Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES)

DIAGNOSTIC PROCEDURES
GENERAL
Here is the basic order suggested to diagnose a suspected engine management or fuel injection related problem. Check the chart in TROUBLESHOOTING section to have an overview of problems and suggested solutions. Check if there is a blinking check engine light or a message displayed by the vehicle information center. If so, use the VCK (Vehicle Communication Kit) and look for fault codes to diagnose the trouble. Check all fuses. Check fuel rail pressure. Check spark plugs condition. Check fuel pump pressure. Check all connections of the wiring harness. Refer to COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT section for procedures.

TPS (Throttle Position Sensor) Faults

Faults which are reported in B.U.D.S. fall into two groups: TPS faults and adaptation faults. These are displayed on the B.U.D.S. system as TPS OUT OF RANGE and TPS ADAPTATION FAILURE. TPS OUT OF RANGE Fault It is caused by the sensor reading going out of its allowable range. This fault can occur during the whole range of movement of the throttle. To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recommended to release the throttle quickly as this may also show up a fault that is intermittent.
POSSIBLE CAUSES Check if connector is disconnected from TPS. Check if sensor is loose. Inspect sensor for damage or corrosion. Inspect wiring (voltage test). Inspect wiring and sensor(resistance test). Fix. Fix and reset Closed Throttle. Replace and reset Closed Throttle. Repair. If bad wiring, repair. If bad TPS, replace and reset Closed Throttle. Test sensor operation (wear test). Replace and reset Closed Throttle. ACTION

ENGINE MANAGEMENT SYSTEM FAULT CODES

General
The faults registered in the ECM are kept when the battery is disconnected. IMPORTANT: After a problem has been solved, ensure to clear the fault(s) in the ECM using the VCK. This will properly reset the appropriate counter(s). This will also record that the problem has been fixed in the ECM memory. Many fault codes at the same time is likely to be burnt fuse(s). For more information pertaining to the code faults (state, count, first, etc.) and report, refer to B.U.D.S. online help. When using the service action suggested in the Fault section of B.U.D.S., the system circuits are referred as 5-32 for instance. It means connector no. 5 and the circuit wire no. 32 as found in the wiring diagram. When they are referred as A-41, it means connector A on the ECM and the circuit 41.

TPS ADAPTATION FAILURE Fault It is caused by the idle position moving out of an acceptable range. Following failures can be affected by a TPS Adaptation Failure: Idle speed is out of range. Engine stops, when throttle is released quickly. Engine runs inconsistent in low partload or low RPM.

smr2005-055

117

Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES)

POSSIBLE CAUSES Sensor has been replaced and TPS closed position not reset. Throttle body has been replaced and TPS closed position not reset. ECM has been replaced and TPS closed position not reset. Throttle cable too tight. Sensor is loose. Throttle bracket is loose. Adjustment screw worn or loose.

ACTION Reset Closed Throttle. Reset Closed Throttle. Reset Closed Throttle. Fix and reset Closed Throttle. Fix and reset Closed Throttle. Fix and reset Closed Throttle. Change throttle body.

Burnt Fuse and Related Fault Code

FUSE NO Main 1 2 FUSE CAPACITY AND FUNCTION 5 A Accessories 10 A Fuel pump 5 A RAVE solenoid 10 A Ignition coil and starter solenoid 3 A Injector 1 (MAG) 3 A Injector 2 (PTO) N CODE

None None P-0231

P-0079 P-0616, P0351, P-0352 P-261, P-262 P-264, P-265

4 5 6

NOTE: Fuses are located on the vehicle control module (VCM). Refer to OVERVIEW for more details.

118

smr2005-055

Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES)

EMS Fault Code Table

COMMENT NORMAL OPERATION RESUMES WHEN... ENGINE SPEED LIMITATION DETECTED WHEN ENGINE RUNS DETECTED WHEN ENGINE STOPPED CHECK ENGINE LIGHT BEEPER CODE DESCRIPTION CODE P0079 Rave valve solenoid signal too 15 low Rave valve solenoid signal to high 15 15 Y N Y The engine speed is limited When the fault is due to the fact that the recovered RAVE aren't opening. The engine speed is limited When the fault is (6300) due to the fact that the recovered RAVE aren't opening. (6300) N When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered

P0080

Y Y

N N

Y Y

Manifold atmospheric P0106 pressure sensor out of range Manifold atmospheric P0107 pressure sensor shorted to ground Manifold atmospheric P0108 pressure sensor shorted to 12 V or open circuit Intake manifold temperature P-0111 sensor functional problem Intake manifold temperature P-0112 sensor shorted to ground Intake manifold temperature P-0113 sensor shorted to 12 V or open circuit Engine temperature functional P-0116 problem Engine temperature sensor P-0117 short circuit to ground Engine temperature sensor short circuit to 12 V P-0118 Engine temperature sensor open circuit Throttle position sensor out of P-0122 range Throttle position sensor short P-0122 circuit to ground Throttle position sensor out of P-0123 range - short-circuit to 12 V or open circuit Fuel pump shorted to ground P-0231 or open circuit P-0232 Fuel pump shorted to 12 V

15 15 15 15 15 15 15 15 15 15 15 15 15 15

Y Y Y Y Y Y Y Y Y Y Y Y Y Y

N N N N N N N N N Y Y N Y N

Y Y Y Y Y Y Y Y Y Y Y Y N Y

N N N N N N

When the fault is recovered When the fault is N recovered When the fault is N recovered When the fault is N recovered When key is N removed When key is 3500 Because of the default (3500) removed value (3500) N N When key is removed When the fault is recovered When the fault is recovered 3500 Because of the default value

smr2005-055

119

Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES)

COMMENT NORMAL OPERATION RESUMES WHEN... ENGINE SPEED LIMITATION DETECTED WHEN ENGINE RUNS DETECTED WHEN ENGINE STOPPED CHECK ENGINE LIGHT BEEPER CODE DESCRIPTION CODE P-0261 Inj #1 short-circuit to ground or open circuit 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 Y Y Y Y Y Y Y N N N Y Y Y Y Y Y Y Y Y Y Y Y N N N N N When the key is removed When the fault is recovered When the key is removed When the fault is recovered When the fault is 3D Series and GTI LE RFI recovered only N Y N N N N Y Y Y Y When the fault is recovered When the fault is (3200) recovered When the fault is (3200) recovered When the fault is (3200) recovered (3200) N When engine stop When engine N Y N stop Y N/A N/A N/A When the fault is N Y 0 At 10 V recovered When the fault is N Y 5128 At 18 V recovered N 3200 because the engine runs on 1 cylinder only 3201 because the engine runs on 1 cylinder only 3202 because the engine runs on 1 cylinder only 3203 because the engine runs on 1 cylinder only

P-0262 Inj # 1 short-circuit to 12 V P-0264 Inj #2 short-circuit to ground or open circuit

P-0265 Inj #2 short-circuit to 12 V Engine speed > [rpm] detected Ignition coil 1 open circuit or P-0351 shorted to ground or to 12 V Ignition coil 2 open circuit or P-0352 shorted to ground or to 12 V P-0513 DESS incorrect key P-0336 P-0562 Battery voltage too low P-0563 Battery voltage too high TPS learns unlikely or checksum fault P-0601 Module call monitoring P-0601 P-0602 ECM not coded P-0604 RAM faulty P-0605 EPROM faulty P-0605 Checksum fault EEPROM P-0605 Coding ID checksum fault P-0605 Coding checksum fault P-0605 Programming checksum fault Sensor 5 V power supply P-0608 short to gnd P-0616 Starter relay open circuit P-0617 Starter relay shorted to 12 V P-0650 Check engine circuit open circuit or shorted to ground

Starter relay shorted to ground 5 5 5 5 N N

N(1) Y Y Y (2) Y Y N Y

120

smr2005-055

Section 06 ENGINE MANAGEMENT (RFI) Subsection 02 (DIAGNOSTIC PROCEDURES)

COMMENT NORMAL OPERATION RESUMES WHEN... ENGINE SPEED LIMITATION DETECTED WHEN ENGINE RUNS DETECTED WHEN ENGINE STOPPED CHECK ENGINE LIGHT BEEPER CODE DESCRIPTION CODE Throttle position sensor adaptation failure Throttle position sensor P-1104 adaptation canceled Fuel injector 1, or 2 safety fuel P-1148 cut off detected Engine speed > [rpm] P-1611 detected P-1102 P-1655 DESS line shorted to 12 V 15 15 15 15 15 Y Y Y N Y Y N N Y Y N Y Y Y Y Y N N Y Y N N Y Y N N N N N N N N When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered When the fault is recovered

P-1656 DESS line shorted to ground 15 Buzzer - Short to Battery 15 Voltage Buzzer short-circuit to ground P-1671 2 or open P-1670

(1) fault detected while cranking (2) Sometimes when pressing the start/stop switch

Beeper Codes
CODE 2 5 15 SIGNAL Continuously beeps. A 2 seconds beep every 1 minute intervals. Off

smr2005-055

121