Page 8 of 431

13B-8V9 MR-372-J84-13B450$020.mif
13B
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
1. HAZARDS ASSOCIATED WITH CONTAMINATION
The high pressure direct injection system is highly 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 up,
– a component losing its sealing.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles
a few microns in size) should have penetrated the system during dismantling.
The cleanliness guidelines must be applied from the filter through to the injectors.
What are the sources of contamination?
– metal or plastic swarf,
– paint,
–fibres:
– from cardboard,
– from brushes,
– from paper,
– from clothing,
– from cloths,
– foreign bodies such as hair,
– the ambient atmosphere,
–etc.
2. INSTRUCTIONS TO BE FOLLOWED PRIOR TO ALL OPERATIONS
Check that you have plugs for the unions to be opened (set of plugs available from the Parts Department). The plugs
are single-use only. After use, they must be discarded (once used they are soiled and cleaning is not sufficient to
make them reusable). Unused plugs must be discarded.IMPORTANT
Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections.
In addition, moisture may collect in the connectors and create faults in the electrical connections.
IMPORTANT
Before carrying out any work on the high pressure injection system, protect:
– the accessories and timing belts,
– the electrical accessories, (starter, alternator, electric power-assisted steering pump),
– the flywheel surface, to prevent any diesel from running onto the clutch friction plate.
DIESEL INJECTION
Fault finding – Cleanliness guidelines
Page 56 of 431

13B-56V9 MR-372-J84-13B450$101.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DF012
CONTINUED 1
1.DEFNOTESNone.
Note:
Supply no.2 is for the following components:
– pedal sensor (gang 2),
– EGR valve position sensor,
– cruise control/speed limiter button (on steering wheel),
– refrigerant pressure sensor.
Measure the feed voltage on the following sensors:
– Connection code 3LU of component 921.
– Connection code 3AAQ of component 1290.
– Connection code 3GC of component 1460.
– Connection code 38Y of component 1202.
If the voltage is more than + 5.1 V, disconnect the sensor connectors one by one.
If, after disconnecting the pedal sensor, the voltage returns to normal,
Check the insulation against + 12 V of the following connection:
– connection code 3LU, between components120 and 921.
If there is a repair method (see Technical Note 6015A, Repairing electrical wiring, Wiring: Precautions for
repair), repair the wiring, otherwise replace it.
If, after disconnecting the EGR valve, the voltage returns to normal,
Check the insulation against + 12 V of the following connection:
– connection code 3GC between components 120 and 1460.
If, after disconnecting the differential pressure sensor, the voltage returns to normal,
Check the insulation against + 12 V of the following connection:
– connection code 3AAQ between components 120 and 1290.
If the voltage returns to normal after the coolant pressure sensor is disconnected,
Check the insulation against + 12 V of the following connection:
– Connection code 38Y between components 120 and 1202.
If the fault is still present, check the conformity of ET413 Cruise control/speed limiter function
If there is a repair method (see Technical Note 6015A, Repairing electrical wiring, Wiring: Precautions for
repair), repair the wiring, otherwise replace it.
Clear the faults created by the multiple disconnections.
Carefully examine the engine management computer connections (for conductive particles, bent pins).
If the fault is still present, contact the Techline.
AFTER REPAIRDeal with any other faults. Clear the fault memory.
Switch off the ignition until the end of the power-latch phase, and carry out a road test
followed by a check using the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58
Page 57 of 431

13B-57V9 MR-372-J84-13B450$101.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DF012
CONTINUED 2
2.DEFNOTESNone.
Note:
Supply no.2 is for the following components:
– pedal sensor (gang 2),
– EGR valve position sensor,
– cruise control/speed limiter button (on steering wheel),
– refrigerant pressure sensor.
Measure the feed voltage on the following sensors:
– Connection code 3LU of component 921.
– Connection code 3AAQ of component 1290.
– Connection code 3GC of component 1460.
– Connection code 38Y of component 1202.
If the voltage is less than 4.9 V, disconnect the sensor connectors one by one.
If, after disconnecting the pedal sensor, the voltage is still too low,
Check the insulation to earth of the following connection:
– Connection code 3LU between components 120 and 921.
If, after disconnecting the EGR valve, the voltage returns to normal,
Check the insulation to earth of the following connection:
– Connection code 3GC between components 120 and 1460.
If, after disconnecting the differential pressure sensor, the voltage returns to normal,
Check the insulation to earth of the following connection:
– Connection code 3AAQ between components 120 and 1290.
If the voltage returns to normal after the coolant pressure sensor is disconnected,
Check the insulation against + 12 V of the following connection:
– Connection code 38Y between components 120 and 1202.
If the fault is still present, check the conformity of ET413 Cruise control/speed limiter function
If there is a repair method (see Technical Note 6015A, Repairing electrical wiring, Wiring: Precautions for
repair), repair the wiring, otherwise replace it.
Clear the faults created by the multiple disconnections.
Carefully examine the engine management computer connections (for conductive particles, bent pins).
If the fault is still present, contact the Techline.
AFTER REPAIRDeal with any other faults. Clear the fault memory.
Switch off the ignition until the end of the power-latch phase, and carry out a road test
followed by a check using the diagnostic tool.
EDC16 C36
Program No.: 91
Vdiag No.: 44, 4C, 48,
50, 54, 58