13B-3V4 MR-372-J84-13B000$010.mif
DIESEL INJECTION
Fault finding – Introduction13B
DDCR INJECTION
Vdiag No.: 44, 48
To cut off + after ignition, proceed as follows:
– disconnect the diagnostic tool,
– press the start button twice briefly (less than 3 seconds),
– check that the + after ignition feed has been cut off by checking that the computer warning lights on the instrument
panel have gone out.
Fault
Faults are declared present or stored (depending on whether they appeared in a certain context and have
disappeared since, or whether they remain present but are not diagnosed within the current context).
The present or stored status of the faults should be taken into consideration when the diagnostic tool is used after
the + after ignition feed has been connected (with no system components activated).
For a present fault,apply the procedure described in the Interpretation of faults section.
For a stored fault, note the faults displayed and apply the Notes paragraph.
If the fault is confirmed when the notes are applied, the fault is present. Deal with the fault.
If the fault is not confirmed, check:
– the electrical lines which correspond to the fault,
– the connectors on these lines (corrosion, bent pins, etc.),
– the resistance of the faulty component,
– the condition of the wires (melted or cut insulation, wear).
Or use diagnostics to check the circuit of the suspect component.
Conformity check
The conformity check is designed to check the statuses and parameters that do not display any faults on
the diagnostic tool when inconsistent. Therefore, this stage is used to:
Run fault finding on faults that do not have a fault display, and which may correspond to a customer complaint,
– Check that the system is operating correctly and that there is no risk of a fault recurring after repair.
– This section features the fault finding procedures for statuses and parameters, and the conditions for checking
them.
If a status is not operating normally or a parameter is outside permitted tolerance values, you should consult
the corresponding fault finding page.
Customer complaints - Fault-finding chart
If the diagnostic tool check is correct, but the customer complaint is still present, it should be dealt with using
Customer complaints.NOTE:
The right-hand and left-hand xenon bulb computers are powered when the dipped headlights are lit. Fault finding
can only be carried out on them after the ignition has been switched on in fault finding mode (forced + after ignition
feed) and the dipped headlights are on.
A summary of the overall procedure to follow is provided on the following page in the form of a flow chart.
13B-11V4 MR-372-J84-13B000$020.mif
DIESEL INJECTION
Fault finding – System operation13B
DDCR INJECTION
Vdiag No.: 44, 48
WITH FLOWMETER (K9K 728)
The flow of fresh air entering the engine is given by a hot wire ratiometric sensor. This flow sensor is used to
manage the amount of exhaust gas to be recirculated to ensure optimum recirculation rates. A fresh air temperature
sensor is built into the flowmeter.
Air flow measurement allows closed-loop control via the EGR valve.
Besides electrical faults with the sensor, there is a consistency test between the measured air flow and an estimated
air flow without EGR.
This flow evaluates the amount of fresh inlet air, based on the values supplied by the surrounding systems:
– the inlet air temperature measured by a sensor located after the turbocharger and/or after the intercooler (if fitted),
– the turbocharging pressure,
– the engine speed.
Pre-postheating actuation
Pre-postheating actuation consists of controlling the heater plugs and preheating warning light on the instrument
panel. The heater plugs are activated by relays, and the power is supplied from the battery. After the ignition is
switched on. Preheating is activated for a period of time. The warning light is illuminated for an activation period that
depends on the battery voltage, the atmospheric pressure, and the coolant temperature. When the temperature is
below a certain threshold, a postheating function can be used to improve the combustion stability, and consequently
engine operation (reducing unburnt particles and pollutant emissions).
Turbocharger control solenoid valve actuation
The turbocharger system comprises a solenoid valve that is used to actuate the vanes (or wastegate) to create an
overpressure or a vacuum in the inlet circuit.
13B-13V4 MR-372-J84-13B000$020.mif
DIESEL INJECTION
Fault finding – System operation13B
DDCR INJECTION
Vdiag No.: 44, 48
Cruise control/speed limiter management:
When activated, the cruise control function maintains the vehicle at a preselected speed, regardless of the driving
conditions encountered. Using the control buttons, the driver can increase or decrease the vehicle speed.
The cruise control function can be deactivated either by using the control buttons or by switching off the cruise
control function selection switch, or when system events are detected such as depressing the brake or clutch
pedals, or when system errors are detected such as an inconsistent vehicle speed or excessive vehicle
deceleration. The cruise control function can also be temporarily suspended when the driver wants to resume
control of the vehicle and exceed the selected cruising speed by depressing the accelerator pedal which then
exceeds the selected fuel flow. The cruising speed is resumed when the driver releases the accelerator pedal.
The cruise control function can be reactivated and the last cruising speed can be resumed after deactivating
the function for whatever reason until the vehicle ignition is switched off (i.e. for as long as computer supply not cut
off). The vehicle will then attempt to return to the cruising speed using a controlled vehicle acceleration rate.
When switched on (using the selection switch), the vehicle speed limiter function limits the vehicle speed to a preset
value. The driver controls the vehicle in the normal way using the accelerator pedal until the limit speed is reached.
If an attempt is made to exceed this speed, the system will ignore the pedal request and will control the vehicle
speed as the cruise control function would do, provided that the driver continues to press the accelerator pedal.
As with the cruise control function, the set speed can be altered by adjusting the control buttons, with single touches
or holding down.
For safety reasons, the cruising speed can be exceeded by depressing the accelerator pedal beyond the pedal
position limiting value. Vehicle speed is then controlled using the accelerator pedal until the vehicle speed is
decreased to below the cruising speed, when the limiter function is activated again.
The driver has the following controls for the cruise control/speed limiter function:
– accelerator pedal,
– brake pedal,
– clutch pedal,
– function selector switch, used to select cruise control or speed limiter operating mode.
Instrument panel display
The computer displays certain information on the instrument panel relating to engine operation. This concerns 5
functions: the MIL (Malfunction Indicator Lamp) of the EOBD (European On Board Diagnostic), pre-postheating,
the coolant temperature, and engine faults: Level 1 (non-critical fault) and Level 2 (emergency stop). These five
functions are represented by 3 warning lights or messages displayed by the on-board computer.
Pre-postheating warning light
This light is used both as an in-operation indicator light and as a system fault indicator:
– permanently lit during + after ignition feed: indicates preheating of the heater plugs.
After preheating and an automatic timed 3 second off period, the warning light will come on if a Level 1 fault occurs
(leading to reduced operation and reduced safety levels. The driver should have repairs carried out as soon as
possible.)
13B-14V4 MR-372-J84-13B000$020.mif
DIESEL INJECTION
Fault finding – System operation13B
DDCR INJECTION
Vdiag No.: 44, 48
Temperature / emergency stop warning light
This indicator light is used both as an in-operation indicator light and as a system fault warning light. It illuminates for
3 seconds when the power is switched on (automatic test procedure controlled by the instrument panel)
Continuously lit: indicates engine overheating or a Level 2 fault.
– if the fault reaches a critical level, the injection cuts off automatically after several seconds.
– in the event of engine overheating, it is the driver's choice to stop the car or continue driving.
ACTIVATION PROGRAMMING OF THE INSTRUMENT PANEL WARNING LIGHTS
Orange SERVICE warning light (level 1)
This warning light comes on, accompanied by the faulty injection message.
The driver should have the repairs carried out as soon as possible.
Red STOP warning light (level 2)
This warning light comes on, accompanied by the faulty injection message.
The driver should have the repairs carried out as soon as possible.
Excess pollution OBD ORANGE warning light:
This warning light is used to alert the driver of any injection faults that could lead to excessive pollution, or if
the EOBD system has been deactivated. The injection computer requests illumination of the OBD warning light for
a present fault only after three consecutive driving cycles.
The 3 second visual inspection when the ignition is switched on (automatic test procedure managed by
the instrument panel) is carried out by the injection computer.
Faults that activate the OBD warning light
Associated
faultTitle Specification
DF010 EGR position sensor circuit CC.1 - CO.0
DF016 EGR control circuit CC.1
DF026 Cylinder 1 injector control circuit CO – CC
DF027 Cylinder 2 injector control circuit CO – CC
DF028 Cylinder 3 injector control circuit CO – CC
DF029 Cylinder 4 injector control circuit CO – CC
DF038 Computer 3. DEF
DF114 EGR solenoid valve circuit 4. DEF
13B-27
AFTER REPAIRDeal with any faults displayed by the diagnostic tool. Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V4 MR-372-J84-13B000$061.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DDCR INJECTION
Vdiag No.: 44, 48
DF005
PRESENT
OR
STOREDENGINE SPEED SENSOR CIRCUIT1.DEF: Inconsistency.
2.DEF: No signal.
3.DEF: Too many additional teeth.
4.DEF: Teeth missing.
5.DEF: Additional teeth.
6.DEF: Too many teeth missing.
NOTESSpecial notes:
If 1.DEF, 2.DEF, 3.DEF, 6.DEF present: the engine stops and the level 1 warning
light illuminates along with the message Faulty injection.
If 4.DEF, 5.DEF, the engine performance is 75%, no warning light illuminates.
Conditions for applying the fault finding procedure to a stored fault:
the fault is present with the engine under the starter or idling.
Check the connection and condition of the 2-track connector of the engine speed sensor. Repair if necessary.
Ensure the sensor is correctly fitted on the engine.
Check the connection and condition of the computer 48-track brown connector B.
Repair if necessary.
Measure the resistance at the engine speed sensor terminals.
Replace the engine speed sensor if the resistance is not:
– for 80hp versions (K9K 722): 800 Ω ± 80 Ω at 20°C
– for 100hp versions (K9K 728/729): 680 Ω ± 68 Ω at 20°C
Check the insulation, continuity and the absence of interference resistance on the following connections:
Sensor connector track A Track F2 computer connector B
Sensor connector track BTrack F3 computer connector B
Repair if necessary.
Check that the flywheel ring gear is not defective (missing teeth).
DDCR_V44_DF005P/DDCR_V48_DF005P
13B-28
AFTER REPAIRDeal with any faults displayed by the diagnostic tool. Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V4 MR-372-J84-13B000$061.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DDCR INJECTION
Vdiag No.: 44, 48
DF007
STOREDRAIL PRESSURE SENSOR CIRCUIT
CC.0: Short circuit to earth.
CO.1: Open circuit or short circuit to + 12 volts.
1.DEF: inconsistency.
2.DEF: Below minimum threshold.
3.DEF: Above maximum threshold.
NOTESPriority when dealing with a number of faults:
– Deal with fault DF113 Sensor supply voltage first.
Conditions for applying the fault finding procedure to a stored fault:
The fault is declared present after the engine is started.
Special notes: if DF007, the engine stops and cannot be restarted, and the level 1
warning light illuminates along with the message Faulty injection.
Check the connection and condition of the 3-track connector of the rail pressure sensor.
Repair if necessary.
Check the connection and condition of the computer 48-track brown connector B.
Repair if necessary.
Check the insulation, continuity and the absence of interference resistance on the following connections:
Sensor connector track 2 Track D3 computer connector B
Sensor connector track 1Track D2 computer connector B
Sensor connector track 3 Track D1 computer connector B
Repair if necessary.
If the fault is still present, there is a rail pressure sensor fault, replace the rail.
DDCR_V44_DF007M/DDCR_V48_DF007M
13B-29
AFTER REPAIRDeal with any faults displayed by the diagnostic tool. Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V4 MR-372-J84-13B000$061.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DDCR INJECTION
Vdiag No.: 44, 48
DF008
PRESENTPEDAL POTENTIOMETER CIRCUIT GANG 1
CO.0: Open circuit or short circuit to earth.
CC.1: Short circuit to +12 volts.
1.DEF: Inconsistency between pedal gang 1 and gang 2.
2.DEF: No signal.
3.DEF: Jammed component.
NOTESPriority when dealing with a number of faults:
– Deal with fault DF113 Sensor supply voltage first.
Special notes:
If DF008: the engine speed is maintained above 1000 rpm,
the level 1 warning light illuminates along with the message Faulty injection.
If DF008 and DF009: the engine speed is fixed at 1300 rpm and the level 1 warning
light illuminates along with the message Faulty injection.
1.DEF
3.DEF
NOTESNone.
Disconnect computer connector A and the pedal potentiometer connector.
Check the insulation between track H2 and track F3 on computer connector A.
Repair if necessary.
Replace the pedal potentiometer if the fault is still present.
DDCR_V44_DF008P/DDCR_V48_DF008P
13B-31
AFTER REPAIRDeal with any faults displayed by the diagnostic tool. Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V4 MR-372-J84-13B000$061.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DDCR INJECTION
Vdiag No.: 44, 48
DF009
PRESENTPEDAL POTENTIOMETER CIRCUIT GANG 2CO.0: Open circuit or short circuit to earth.
CC.1: Short circuit to +12 volts.
NOTESPriority when dealing with a number of faults:
– Deal with fault DF122 Potentiometer gang 2 supply voltage first.
Special notes: if fault DF009: the engine speed is maintained above 1000 rpm and
the level 1 warning light illuminates along with the message Faulty injection.
If DF009 and DF008: the engine speed fixed at 1300 rpm and the level 1 warning
light illuminates along with the message Faulty injection.
CC.0
NOTESNone.
Check the connection and condition of the 6-track connector for the pedal potentiometer.
Repair if necessary.
Check the connection and condition of the black 32-track computer connector A.
Repair if necessary.
Measure the resistance between tracks 2 and 6 of the pedal potentiometer.
Replace the pedal potentiometer if the resistance is not 2.85 kΩ +
2.05 kW.
Disconnect computer connector A and the pedal potentiometer connector.
Check the insulation from earth on track F3 of computer connector A.
Repair if necessary.
Check the continuity of the connection between:
Sensor connector track 1 Track F3 computer connector A
Repair if necessary.
DDCR_V44_DF009P/DDCR_V48_DF009P