding
PR015: Anti-pinking X≤5
procedure
correction
PR013
PR016: Atmospheric 1000 mbar ± 3% In the event of a fault:

Atmospheric pressure (Atmospheric refer to fault finding
2 pressure) procedure
pressure sensor
PR001
PR001: Manifold pressure 280 < X < 360 mbar
POLLUTANT EMISSIONS
2500 rpm after driving. CO < 0.3 %

CO2 > 13.5 % refer to the emission
control technical note
O2 < 0.8 %
HC < 100 ppm
Pollutant
3 0.97 < λ < 1.03
emissions
With the engine at idling CO < 0.5 %

speed, wait for stabilisation.
HC < 100 ppm
0.97 < λ < 1.03
17-79
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Interpretation of states
HEATED WINDSCREEN
ET013
NOTES There must be no faults present or stored.

Computer track G3, connector A "Air conditioning" computer.
If the fault is still present, perform fault finding on the Air Conditioning computer.
17-80
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
UPSTREAM O2 SENSOR HEATING

ET030
Check the cleanliness, connection and condition of the upstream oxygen sensor connector.
Check the heating resistance of the upstream oxygen sensor (see the value in the Help section).
With the ignition on, check for the presence of + 12 V on track A of the upstream oxygen sensor connector.

17-81
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DOWNSTREAM O2 SENSOR HEATING

ET031
Check the cleanliness, connection and condition of the downstream oxygen sensor connector.
Check the heating resistance of the downstream oxygen sensor (see the value in the Help section).
With the ignition switched on, check the presence of + 12 V on track A of the downstream oxygen sensor
connector.

Computer track G3, connector C Downstream oxygen sensor
17-82
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
POWER ASSISTED STEERING PRESSURE SWITCH

ET034
Check the power assisted steering fluid level.

Check that there are no leaks.
Check the cleanliness, connection and condition of the power steering pressure switch connector.
Replace the pressure switch if necessary.
Disconnect the connector and check for the presence of earth (check the track number on the relevant wiring
diagram).

Disconnect the computer. Check the cleanliness and condition of the connections.
Computer track C4, connector B Power assisted steering pressure switch
Pressure switch Earth
Check that the pump is operating correctly.
If these points are correct, replace the power assisted steering pressure switch.
17-83
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
LOW-SPEED FAN ASSEMBLY

ET035
Check the cleanliness and general condition of the fan unit (no point of resistance).
Check the cleanliness, connection and condition of the fan assembly relay connector.
Disconnect the low-speed fan relay.

Check for the presence of + 12 V on track 3 on the connector side of the relay.
With the ignition on, check for the presence of + 12 V on track 1 of the relay, connector side.
section).


Check the insulation, the continuity and the absence of interference resistance of the connection
between track 5 of the relay and the fan assembly.
Check the insulation, the continuity and the absence of interference resistance of the fan unit earth
connection.
If that still does not work, replace the fan assembly.
17-84
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
HIGH-SPEED FAN ASSEMBLY

ET036
Check the cleanliness and general condition of the fan unit (no point of resistance).
Check the cleanliness, connection and condition of the fan assembly relay connector.
Disconnect the high-speed fan relay.

Check for the presence of + 12 V on track 3 on the relay, connector side.
With the ignition on, check for the presence of + 12 V on track 1 of the relay, connector side.
Check the resistance of the high-speed fan assembly relay on tracks 1 and 2 (see the value in the Help
section).

Computer track F2, connector C High-speed fan relay

connection.
If that still does not work, replace the fan assembly.
17-85
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
RICHNESS REGULATION
ET037
Check the cleanliness, connection and condition of the connector for the upstream oxygen sensor.
Check the resistance of the upstream oxygen sensor signal circuit (check the value in the Help section).
With the ignition on, check for the presence of + 12 V on the upstream oxygen sensor connector (see the track
number of the connector on the corresponding wiring diagram).

Computer track C1, connector C Upstream oxygen sensor
Computer track B1, connector C Upstream oxygen sensor
– Check the condition of the air filter.

– Check the spark plugs and the entire ignition circuit.
– Check that there are no leaks in the fuel vapour absorber bleed circuit,
– Check that the inlet manifold and the exhaust system are completely sealed.
– Check the petrol supply circuit and its filter.
– Check fuel pressure.
– If idling is irregular, check the valve clearances and the timing.
Replace the oxygen sensor if the fault persists.
17-86
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
IDLE SPEED REGULATION

ET039
NOTES Idle speed is too slow.
– Clean the air supply circuit (throttle unit, idle speed regulation stepper motor), since it may be dirty.
– Check the engine oil level (too high => splashing).
– Check the engine compression
– Check the valve clearances and timing.
– Check ignition.
– Check the injectors
NOTES Idle speed is too high.
– Check the engine oil level.

– Check that the pressure sensor is operating correctly.
– Check the cleanliness of the pipes on the manifold.
– Check the pneumatically-controlled solenoid valves.
– Check the manifold gaskets.
– Check the throttle unit gaskets.
– Check the brake servo sealing.
– Check that the restrictions are present in the oil vapour rebreathing circuit.
– Check the valve clearances and timing.
17-87
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
FLYWHEEL SIGNAL WITH ENGINE RUNNING

ET060
Check the cleanliness, connection and condition of the target sensor, its connector and the cable.
Check that the engine flywheel is mounted correctly.

Check the sensor/flywheel air gap.

Computer track E4, connector B Target sensor
Computer track F3, connector B Target sensor
Check the resistance of the target sensor (see the value in the Help section).
If there is still a fault, check the cleanliness and condition of the flywheel.
17-88
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
BRAKE PEDAL
ET110
Check that the pedal assembly is in sound condition.
Check the cleanliness, connection and condition of the double-contact brake switch and its connector.

Computer track E4 or G3, connector A Brake pedal
If it still does not work, replace the switch.
Refer to the ABS fault finding procedure if necessary.
17-89
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
REDUNDANT BRAKE PEDAL (confirmation signal)

ET143

Refer to the ABS / ESP and Multiplex network sections in the Workshop Repair Manual.
Carry out fault finding on the ABS and ESP if necessary.
17-90
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
UPSTREAM SENSOR STATE

ET157

Check the fuel vapour absorber bleed and its circuit.
Check the cleanliness, connection and condition of the upstream oxygen sensor connector.
Check the resistance of the upstream oxygen sensor (see the value in the Help section).
With the ignition on, check the presence of + 12 Volts on the upstream oxygen sensor.

Computer track C1, connector B Upstream oxygen sensor
Computer track B1, connector B Upstream oxygen sensor
17-91
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DOWNSTREAM SENSOR STATE

ET158
Verify the condition and fitting of the downstream sensor.
Check the connection and condition of the downstream oxygen sensor connector.
Check the resistance of the downstream oxygen sensor circuit (see the value in the Help section).
With the ignition on, check the presence of + 12 V on the downstream oxygen sensor.

Computer track B2, connector B Downstream oxygen sensor
Computer track A2, connector B Downstream oxygen sensor
17-92
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Interpretation of parameters
MANIFOLD PRESSURE
PR001:

Check the cleanliness, connection and condition of the sensor and its connection.

Check that the pressure sensor is properly connected pneumatically and that the pipe is in sound condition.
Using a vacuum pump, check the consistency of the manifold pressure.

Check consistency with parameter PR001 in the diagnostic tool.
If PR001 > Maximum at idling speed:

Check the valve clearance.
Check that the fuel vapour absorber bleed is closed at idling speed
Check the cylinder compressions.
17-93
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
COOLANT TEMPERATURE
PR002:
Check the cleanliness, connection and condition of the coolant temperature sensor connector.
Check the resistance of the coolant temperature at different temperatures (see the values in the Help section).
Replace the coolant temperature sensor, if necessary.

17-94
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
AIR TEMPERATURE
PR003:
Check the cleanliness, connection and condition of the manifold air temperature sensor connector.
Check the resistance of the manifold air temperature sensor at various temperatures (see the values in the
Help section).
Replace the air temperature sensor, if necessary.

Computer track E3, connector B Manifold air temperature sensor
Computer track E2, connector B Manifold air temperature sensor
17-95
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
COMPUTER SUPPLY VOLTAGE

PR004
There must be no faults present or stored.

NOTES
No electrical consumers.
If the voltage is minimum:

Ignition on Check the battery and the charge circuit (refer to the relevant section in the
Workshop Repair Manual).
If the voltage is maximum:

Check that the charge voltage is correct and that no consumers are on (see the
relevant section in the Workshop Repair Manual).
If the voltage is minimum:

At idle speed Check the battery and the charge circuit (refer to the relevant section in the
Workshop Repair Manual).
If the voltage is maximum:

Check that the charge voltage is correct and that no consumers are on (see the
relevant section in the Workshop Repair Manual).
17-96
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
PINKING SIGNAL
PR013
The pinking sensor should give a signal which is not zero, to prove that it is recording the mechanical
vibrations of the engine.
Check that the fuel in the fuel tank is of the correct type.
Check the conformity of the spark plugs.
Check that the pinking sensor is tightened.
Check the cleanliness, connection and condition of the sensor and the connector.

Computer track A2, connector B Pinking sensor
Computer track B2, connector B Pinking sensor
Computer track C2, connector B Pinking sensor screening
If the fault persists, replace the pinking sensor.
17-97
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
MEASURED THROTTLE POSITION

PR017
IMPORTANT:
NOTES
Check that there are no foreign bodies at the throttle valve level.

Computer track D3, connector B Throttle position potentiometer
Check that the resistances of tracks 1 and 2 of the throttle potentiometer follow their curves correctly, by
moving the throttle from no load to full load (check the values in the Help section).
AFTER REPAIR
Repeat the conformity check.
17-98
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
RICHNESS ADAPTIVE OPERATION

PR030

NOTES If the PR030 or PR031 is near the min. stop, there is too much petrol.
If the PR030 or PR031 is near the max. stop, there is insufficient petrol.

– Check the spark plugs and the entire ignition circuit.
– Check that there are no leaks in the fuel vapour absorber bleed circuit,
– Check the lsealing of the inlet manifold and the complete exhaust system.
– Check the petrol supply circuit and its filter.
– If idling is irregular, check the valve clearances and the timing.
Check the cleanliness, connection and condition of the connector for the upstream oxygen sensor.
With the ignition on, check for the presence of + 12 V on track A of the upstream oxygen sensor connector.

Computer track C1, connector C Upstream oxygen sensor
Computer track B1, connector C Upstream oxygen sensor
Replace the oxygen sensor if the fault persists.
17-99
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
MEASURED ACCELERATOR PEDAL POSITION

PR112

Check that the resistances of the pedal potentiometer, tracks 1 and 2 correctly follow their curves of
resistance.
(See the values in the "HELP" section).
Replace the potentiometer pedal if the fault persists.
17-100
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Interpretation of controls
FUEL PUMP RELAY

AC010

Replace the fuse if necessary.
Check the connection and condition of the fuel pump relay connector.
Disconnect the relay.

With the ignition on, check for the presence of + 12 V on track 1 of the fuel pump relay, connector side.
Check the resistance of the fuel pump relay on tracks 1 and 2 (see the value in the Help section).
Replace the fuel pump relay if necessary.

Computer track D1 connector C Fuel pump relay
If the fault persists, replace the relay.
17-101
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CANISTER BLEED SOLENOID VALVE

AC016
Check the cleanliness and condition of the fuel vapour absorber bleed solenoid valve connector.
With the ignition on, check for the presence of + 12 V on the fuel vapour absorber bleed solenoid valve.
Check the resistance of the fuel vapour absorber bleed solenoid valve (see value in the Help section).
Replace the solenoid valve, if necessary.

Computer track E1, connector C Canister bleed solenoid valve
If the fault persists, replace the solenoid valve.
17-102
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
LOW-SPEED FAN RELAY

AC271
Check the connection and condition of the low-speed fan assembly relay connector.

section).

connection.
Check the condition of the fan assembly.

Replace the fan assembly if necessary.
17-103
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
HIGH-SPEED FAN RELAY

AC272
Check the cleanliness, connection and condition of the high-speed fan assembly relay connector.

Check the resistance of the high-speed fan assembly relay on tracks 1 and 2 (see the value in the Help
section).

Computer track F2, connector C High-speed fan relay
connection.
Check the condition of the fan assembly.

Replace the fan assembly if necessary.
17-104
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
MOTORISED THROTTLE
AC612
IMPORTANT:
NOTES
Check the cleanliness of the throttle unit and that the throttle rotates correctly.
Check the cleanliness, connection and condition of the connections.


Computer track G4, connector B Motorised throttle valve
AFTER REPAIR
Repeat the conformity check.
17-105
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Help
ELECTRICAL RESISTANCE OF COMPONENTS
Resistance values of components at 20°C:
Injectors 1.8 Ω ± 5%
Actuator relays 65 Ω ± 10%
Throttle valve motor 1.5 Ω ± 5 %
Fuel vapour absorber bleed

25 Ω ± 10%
solenoid valve
Ignition coils Primary: 0.5 Ω
Ignition coils Secondary: 11 kΩ ± 20%
17-106
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Flywheel sensor 230 Ω ± 20%
Oxygen sensor heater Upstream: 9 Ω ± 10%
Oxygen sensor heater Downstream: 9 Ω ± 10%
High-speed fan assembly relay 65 Ω ± 10%
Low-speed fan assembly relay 65 Ω ± 10%
17-107
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Values for variable resistance components:
Temperature in °C - 10 25 50 80 110
Manifold air temperature 10450 2120 860

to to to - -
sensor, in Ω 8585 1880 760
Coolant temperature sensor, 2360 850 290 117

- to to to to
in Ω 2140 770 275 112
Accelerator pedal potentiometer (20°C)
No load position, Tracks G2 and H2, Tracks H3 and H2,

connector A of computer connector A of computer
track 1
2300 Ω ± 20% 1290 Ω ± 20%
Full load position, Tracks G2 and H2, Tracks H3 and H2,

connector A of computer computer connector A
track 1
1250 Ω ± 20% 2270 Ω ± 20%
No load position, Tracks F2 and F3, Tracks F3 and F4,

connector A of computer connector A of computer
track 2
2900 Ω ± 20% 1240 Ω ± 20%
Full load position, Tracks F2 and F3, computer Tracks F3 and F4, computer
connector A connector A
track 2
2200 Ω ± 20% 2000 Ω ± 20%
17-108
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Throttle potentiometer VDO (20°C)
Throttle limp-home Tracks G3 and G2, Tracks G3 and G4,

position, track 1 connector B of computer connector B of computer
1350 Ω ± 20% 775 Ω ± 20%
(Throttle position with
engine stopped)
Throttle fully open

position, track 1 Tracks G3 and G2, tracks G3 and G4,
computer connector B computer connector B
(Keep throttle open 500 Ω ± 20% 1300 Ω ± 20%
manually)
Throttle limp-home Tracks D3 and G2, Tracks D3 and G4,

position, track 2 connector B of computer connector B of computer
600 Ω ± 20% 1150 Ω ± 20%
(Throttle position with
engine stopped)
Throttle fully open

position, track 2 Tracks D3 and G2, Tracks D3 and G4,
computer connector B computer connector B
(Keep throttle open 1250 Ω ± 20% 440 Ω ± 20%
manually)
17-109
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Customer complaints
Only consult the customer complaints after a complete check using the
NOTES
diagnostic tool.
NO DIALOGUE WITH THE COMPUTER CHART 1
THE ENGINE WILL NOT START CHART 2
IDLE SPEED FAULTS CHART 3
FAULTS WHEN DRIVING CHART 4
AFTER REPAIR Perform a test using the diagnostic tool.
17-110
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
Fault finding - Fault finding chart
CHART 1 No dialogue with the computer
NOTES None.
Check the condition of the battery and the vehicle earths.

Check the condition of the diagnostic lead.

Check the cleanliness and condition of the diagnostic socket and its connections.
Try the diagnostic tool on another vehicle.
– Check the injection, engine and passenger compartment fuses.

– Check, on the vehicle, the cleanliness and condition of the diagnostic socket and its connections.
– Use the diagnostic socket to check the following tracks:
Track 1 + After ignition
Track 16 + Battery
Tracks 4 and 5 Earth

Injection computer track H1, connector C Earth
Injection computer track H4, connector A Earth
Injection computer track G4, connector A Earth
Injection computer track B4, connector A Diagnostic socket track 7
Injection computer track A4, connector B + After ignition
Injection computer track G2, connector C + After ignition
Check the connection and condition of the injection actuator relay connector.
Check the resistance of the injection actuator relay (see the value in the Help section).
Replace the actuator relay, if necessary.
Check the presence of + 12 V on track 1 of the injection actuators relay.

Repair the wire to the fuse.
Check the insulation and continuity of the connection between:

Injection computer track D4, connector B Injection actuator relay.
17-111
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CHART 2 The vehicle will not start
Follow CHART 2 after performing a complete check using the diagnostic tool.
NOTES
(Use the Workshop Repair Manual for more information on certain operations).
If the starter motor does not engage, there may be an engine immobiliser fault.
Check the "Immobiliser" function using the diagnostic tool.
Check that the impact sensor is not switched on.

Check that it is working.
– Check the cleanliness and condition of the battery.

– Check that the battery is correctly earthed to the vehicle body.
– Check + battery connections.
– Check the battery charge.
– Check that the starter motor is properly connected.

– Check that the starter motor is operating correctly.
– Check the condition and cleanliness of the pencil coils.

– Check the condition and conformity of spark plugs.
– Check the secondary ignition circuits.
– Check the mounting, cleanliness, condition and air gap of the flywheel signal sensor.
– Check the condition of the flywheel.
– Check that the air intake circuit is not clogged up.

– Check that the throttle is rotating correctly
– Check whether there is fuel in the tank (fuel gauge fault).

– Check that the tank vent is not blocked.
– Check that the fuel is of the correct type.
– Check that there is no leak in the fuel circuit, from the fuel tank to the injectors.
– Check that no hoses are pinched (especially after a removal operation).
– Check the condition of the fuel filter.
– Check that the fuel pump is operating correctly.
– Check that the injectors are working.
– Check that the exhaust system is not blocked nor the catalytic converter clogged.
– Check the timing.
17-112
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CHART 3 Idle speed faults
Follow CHART 3 after performing a complete check with the diagnostic tool.
NOTES
– Check on the dipstick that the oil level is not too high.

– Check the condition and cleanliness of the flywheel.

– Check that the inlet line is tight, from the throttle to the cylinder.
– Verify that no seals are defective.
– Check that the fuel vapour absorber bleed is not disconnected or jammed open.
– Check that there are no leaks in the fuel vapour absorber bleed circuit.
– Check that there is no leak in the brake servo circuit.
– Verify that the manifold air temperature sensor is properly fitted.
– Check that the manifold pressure sensor is properly fitted.
– Check that the resonator is not cracked.
– Check that throttle unit is not clogged.
– Check that the throttle is rotating correctly.

17-113
INJECTION
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
CHART 4 Faults when driving
Follow CHART 4 after performing a complete check using the diagnostic tool.
NOTES
– Check on the dipstick that the oil level is not too high.
– Check that the exhaust manifold is not leaking.

– Check the condition and cleanliness of the flywheel.

– Check that the inlet line is tight, from the throttle to the cylinder.
– Verify that no seals are defective.
– Check that the fuel vapour absorber bleed is not disconnected or jammed open.
– Check that there are no leaks in the fuel vapour absorber bleed circuit.
– Check that there is no leak in the brake servo circuit.
– Verify that the manifold air temperature sensor is properly fitted.
– Check that the manifold pressure sensor is properly fitted.
– Check that the resonator is not cracked.
– Check that the throttle valve unit is not clogged.
– Check that the throttle is rotating correctly.

17-114

Nissan Primastar X83 (2002-2006) Service Manual #6

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Nissan Primastar X83 (2002-2006) Service Manual #6

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112

Remove the three screws on the air filter cover to gain

Manifold mounting nut 2.8 Remove:

Put the vehicle on a two-post lift.

Disconnect the battery.

Remove the engine undertray.

Remove the electrical exhaust gas recirculation

Proceed in the reverse order to removal.

Remove the heater unit mounting bolt and three nuts

Connector for air flowmeter with integrated air

Air temperature sensor resistance (between tracks 1

X Timed period (seconds)

The pressure regulation valve is open in rest position.

NOTE: Vacuum value

Loosen the lock nut (1).

Use a magnetic base fitted with a gauge which should

Confirm the repair with a road test, checking

Turbocharger mounting nut 2.4 ± 1

Oil inlet union on the turbocharger

NOTE: – both exhaust system mounting nuts (6) and allow it to

Put the vehicle on a two-post lift.

Disconnect the battery.

Remove the engine undertray.

Remove the retaining clip screw (1).

Refitting is the reverse of removal.

Vehicle Gearbox Cubic Emission

XLOC PK5 and

ENGINE SPEED (rpm) FUME OPACITY

Maximum - full Homologation Maximum -

Description Make/Type Special notes

High-pressure pump BOSCH CR / CP3 Pressure from 250 to 1350 bar

Booster pump (low-pressure) BOSCH EKP3 Pressure 2.5 bar maximum

Diesel pressure sensor BOSCH Screwed to the injection rail

Injectors BOSCH Solenoid injector

Pressure regulator Incorporated in the high-pressure pump (not

Injection computer BOSCH EDC 15 128-track computer

Accelerator pedal sensor HELLA Dual track potentiometer

Pre/postheating unit NAGARES BED/7 With pre/post-heating function controlled by the

Engine speed sensor MGI Resistance: 800 ± 80 Ω at 20 °C

Preheater plugs BERU or CHAMPION Resistance: 0.6 Ω connector disconnected

Air intake temperature sensor SIEMENS Incorporated in the air flowmeter

Diesel temperature sensor MAGNETTI Resistance = approximately 2050 Ω at 25 °C

Atmospheric pressure sensor - Incorporated into the computer

Camshaft sensor ELECTRICIFIL Hall effect sensor

Turbocharging pressure DELCO Resistance: 4 kΩ across tracks A and C

Turbocharger control solenoid BITRON Resistance: 16.5 ± 1 Ω at 25 °C

Air flowmeter SIEMENS Air flowmeter with integrated air temperature

Exhaust gas recirculation PIERBURG/SIEBE Track resistance: 8 ± 0.5 Ω at 20 °C (tracks 1 and 5)

Turbocharger ALLIED SIGNAL Wastegate setting:

Thermoplungers - Resistance: 0.45 ± 0.05 Ω at 20 °C

Engine coolant temperature ELTH Resistance: 2252 ± 112 Ω at 25 °C

The system consists of:

The injected flow to the engine is determined by:

It is absolutely vital that you observe the tightening torque:

When replacing the high-pressure pipe, follow the method below:

Dismantling the interior components of the pump is prohibited.

Loosening a High-pressure pipe connection when the engine is running is prohibited.

Risks relating to contamination

WHAT ARE THE SOURCES OF CONTAMINATION?