13B-4
MR-372-J84-13B200$036.mif
V13
EDC16
Program No: C1
Vdiag No: 18, 1C, 20,
50, 58, 5CDIESEL INJECTION
Fault finding – Introduction13B
3. FAULT FINDING PROCEDURE
* Check the battery charge, the condition of the fuses and the level of the fuel in the tank.
Perform a pre-diagnostic on the
system
Print the system fault finding log
(available on CLIP and in the
Workshop Repair Manual or
Technical Note)
Connect CLIP
no
Dialogue with
computer?
yes
Read the faults
no
Faults
present
yes
Deal with present faults
Deal with stored faults
no
The cause is
still presentFault
solved
yes
See ALP no. 1
Conformity check
no
The cause is
still presentFault
solved
Use fault finding charts
(ALPs)
no
The cause is
still presentFault
solved
Contact the Techline with the
completed fault finding log
13B-7
MR-372-J84-13B200$036.mif
V13
DIESEL INJECTION
Fault finding – Introduction
EDC16
Program No: C1
Vdiag No: 18, 1C, 20,
50, 58, 5C
13B
Visual inspection of the sealing:
(Only for watertight connectors)
Check for the seal on the connection (between the 2 parts of the connection).
– Check the seal at the back of the connectors:
– For unit
joints (1 for each wire), check that the unit joints are present on each electrical wire and that they are
correctly positioned in the opening (level with the housing). Check that plugs are present on openings which are
not used.
– For a grommet
seal (one seal which covers the entire internal surface of the connector), check that the seal is
present.
– For gel
seals, check for gel in all of the sockets without removing the excess or any protruding sections (it does
not matter if there is gel on the contacts).
– For hotmelt
sealing (heat-shrink sheath with glue), check that the sheath has contracted correctly on the rear of
the connectors and electrical wires, and that the hardened glue comes out of the side of the wire.
– Check that there is no damage to any of the seals (cuts, burns, significant deformation, etc.).
If a fault is detected, consult Technical Note 6015A, Repairing electrical wiring.
4. FAULT FINDING LOG
You will always be asked for this log:
– when requesting technical assistance from Techline,
– for approval requests when replacing parts for which approval is mandatory,
– to be attached to monitored parts for which reimbursement is requested. The log is needed for warranty
reimbursement, and enables better analysis of the parts removed.
5. SAFETY INSTRUCTIONS
Safety rules must be observed during any work on a component to prevent any damage or injury:
– check the battery voltage to avoid incorrect operation of computer functions,
– Use the proper tools. IMPORTANTIMPORTANT
Any fault on a complex system requires thorough fault finding with the appropriate tools. The
FAULT FINDING LOG, which should be completed during the procedure, enables you to keep
track of the procedure which is carried out. It is an essential document when consulting the
manufacturer.
IT IS THEREFORE MANDATORY TO FILL OUT A FAULT FINDING LOG EACH TIME FAULT FINDING IS
CARRIED OUT.
13B-13
MR-372-J84-13B200$108.mif
V13
DIESEL INJECTION
Fault finding – System operation
EDC16
Program No: C1
Vdiag No: 18, 1C, 20,
50, 58, 5C
13B
Some vehicles have adopted a sensor for detecting water in the diesel fuel, located in the filter. If there is water in
the diesel fuel, the orange "Injection and pre-post heating" warning light will come on.
The system can inject diesel fuel into the engine at a pressure of up to 1600 bar. Before each operation, check that
the injector rail is depressurised and that the fuel temperature is not too high.
You must respect the cleanliness guidelines and safety advice specified in this document for any work on the high
pressure injection system.
Do not remove the internal parts of the pump and injectors. Only the flow actuator, the diesel temperature sensor
and the Venturi tube can be replaced.
For safety reasons, do not loosen high pressure pipe unions when the engine is running.
It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit contamination
faults. If the pressure sensor fails, the pressure sensor, the rail and the five high pressure pipes must be replaced.
Do not remove an injection pump pulley marked with the number 070 575. If the pump needs to be replaced, replace
the pulley.
Supplying any system component directly with +12V is prohibited.
Ultrasonic decoking and cleaning are prohibited.
Never start the engine unless the battery is connected correctly.
Disconnect the injection computer when carrying out any welding work on the vehicle.
b)The connections between the vehicle's various computers are multiplexed.
The electronic system fitted in this vehicle is multiplexed. This system enables dialogue between the various vehicle
computers. As a result:
– the activation of the fault warning lights on the instrument panel is performed by the multiplex network, with the
vehicle speed sensor on the gearbox deactivated,
– vehicle faults are displayed by the multiplex network,
– the vehicle speed sensor on the gearbox is not needed.
The vehicle speed signal on the instrument panel is transmitted by the ABS computer via a wire connection, then
sent out on the multiplex network by the instrument panel. The vehicle speed signal is used mainly by the injection
computer and the airbag computer.WARNING
The engine must not operate with:
– Diesel fuel containing more than 10% diester.
– petrol, even in tiny quantities.
13B-21
MR-372-J84-13B200$144.mif
V13
13B
DIESEL INJECTION
Fault finding – Replacement of components
COMPUTER REPLACEMENT OR REPROGRAMMING
Two operations must be performed when replacing or reprogramming the computer:
SC003 Save computer data and SC001 Enter saved data.
– Run command SC003 Save computer data before replacing or reprogramming the computer. This enables
certain data to be saved in the diagnostic tool so that the new computer* can be reconfigured like the old one.
The saved data includes: injector codes, EGR programming, specific data for particle filter operation and vehicle
options.
– Run command SC001 Write saved data after replacing or reprogramming the computer. This command
enables the data (saved by the command SC003 Save computer data) to be rewritten in the new computer*.
If you cannot establish dialogue with the computer being replaced: you will not be able to save anything.
After replacing the computer:
– Manually enter the IMA codes for each injector by reading the code on each injector (see 13B, Diesel injection,
Replacement of components, Injector replacement).
– Enter the data specific to particle filter operation by running SC036 Reinitialise programming and select After
replacing the injection computer with no save option.
Exhaust gas recirculation valve data is programmed automatically the 1st time the new computer is switched on*.
* New computer or reprogrammed computer.
Specific to the cruise control/speed limiter operation to be carried out before reprogramming of the
computer:
Before reprogramming the injection computer, move the main cruise control/speed limiter switch to the rest
position. The information about the cruise control or the speed limiter displayed on the instrument panel
disappears.
Otherwise, if the main switch remains in the cruise control or speed limiter position during and after reprogramming,
the Cruise control/Speed limiter function will not be operational.
The procedure for resetting the function is as follows:
– Vehicle ignition on.
– Position the cruise control/speed limiter switch in the rest position (the computer then detects the rest position).
– Position the cruise control/speed limiter switch in the Cruise control position to activate the Cruise control
function.
– Position the cruise control/speed limiter switch in the Speed limiter position to activate the Speed limiter function. IMPORTANT
– Switch on the diagnostic tool (mains or cigarette lighter supply).
– Connect a battery charger.
– Cut off all the electrical consumers (lights, interior lighting, air conditioning, radio CD, etc.).
– Wait for the engine to cool (engine coolant temperature < 60° and air temperature < 50°).
– For Vdiags 50, 58, 5C, during (re)programming of the computer, the engine fan assemblies are actuated
automatically.
– For Vdiags 18, 1C, 20, during (re)programming of the computer, the instrument panel screen displays
“Oil pressure fault”.
– Ignore this message and do not take any action in connection with it.
EDC16
Program No: C1
Vdiag No: 18, 1C, 20,
50, 58, 5C
MR-372-J84-13B200$144.mif
13B-28
MR-372-J84-13B200$216.mif
V13
DIESEL INJECTION
Fault finding – Fault summary table
EDC16
Program No: C1
Vdiag No: 18, 1C, 20,
50, 58, 5C
13B
Tool
faultDiagnostic tool titleAssociated
DTCLevel 1 fault
warning light
(Orange
heater plugs
"on" indicator
light)Level 2 fault
warning light
(Red
overheating
warning light)No fault
warning
light onOBD
warning
light lit
DF032Thermoplunger relay 1
control circuit (Vdiag
58, 5C only)1641CO/CC.0/
CC.1/
1.DEF
DF033Thermoplunger relay 2
control circuit (Vdiag
58, 5C only)1642CO/CC.0/
CC.1/
1.DEF
DF034Thermoplunger relay 3
control circuit (Vdiag
58, 5C only)1643CO/CC.0/
CC.1/
1.DEF
DF037Engine immobiliser C167 X
DF038Computer 6066.DEF/8.DEF/
12.DEF1.DEF/2.DEF/
3.DEF/4.DEF/
5.DEF/7.DEF
10.DEF/
11.DEF/
13.DEF/
14.DEF6.DEF
DF039Inlet air temperature
sensor circuit110 CC.0/CO.1
DF040Cylinder 1 injector
circuit201 COCC.1/CC/
1.DEFCO
DF041Cylinder 2 injector
circuit202 COCC.1/CC/
1.DEFCO
DF042Cylinder 3 injector
circuit203 COCC.1/CC/
1.DEFCO
DF043Cylinder 4 injector
circuit204 COCC.1/CC/
1.DEFCO
DF046Battery voltage 5601.DEF/
2.DEF
13B-55
MR-372-J84-13B200$252.mif
V13
DIESEL INJECTION
Fault finding – Interpretation of faults
EDC16
Program No.: C1
Vdiag no.: 18, 1C, 20,
50, 58, 5C
13B
DF015
PRESENT
OR
STOREDMAIN RELAY CONTROL CIRCUIT
1.DEF : Relay cut out too soon
2.DEF : Relay cut out too late
NOTESConditions for applying the fault finding procedure to stored faults:
Only deal with this fault if it is stored.
Special notes:
The supply relay of the injection control unit (50A) is located on a relay plate in the
engine connection unit under the Protection and Switching Unit.
If the fault is present, the level 1 warning light is lit.
Use bornier Elé.1681 or Elé.1590 for any operation on the injection computer
connectors.
Check the Protection and Switching Unit connections (Vdiag 50, 58, 5C only).
Check the injection computer connections.
Repair if necessary.
Check the condition of the battery terminals making sure they are correctly tightened.
Check the condition of the injection supply relay and its mounting.
Check the 5D (5A) + after ignition supply located on the UPC (Protection and Switching Unit) (Vdiag 50, 58, 5C
only).
Repair if necessary.
Check the continuity and absence of interference resistance of connection 3AA between components 120 and
983.
If the connection or connections are faulty and there is a repair method (see Technical Note 6015A, Repairing
electrical wiring, Wiring: Precautions for repair), repair the wiring, otherwise replace it.
If the fault is still present, contact the Techline.
IMPORTANT!WA R N I N G
If the Protection and Switching Unit (Vdiag 50, 58, 5C only) no longer detects the injection
computer signals, GMV 1 will be actuated until the battery is completely discharged.
In the event that engine cooling fan 1 is not working, GMV 2 will be supplied.
AFTER REPAIRDeal with any faults.
Carry out a road test followed by another check with the diagnostic tool.
EDC16_V50_DF015/EDC16_V58_DF015/EDC16_V5C_DF015/EDC16_V18_DF015/EDC16_V1C_DF015/EDC16_V20_DF015
13B-63
MR-372-J84-13B200$288.mif
V13
DIESEL INJECTION
Fault finding – Interpretation of faults
EDC16
Program No.: C1
Vdiag no.: 18, 1C, 20,
50, 58, 5C
13B
DF038
PRESENT
OR
STORED
COMPUTER1.DEF: Permanent high signal
2.DEF: Permanent low signal
3.DEF: Configuration absent or incorrect
4.DEF: Analogue/digital converter fault
5.DEF: Communication disrupted
6.DEF: EEPROM fault
7.DEF: Watchdog activation
8.DEF: Signal outside upper limit
10.DEF: Injector control
11.DEF: Injector control capacitor fault
12.DEF: Injection fault when decelerating
13.DEF: Initialisation error
14.DEF: Open circuit or internal electronic fault.
NOTESConditions for applying the fault finding procedure to a stored fault:
The fault is declared present after one attempt to start the engine, or with the engine
running.
Special notes:
If 6.DEF, 8.DEF, 12.DEF is present the level 1 warning light is lit.
If one of the other faults is present, the level 2 warning light is lit.
If 6.DEF is present, the OBD warning light will come on after three consecutive driving
cycles (starting + 5 seconds, switch off the ignition and wait for 1 minute).
Use bornier Elé.1681 or Elé.1590 for any operation on the injection computer
connectors.
Priority when dealing with a number of faults:
Deal with fault DF046: Battery voltage first if it is present or stored.
AFTER REPAIRDeal with any faults.
Carry out a road test followed by another check with the diagnostic tool.
EDC16_V50_DF038/EDC16_V58_DF038/EDC16_V5C_DF038/EDC16_V18_DF038/EDC16_V1C_DF038/EDC16_V20_DF038
13B-65
MR-372-J84-13B200$288.mif
V13
EDC16
Program No.: C1
Vdiag no.: 18, 1C, 20,
50, 58, 5CDIESEL INJECTION
Fault finding – Interpretation of faults13B
DF038
CONTINUED 2
11.DEF
NOTESIf there are a number of faults, deal with the other system
faults first.
Display the stored context for fault DF038.
PR142 Computer fault = 10
NO YES
Contact the Techline
NO YES
Check the charge circuit and carry out the
necessary repairs:
– Check the condition of the battery terminals,
– carry out fault finding on the alternator.
Recharge or replace the battery.
YES
Check the condition of the wiring harness between the computer and the battery, carry out the necessary repairs.
– Start the vehicle.
– Clear the stored faults.
– Check the faults:
– If DF038 is stored, end of fault finding.
– If DF038 is present, contact the Techline.
Main screen parameters.
PR071 Computer supply voltage > 10 V
NO
Contexts stored for DF038.
PR071 Computer feed voltage > 10 V
AFTER REPAIRDeal with any faults.
Carry out a road test followed by another check with the diagnostic tool.