13B-11V9 MR-372-J84-13B450$030.mif
DIESEL INJECTION
Fault finding – List and location of components13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Refrigerant pressure sensor:
This sensor is located on the coolant circuit.
Engine coolant temperature sensor:
This sensor is located on the cylinder head near the engine water chamber.
Air temperature sensor:
The air temperature sensor is located at the air circuit inlet, integrated into the air flowmeter.
Turbocharging pressure sensor solenoid valve:
This solenoid valve is located on the turbocharger.
Catalytic converter:
The catalytic converter is located downstream of the turbocharger.
Fuel temperature sensor:
This sensor is located near the injection pump and injector return.
Cruise control/speed limiter on/off switch:
This switch is located in the passenger compartment to the left of the steering wheel near the lighting dimmer.
Fan unit relay:
The relay is located on the cooling radiator.
Accelerator potentiometer:
The potentiometer is located on the accelerator pedal.
Clutch pedal switch:
The switch is located on the clutch pedal.
Heater plugs:
The heater plugs are located on the cylinder head.
The richness ratio sensor:
The richness ratio sensor is mounted in the turbo outlet.
The turbocharger cooling pump:
This pump is located next to the turbocharger.
Particle filter downstream temperature sensor:
The sensor is located after the particle filter (only on certain F9Q816 engines in Vdiag 48).
Particle filter upstream temperature sensor:
The sensor is located before the particle filter (only on engine type F9Q816).
Particle filter differential pressure sensor:
The sensor is located on the particle filter (only on engine type F9Q816).
13B-13V9 MR-372-J84-13B450$040.mif
DIESEL INJECTION
Fault finding – Role of components13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Particle filter:
The particle filter retains the particles for destruction during regeneration, preventing these particles from being
discharged into the atmosphere (engine type F9Q816 only).
TDC sensor:
The angular position is measured using a magneto-inductive sensor triggered by the machined teeth on the engine
flywheel. This sensor gives the engine speed as well as the position of the crankshaft for injection.
Camshaft sensor:
This sensor provides a signal to perform the injection cycle.
When the piston for cylinder 1 is at top dead centre (TDC), it may be either at the end of the compression stroke or
at the end of the exhaust stroke. The camshaft sensor makes the distinction between these two states.
Electric coolant pump:
The electric water pump is activated if the coolant temperature has reached a significant temperature threshold
when the engine has stopped.
Role: to cool the turbocharger when the engine is stopped.
Refrigerant pressure sensor:
Its role is to measure the refrigerant pressure in the air conditioning circuit.
Heating elements:
The heating elements heat the engine coolant to improve user comfort (only on certain types of F9Q816 engine
in Vdiag 48).
Engine coolant temperature sensor:
The engine coolant temperature sensor informs the computer of the engine coolant temperature.
Air temperature sensor:
The air temperature sensor is fitted inside the inlet manifold and informs the computer of the temperature of the air
taken in by the engine.
Turbocharging pressure sensor solenoid valve:
This solenoid valve operates the turbocharger wastegate pneumatic circuit to lower the turbocharging pressure.
Catalytic converter:
The role of the catalytic converter is to convert pollutant gases into harmless gases.
Fan unit relay:
This relay controls the activation of the engine cooling fan assembly when a temperature threshold has been
exceeded.
Accelerator potentiometer:
The accelerator potentiometer informs the computer of the position of the accelerator pedal (engine load).
13B-15V9 MR-372-J84-13B450$050.mif
13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
System outline
The high pressure injection system is designed to deliver a precise quantity of diesel fuel to the engine at a set
moment.
It is fitted with a BOSCH 128-track computer, type EDC16C36.
The system comprises:
– a priming bulb on the low pressure circuit,
– a diesel filter,
– a high pressure pump with a built-in low pressure pump (transfer pump),
– a high pressure regulator mounted on the pump,
– an injector rail,
– a diesel fuel pressure sensor built into the rail,
– four solenoid injectors,
– a diesel temperature sensor,
– a coolant temperature sensor,
– a cylinder reference sensor,
– an engine speed sensor,
– a turbocharger pressure sensor,
– an accelerator pedal potentiometer,
– an exhaust gas recirculation solenoid valve,
– a recycled gas cooling solenoid valve,
– an atmospheric pressure sensor integrated into the injection computer,
– an air flowmeter fitted with an air temperature sensor,
– a turbocharging pressure limitation solenoid valve,
– a motorised damper valve,
– a particle filter (F9Q816 engine only),
– a particle filter differential pressure sensor (F9Q816 engine only),
– a temperature sensor upstream of the particle filter (F9Q816 engine only),
– a temperature sensor downstream of the particle filter (only on certain F9Q816 engines in VDiag 48),
– a temperature sensor upstream of the turbine (F9Q816 engine only),
– a richness ratio sensor,
– a turbocharger cooling pump.
The common rail direct high pressure injection system works sequentially (based on the petrol engine multipoint
injection).
This injection system reduces operating noise, reduces the volume of pollutant gases and particles and produces
high engine torque at low engine speeds thanks to a pre-injection procedure.
The high pressure pump generates the high pressure and transmits it to the injector rail. The actuator located on the
pump controls the quantity of diesel supplied, according to the demand determined by the computer. The rail
supplies each injector through a steel pipe.
DIESEL INJECTION
Fault finding – Features
13B-16V9 MR-372-J84-13B450$050.mif
DIESEL INJECTION
Fault finding – Features13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump).
It supplies the rail, the pressure of which is controlled by the fuel flow actuator (MPROP) for charging, and for
discharging by the injector valves. This compensates for pressure drops. The flow actuator allows the high pressure
pump to supply the exact quantity of diesel fuel required to maintain the pressure in the rail. This component
minimises the heat generated and improves engine output. In order to discharge the rail using the injector valves,
the valves are controlled by brief electrical pulses which are:
– short enough not to open the injector (passing through the feedback circuit from the injectors),
– long enough to open the valves and discharge the rail.
Some vehicles have a presence sensor mounted in the filter for detecting water in the diesel. 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.
Removal of the internal parts of the pump and injectors is prohibited. Only the fuel flow regulator/actuator, diesel fuel
temperature sensor and the venturi can be replaced.
For safety reasons, it is strictly prohibited to undo a high pressure pipe union when the engine is running.
It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit contamination
faults. If the pressure sensor is defective, replace the pressure sensor, rail and high pressure pipes associated with
the rail.
Supplying + 12 V directly to any component in the system 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. WARNING
The engine must not operate with:
– Diesel fuel containing more than 10% diester,
– petrol, even in tiny quantities.
13B-24V9 MR-372-J84-13B450$050.mif
DIESEL INJECTION
Fault finding – Features13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
ORANGE particle filter specific warning light (F9Q816 engine only):
F9Q816 Vdiag 48 engines:
This warning light is used to warn the driver that the particle filter is loaded with particles (weight of soot greater than
36 g or more than 6 regeneration failures while driving due to driving conditions not being favourable for
regeneration). As soon as possible the driver must then drive at an average speed of 48 mph (80 km/h) subject to
the road conditions and authorised speed limits.
F9Q816 Vdiag 50 engines:
This warning light is used to warn the driver that the particle filter is loaded with particles.
European On Board Diagnostic management:
The OBD (On Board Diagnostic) system permits detection of any faults relating to the vehicle emission control
system (OBD EURO IV emission control standards being exceeded).
This system should be active for the entire life of the vehicle.
1. Conditions of an OBD fault appearing
An OBD fault will be detected after 3 trip cycles.
It allows the driver to know whether the vehicle has a fault directly linked to the emission control system.
2. System faults displayed by the OBD
List of the faults recorded by the OBD system:
– DF002 Air temperature sensor circuit.
– DF004 Turbocharging pressure sensor circuit.
– DF011 Sensor supply voltage no. 1.
– DF012 Sensor supply voltage no. 2.
– DF013 Sensor supply voltage no. 3.
– DF026 Cylinder 1 injector control circuit.
– DF027 Cylinder 2 injector control circuit.
– DF028 Cylinder 3 injector control circuit.
– DF029 Cylinder 4 injector control circuit.
– DF054 Turbocharging solenoid valve control circuit.
– DF055 Turbocharging pressure regulation circuit.
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DIESEL INJECTION
Fault finding – Defect modes13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
* normally aspirated: naturally aspiratedDefect
modesCause of fault Customer perception
Turbocharger
cut-off– Turbocharging pressure loop difference (vanes jammed,
compressor/turbine fault, turbocharging pressure sensor fault,
sensor connection fault, functional solenoid valve fault
(disconnected, hose kinked, solenoid valve mechanism jammed),
high pressure circuit leak (high pressure hose, major distributor
leak).
– Flowmeter failure (plausibility of the reading):
– significant line resistance on earth sensor,
– significant line resistance on sensor feed, significant line resistance
on sensor signal,
– flowmeter sensing element damaged,
– wiring/connection fault,
– flowmeter voltage or 5 V reference voltage deviation.
– Flowmeter failure (plausibility of sensitivity variation):
– flowmeter clogged/flow underestimated,
– flow overestimated,
– air circuit leak between flowmeter and compressor,
– air circuit leak after compressor.
– Electrical faults:
– signal short circuit to + 12 V,
– signal short circuit to earth,
– signal open circuit,
– sensor feed open circuit,
– open circuit, short circuit to earth and turbocharger solenoid valve
short circuit to + 12 V.
– Turbocharger pressure sensor fault (sensor signal short circuit with
sensor feed, sensor signal short circuit to + 12 V, sensor open
circuit to earth, sensor signal short circuit to earth, sensor feed open
circuit, sensor signal open circuit, significant line resistance on
sensor feed, significant line resistance on sensor signal, significant
line resistance on sensor earth, significant pressure difference
measured between the atmospheric pressure sensor and the
turbocharger pressure sensor at idle speed).
– EGR valve fault (valve clogged, valve jammed open).
– Camshaft sensor fault.
– Engine speed sensor fault.
– Sensor feed No. 1 fault.25-50% loss of engine
performance (normally
aspirated engine)
Rail pressure
limited– Rail pressure sensor fault.
– Sensor feed No. 3 fault.Poor performance
Rail pressure
reduction
– Positive rail pressure loop difference (measurement < setpoint).
Poor performance
13B-34V9 MR-372-J84-13B450$090.mif
13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Management of instrument panel warning lights according to the faults notified.
FaultDTC code in
hexadecimalLevel 1 fault
warning light
(orange
SERVICE
warning light)Level 2 fault
warning light
(red STOP
warning light)No fault
warning
light litOBD
warning
light lit
DF001 Coolant temperature
sensor circuit115 CC.0/CO.1 - - -
DF002 Air temperature sensor
circuit110 - - CC.0/CO.1CC.0/
CO.1
DF004 Turbocharging
pressure sensor circuit235CO.0/CC.1/
1.DEF--CO.0/
CC.1/
1.DEF
DF007 Rail pressure sensor
circuit190CC.0/CO.1/
1.DEF/2.DEF---
DF011 Sensor supply
voltage no. 1641 1.DEF/2.DEF - -1.DEF/
2.DEF
DF012 Sensor supply
voltage no. 2651 1.DEF/2.DEF - -1.DEF/
2.DEF
DF013 Sensor supply
voltage no. 3697 - 1.DEF/2.DEF -1.DEF/
2.DEF
DF017 Pre-heating unit
control circuit670CC.0/CO/CC.1/
1.DEF---
DF025 Preheating unit fault
finding connection380 - - - 1.DEF
DF026 Cylinder 1 injector
control circuit201 CO CC/1.DEF -CO/CC/
1.DEF
DF027 Cylinder 2 injector
control circuit202 CO CC/1.DEF -CO/CC/
1.DEF
DF028 Cylinder 3 injector
control circuit203 CO CC/1.DEF -CO/CC/
1.DEF
DF029 Cylinder 4 injector
control circuit204 CO CC/1.DEF -CO/CC/
1.DEF
DIESEL INJECTION
Fault finding – Fault summary table
13B-35V9 MR-372-J84-13B450$090.mif
DIESEL INJECTION
Fault finding – Fault summary table13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Management of instrument panel warning lights according to the faults notified.
FaultDTC code in
hexadecimalLevel 1 fault
warning light
(orange
SERVICE
warning light)Level 2 fault
warning light
(red STOP
warning light)No fault
warning
light litOBD
warning
light lit
DF032 Thermoplunger 1 relay
control circuit1641 - - CC.1/1.DEF -
DF033 Thermoplunger 2 relay
control circuit1642 - - CC.1/1.DEF -
DF034 Thermoplunger 3 relay
control circuit1643 - - CC.1/1.DEF -
DF038 Computer 606 1.DEF/ 3.DEF 1.DEF/2.DEF 1.DEF -
DF046 Battery voltage 560 - -1.DEF/
2.DEF/
3.DEF
DF047 Computer feed voltage 2505 - - 1.DEF -
DF051 Cruise control/speed
limiter function575 - - 1.DEF -
DF053 Rail pressure
regulation function89 3.DEF/2.DEF1.DEF/4.DEF/
3.DEF--
DF054Turbocharging
solenoid valve control circuit45CC.1/CC.0/
CO/ 1.DEF--CC.1/
CC.0/CO/
1.DEF
D F055 Turbocharging
pressure regulation circuit2263 1.DEF/2.DEF - -1.DEF/
2.DEF
DF056 Air flow sensor circuit 100CO.0/CC.1/
1.DEF--CO.0/
CC.1/
1.DEF
DF059 Misfiring on cylinder 1 301 - - 1.DEF -