Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Engine Cooling
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the cooli ng s ys t em, refer t o t he rel evant Des cript ion and Operat ion secti on in the workshopmanual.REFER to: Engine Cooli ng (303-03A Engi ne Cool ing - I6 3.2L Pet rol , Descri pti on and Operat ion).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual InspectionMechanicalElectrical
Coolant leaksCoolant expans ion t ankElectric fanRadiat or
FuseW i ri ng harnessLoos e or corroded connect or(s )Engi ne Coolant Temperature (ECT) s ensor
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseActionCoolant los sHosesHose connect ionsRadi atorCool ant pumpHeat er coreGasketsEngi ne cas t ing cracksEngi ne block core plugs
GO t o Pinpoint Test A.
Engine overheati ngEngi ne cool ant (level/condit ion)Thermos tatFan motorFan motor fus es and/or circui tsECT s ens orEngi ne cont rol module (ECM)Fan speed module
GO t o Pinpoint Test B.
Engine not reaching normal operat ing t emperat ureThermos tatElect ric fanFan speed module
GO t o Pinpoint Test C.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve ext rainformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces, and wi th a current cali brati on cert ifi cat e. W hen t est ing res is tance, al ways take t he res is t ance of t he DMM leadsint o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
DT CDescriptionPossible CauseAction
P011600Engine coolant temperature s ens or 1circui t range/performanceEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: hi ghCheck t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l a
Publi s hed: 11-May-2011
Engine Cooling - TD4 2.2L Diesel - Engine Cooling
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the cooli ng s ys t em, refer t o t he rel evant Des cript ion and Operat ion secti on in the workshop
manual.
REFER to: Engine Cooli ng (303-03B Engi ne Cool ing - TD4 2.2L Dies el, Des cript ion and Operat ion).
Inspection and Verification CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is
NO T acceptabl e. Subs ti tut ion of cont rol modules does
not guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he v ehi cl e being t est ed and/or t he donor
vehi cl e.
1. Verify t he cus t omer concern.
1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.
2.
Visual Inspection Mechanical Electrical
Coolant leaks Coolant expans ion t ank
Electric fan
Radiat or Fuse
W i ri ng harness
Loos e or corroded connect or(s )
Engi ne Coolant Temperature (ECT) s ensor
3.
If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) before
proceeding t o t he next s t ep
3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Ch art, al ternat ively, check for
Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.
4.
Symptom Chart Symptom Possible CauseAction
Coolant los s Hoses Hose connect ions
Radi ator
Cool ant pump
Heat er core
Gaskets
Engi ne cas t ing cracks
Engi ne block core plugs GO t o Pinpoint Test
A.Engine overheati ng
Engi ne cool ant (level/condit ion) Thermos tat
Fan motor
Fan motor fus es and/or circui ts
ECT s ens or
Engi ne cont rol module (ECM)
Fan speed module GO t o Pinpoint Test
B.Engine not reaching normal operat ing t emperat ure
Thermos tat Elect ric fan
Fan speed module GO t o Pinpoint Test
C.DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains unde r manufacturer warrant y, refer t o the
W arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or appr oval programme is in operat ion, pri or
t o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digi t codes . Mat ch the five di git s from t he
s can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he fa ul t (t he las t t wo digi ts gi ve ext ra
informat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci mal
places, and wi th a current cali brati on cert ifi cat e. W hen t est ing res is tance, al ways take t he res is t ance of t he DMM leads
int o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi n g pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is no t present , an int ermi tt ent concern may
be t he caus e. Always check for loose connect ions and corroded terminals .
DT C Description Possible Cause Action
P011600 Engine Coolant Temperat ure
Sensor 1 Circuit Mini mum temperat ure or
increas e not achi eved wi thi n Check int egrit y of cool ing s ys tem.
REFER t o: Engi ne Cool ing (303-03B
Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Charging and Controls
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel chargi ng and cont rol s, refer t o the relevant Descri pti on and Operat ion s ect ion in t heworks hop manual .REFER to: Fuel Chargi ng and Controls (303-04A Fuel Chargi ng and Cont rol s - I6 3.2L Pet rol, Des cri pt ion and Operati on).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
• NOTE: For di agnos t ic purpos es the cyli nders are divided i nt o t wo banks: Bank 1 - Cyl inder numbers 1, 2 and 3. Bank 2 -Cylinders 4, 5 and 6
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual Inspection
MechanicalElectricalFuel l evelFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel contami nati on/grade/quali tyThrot tl e bodyDamaged fuel t ank fi ller pipe capDamaged fuel t ank fi ller pipe
FusesLoos e or corroded elect rical connect orsHarnes s esSensor(s )Engine Control Modul e (ECM)
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseAction
Engine cranks , but does not fi reEngine breat her s ys temdis connected/res trictedIgni ti on s ys t emFuel s ys temElectronic engine control
Ens ure the engine breat her sys tem isfree from rest ri ct ion and is correct lyi nst all edFor igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
Engine cranks and fires , but wil lnot s tartEvaporati ve emis s ions purgevalveFuel pumpSpark pl ugsHT s hort t o ground (t racki ng)check rubber boots forcracks/damageIgni ti on s ys t em
For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Di fficul t col d s t artEngine coolant level/ant i-freeze cont entBatt eryElectronic engine controlsFuel pumpPurge valve
Check t he engi ne cool ant l evel andcondit ion.REFER t o: Specificati ons (303-03AEngine Cool ing - I6 3.2L Pet rol ,Specificat ions ).Ens ure the bat tery is i n a full y chargedand s ervi ceable condit ionRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.
Publi s hed: 11-May-2011
Glow Plug System - Glow Plug System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the gl ow plug sys tem, refer t o t he rel evant Des cript ion and Operat ion s ecti on in the works hopmanual.REFER to: Gl ow Plug Sys tem (303-07B Glow Pl ug Syst em, Des cript ion and Operat ion).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of damage.2.
Visual InspectionElectrical
Fuse(s )Gl ow plug relayEngine management cont rol rel ayW iri ng harnes sElectrical connect or(s )Gl ow plug(s )Engine control modul e (ECM)
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart.4.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve addi ti onalinformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces, and wi th an up-t o-date cal ibrat ion cert ificate. W hen tes ti ng res is t ance al ways take t he res is t ance of t he DMMleads i nt o account .
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
DT CDescriptionPossible CauseAction
P038000Gl ow Plug/Heat er Circuit AGl ow plug s ys tem fault - fail ure of aglow plug, rel ay fail ure, s hort circuiti n a gl ow plug or over current
Carry out t he pinpoint t es t sas s oci ated wi th thi s DTC us ing t hemanufact urer approved diagnos t ics ys tem
P038300Gl ow Plug Cont rol Modul eControl Circuit LowGl ow plug relay control ci rcuit - s hortt o groundRefer to el ect ri cal circui t diagrams andcheck glow pl ug rel ay cont rol ci rcuitfor s hort to ground
P038400Gl ow Plug Cont rol Modul eControl Circuit Hi ghGl ow plug relay control ci rcuit - s hortt o powerRefer to el ect ri cal circui t diagrams andcheck glow pl ug rel ay cont rol ci rcuitfor s hort to powerP138A00Gl ow Plug Cont rol Modul eControl CircuitRange/Performance
Gl ow plug relay exces s t emperat ureCarry out t he pinpoint t es t sas s oci ated wi th thi s DTC us ing t hemanufact urer approved diagnos t ics ys temP138B00Gl ow Plug Cont rol Modul eSys tem Vol tageGl ow plug s ys tem fault - short ci rcuiti n a gl ow plug, over-current or relays t uck
Carry out t he pinpoint t es t sas s oci ated wi th thi s DTC us ing t hemanufact urer approved diagnos t ics ys tem
Publi shed: 13-Jul-2011
Fuel Tank and Lines - I6 3.2L Petrol - Fuel Tank and Lines
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel tank and l ines s ys t ems , refer t o t he rel evant Des cript ion and Operat ion s ecti on in theworks hop manual .REFER to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - I6 3.2L Pet rol , Descri pti on and Operat ion).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
• NOTE: For di agnos t ic purpos es the cyli nders are divided i nt o t wo banks: Bank 1 - Cyl inder numbers 1, 2 and 3. Bank 2 -Cylinders 4, 5 and 6
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual Inspection
MechanicalElectricalFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel l evelFuel contami nati on/grade/quali tyDamaged fuel t ank fi ller pipe capDamaged fuel t ank fi ller pipe
FusesLoos e or corroded elect rical connect orsHarnes s esFuel Pump Dri ver Module (FPDM)Central Junct ion Box (CJB)Fuel pump relayEngine Control Modul e (ECM)
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep.3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseAction
Engine cranks , but does not fi reEngine breat her sys temdi sconnect ed/res trict edIgnit ion s yst emFuel sys temEl ect ronic engine controls
Ens ure t he engi ne breat her s ys tem is free fromres t ri ct ion and is correct ly i nst all edFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
Engine cranks and fires , but wil lnot s tartEvaporati ve emis s ionspurge val veFuel pumpSpark pl ugsIgnit ion coil fai lure(s )
For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel pump t es t s . Check for DTCs and refert o DTC Index in t his s ecti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Di fficul t col d s t artCheck engi ne cool antl evel /anti -freeze cont entBat teryEl ect ronic engine controlsFuel pumpEvaporati ve emis s ionspurge val ve
Check the engine coolant level and condit ion.REFER to: Specifi cat ions (303-03A EngineCooli ng - I6 3.2L Petrol, Speci fi cat ions ).Ens ure t he batt ery i s in a ful ly charged ands erviceable condi ti onFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).
Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Tank and Lines
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel tank and l ines s ys t ems , refer t o t he rel evant Des cript ion and Operat ion s ecti on in the
works hop manual .
REFER to: Fuel Tank and Lines (310-01B Fuel Tank and Lines - TD4 2.2L Dies el, Des cript ion and Operat ion).
Inspection and Verification CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is
NO T acceptabl e. Subs ti tut ion of cont rol modules does
not guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he v ehi cl e being t est ed and/or t he donor
vehi cl e.
1. Verify t he cus t omer concern.
1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.
2.
Visual Inspection Mechanical Electrical
Fuel l eaks Damaged fuel l ines
Damaged push connect fit t ings
Fuel l evel
Fuel contami nati on/grade/quali ty
Damaged fuel t ank fi ller pipe cap
Damaged fuel t ank fi ller pipe Fuses
Loos e or corroded elect rical connect ors
Harnes s es
Fuel Pump Dri ver Module (FPDM)
Central Junct ion Box (CJB)
Fuel pump relay
Engine Control Modul e (ECM)
3.
If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) before
proceeding t o t he next s t ep.
3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Ch art, al ternat ively, check for
Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.
4.
Symptom Chart Symptom Possible Cause Action
Engine cranks , but
does not fi re Low/contaminated fuel Intake air l eakage
Fuel sys tem leak, blocked/res tricted
El ect ronic engine controls Check for l ow/contami nat ed fuel
Check int egrit y of i nt ake air s yst em
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Di fficul t t o s tart
Gl owpl ug faul t Low/contaminated fuel
Check engi ne cool ant l evel /anti -
freeze cont ent Bat tery
Intake air s ys tem leak
El ect ronic engine controls
Injector l eak
Fuel sys tem leak, blocked/res tricted Check int egrit y of glowpl ug sys t em
Check for l ow/contami nat ed fuel
Check t he engi ne cool ant l evel and condi ti on.
REFER t o: Specificati ons (303-03B Engine Cool ing
- TD4 2.2L Di es el, Specificat ions ). Ens ure the bat tery is i n a full y charged and
servi ceable condit ion Check int ake air s yst em for leaks
For electronic engine control t es ts .
REFER t o: Electroni c Engi ne Control s (303-14,
Diagnos is and Tes t ing). Carry out i njector leak t est s , ins tal l new inject ors
as neces sary.
REFER t o: Fuel Injector (303-04B Fuel Charging
and Cont rols - TD4 2.2L Di esel , Removal and
Ins tal lati on). Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Rough idl e
Intake air s ys tem leak Low/contaminated fuel
Fuel sys tem leak, blocked/res tricted
EGR val ve fault Check int ake air s yst em for leaks
Check for l ow/contami nat ed fuel
Check fuel s yst em for leaks and
bl ockage/res t ri ct ion. Read DTCs and refer to
relevant DTC Index Check EGR s ys tem for fai lure.
REFER t o: Engi ne Emis s ion Cont rol (303-08B
Engine Emis s ion Control - TD4 2.2L Di esel ,
Diagnos is and Tes t ing).
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only 5-digi t codes . Match t he 5 digi ts from t he s cant ool t o t he fi rs t 5 di gi ts of the 7-digit code li s ted t o i dent ify the fault (the last 2 digi ts gi ve ext ra informati on read by themanufacturer-approved di agnos ti c s ys t em).
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
• NOTE: Pri or to ins tall ati on/replacement of the Headlamp Ass embly carry out all relevant i nternal vis ual and mechanicalchecks for correct cable l ocat ion and t erminati on including: checks for corroded, bent or backed out pi ns or terminals ,incorrect ly i nserted connect ors and harnes s damage due t o chaffi ng or incorrect routing.
• NOTE: If the control modul e has been removed and rei nst all ed, carry out a DTC code clear, cycl e t he ignit ion st ate to off,t hen on. This will erase any DTCs that have been l ogged during t he module ins tall ation procedure
For a compl ete lis t of all Di agnos ti c Trouble Codes (DTCs) t hat could be logged on this vehicle, pleas e refer to Sect ion100-00.
REFER to: Di agnos ti c Trouble Code (DTC) Index - DTC: Headlamp Cont rol Modul e (HCM) (100-00 General Informati on,Des cript ion and Operat ion).
Symptom Chart
SymptomPossible CausesActionLow beam lamp(s )i noperat iveBulb fail ureFus e(s ) blownCi rcuit faul tLight ing control s wi tchfaul tLeft -hand s t eeringcolumn mult ifuncti ons wit ch faul t
Check t he bulb and fuse condit ion (s ee vis ual i nspecti on). Check theheadlamp ci rcuit s . Check t he li ght ing control swit ch funct ion. Check theleft -hand s t eering column mult ifunct ion s wi tch operat ion. Refer to theel ect ri cal guides . Check for DTCs indicati ng a headl amp or rel atedci rcuit faul t.Hi gh beam lamp(s )i noperat ive
Low beam lamp(s )dimIncorrect bul b rat ingTouri st l ever s et in thewrong pos i ti onCi rcuit faul tLight ing control s wi tchfaul tLeft -hand s t eeringcolumn mult ifuncti ons wit ch faul t
Check t he bulb condi ti on and rat ing. Check the t ouris t l ever i s s etcorrectl y. Check the headlamp ci rcuit s . Check t he li ght ing control swit chfunct ion. Check the l eft -hand s teering column mult ifuncti on s wit chfunct ion. Refer t o t he electrical gui des .
Hi gh beam lamp(s )dim
Low beam lamp(s )s tuck onCi rcuit faul tLight ing control s wi tchfaul tLeft -hand s t eeringcolumn mult ifuncti ons wit ch faul tHeadlamp ti merfunct ion faul t
Check t he headl amp circui ts . Check t he l ighti ng cont rol s wit ch functi on.Check t he left-hand st eeri ng col umn mul ti funct ion swi tch operat ion.Check t he headl amp t imer funct ion. Refer to the el ect ri cal guides .Check for DTCs i ndicat ing a headl amp circui t fault
Hi gh beam lamp(s )s tuck on
Headlamp l ow/hi ghbeam s wi tchingfunct ion i noperat ive
Ci rcuit faul tLeft -hand s t eeringcolumn mult ifuncti ons wit ch faul tXenon lamp s hut termechani s m fault
Check t he headl amp circui ts . Check t he l eft-hand s teeri ng col umnmult ifunct ion s wit ch operati on. Check t he xenon l amp s hutt ermechanis m operati on. Refer t o t he electrical gui des . Check for DTCsindicati ng a headl amp circui t fault
W arning l amp(s )i noperat iveFus e(s ) blownLight ing control s wi tchfaul tLeft -hand s t eeringcolumn mult ifuncti ons wit ch inoperat iveCi rcuit faul tInst rument clus t erfaul t
Check t he fus e(s ) (s ee vi s ual i ns pecti on). Check t he li ghti ng cont rolswi tch funct ion. Check t he l eft -hand s teeri ng column mul ti functi onswi tch funct ion. Check t he warni ng lamp circuit s . Refer to the el ect ri calgui des . Check for DTCs indicat ing an i nst rument clus ter or CAN s ys temfault .
Headlamp W et -InternalCondens ati onW at er Ingres sCheck for out st anding Techni cal Service Bull eti ns (TSBs ) rel at ing to'Headl amp Internal Condens ati on'. Carry out the i nst ruct ions in theservi ce bullet in to det ermi ne if t he faul t is relat ed to condens at ion orwater ingres s .
Publi shed: 26-Jul-2011
Seating - Heater Mats
Diagnosi s and Tes ti ng
Principles of Operation
Heated s eats incorporate heat er elements in t he cushi on and the backres t of the s eat. Each cus hion heat er el ement has at hermal sens or, whi ch suppli es a feedback temperat ure si gnal t o t he rel at ed s eat heat er modul e. The backres t heat erelement s do not have a thermal sens or, and are regulat ed at the s ame temperat ure as the cus hi on heat er elements .
For a detail ed descripti on of the seat heater mat , refer t o t he rel evant Des cript ion and Operat ion s ecti on in the workshopmanual. REFER to: Seats (501-10, Descripti on and Operat ion).
Inspection and Verification
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual inspectionMechanicalElectrical
Seat heat er swi tches condi ti on and ins tal lati onFusesHarnes s es and connect orsSeat heat er modul eSeat heat er swi tchesSeat heat er mat
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep.3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart.4.
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o thewarranty poli cy and procedures manual (s ect ion B1.2), or det ermine i f any prior approval programme is i n operati on, priort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve addi ti onalinformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to threedeci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t ance, always take t he res i st ance of t heDMM leads int o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
DTC Index
For a compl ete lis t of all di agnos ti c troubl e codes that coul d be l ogged on t his vehicle, pleas e refer to s ect ion 100-00.
Seat Heater Mat Application C hart• NOTE: To ens ure an accurate res is t ance readi ng, cali brated tes t equi pment must be used
Vehicle/YearCushion /Backrest
Heater Mat/ NT CResistor
Left Hand DriveRight Hand DriveMinimumResistanceMaximumResistance
PassengerSideConnector /Pin
Driver SideConnector /Pin
PassengerSideConnector /Pin
Driver SideConnector /PinOhms At20°C ±10°COhms At20°C ±10°CDi scovery 32006Cushi onHeater matC2950-1 andC2950-4C0085-1 andC0085-4C2950-1 andC2950-4C0085-1 andC0085-40,751,0
NTCres is t orC2950-2 andC2950-3C0085-2 andC0085-3C2950-2 andC2950-3C0085-2 andC0085-34 00010 000
Backres tHeater matconnect ed ins eri esconnect ed ins eri esconnect ed i nseriesconnect ed inseries0,440,59
Di scovery 42010Cushi onHeater matC3542-1 andC3542-4C3542-1 andC3542-4C3542-1 andC3542-4C3542-1 andC3542-40,701,0
NTCres is t orC3542-2 andC3542-3C3542-2 andC3542-3C3542-2 andC3542-3C3542-2 andC3542-34 00010 000
Backres tHeater matC3543-1 andC3543-2C3543-1 andC3543-2C3543-1 andC3543-2C3543-1 andC3543-20,40,7
Range RoverSport 2010Cushi onHeater matC3542-1 andC3542-4C3542-1 andC3542-4C3542-1 andC3542-4C3542-1 andC3542-40,931,25
NTCres is t orC3542-2 andC3542-3C3542-2 andC3542-3C3542-2 andC3542-3C3542-2 andC3542-34 00010 000
Backres tHeater matC3543-1 andC3543-2C3543-1 andC3543-2C3543-1 andC3543-2C3543-1 andC3543-20,430,6