Manual de Diag. JMC - N601

(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung!
Besonders nicht, wenn

Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche
Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie
sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.
(E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores,
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar
la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y
Seguridad.
(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an
injection under the skin, contact a doctor immediately. Please refer to the health and
security fuel documents.
(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression injecté sous la peau peut causer des blessures mortelles. En cas
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de
santé et de sécurité du gazole.
(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione
possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare
immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de
gezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar
ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um
médico. Consulte por favor a documentação respeitante a saúde e segurança de
combustíveis.
(D) Schutzbrille/Gesichtsschutz tragen.

(E) Úsese protección para los ojos/la cara.
(EN) Wear eye/face protection.
(F) Porter un appareil de protection des yeux / du visage.
(IT) Proteggersi gli occhi/la faccia.
(NL) Veiligheidsbril/-masker gebruiken.
(P) Use protecção da face/olhos.
(D) Von Zündquellen fernhalten - Nicht rauchen.

(E) Conservar alejado de toda llama o fuente de chispas -No fumar.
(EN) Keep away from sources of ignition - No smoking.
(F) Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer.
(IT) Conservare lontano da fiamme e scintille - Non fumare.
(NL) Ver van open vuur en ontstekingsbronnen houden – Niet roken.
(P) Mantenha afastado de fontes de ignição – Proibido fumar.
(D) Geeignete Schutzhandschuhe tragen.

(E) Usen guantes adecuados.
(EN) Wear suitable gloves.
(F) Porter des gants appropriés.
(IT) Usare guanti adatti.
(NL) Aangepaste veiligheidshandschoenen dragen.
(P) Use luvas apropriadas.
TABLE OF CONTENTS
DIAGNOSTICS I
APPENDIX II
Produced and published by:

Delphi Diesel Systems Ltd.
Spartan Close
Warwick CV34 6AG Tel: +44 (0) 1926 472 900
England Fax: +44 (0) 1926 472 901
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 i

I DIAGNOSTICS
TABLE OF CONTENTS
1. DIAGNOSTIC TOOL FUNCTIONS

1.1 Reading The Fault Codes..............................................................................................................................................1-1
1.1.1 Principle........................................................................................................................................................1-1
1.1.2 Environmental data......................................................................................................................................1-1
1.2 Reading Dynamic Parameters......................................................................................................................................1-2
1.2.1 The gross value............................................................................................................................................1-3
1.2.2 The linearised value.....................................................................................................................................1-3
1.2.3 The physical value........................................................................................................................................1-3
1.2.4 List of parameters........................................................................................................................................1-3
1.3 DCU Identification.........................................................................................................................................................1-8
1.4 Actuator Control............................................................................................................................................................1-8
1.5 Aftermarket Management Of C2I And Programming................................................................................................1-9
1.5.1 Definition of C2I and programming............................................................................................................1-9
1.5.2 Replacing an injector.................................................................................................................................1-10
1.5.3 Replacing a DCU.........................................................................................................................................1-10
1.5.4 Replacing the system.................................................................................................................................1-11
1.6 Test Routines...............................................................................................................................................................1-13
1.6.1 Leak detection cycle...................................................................................................................................1-13
1.7 Reading / Writing The VIN..........................................................................................................................................1-14
1.7.1 Principle......................................................................................................................................................1-14
1.7.2 Procedure....................................................................................................................................................1-14
1.8 Vehicle Configuration Options...................................................................................................................................1-14
2. TROUBLE CODES AND CHECKS
2.1 Diagnostic Charts / Trouble Codes............................................................................................................................2-15
3. NON DETECTABLE FAULTS
3.1 List of Faults / Symptoms.........................................................................................................................................3-169
3.1.1 Irregular acceleration / deceleration.......................................................................................................3-169
3.1.2 Engine hesitation......................................................................................................................................3-170
3.1.3 Engine stop / stalling................................................................................................................................3-171
3.1.4 Rushing noise...........................................................................................................................................3-172
3.1.5 Noise interference....................................................................................................................................3-173
3.1.6 Engine knocking / engine noisy..............................................................................................................3-174
3.1.7 Excessive fuel consumption....................................................................................................................3-175
3.1.8 Engine difficult to start when hot............................................................................................................3-176
3.1.9 Engine starts then stalls...........................................................................................................................3-177
3.1.10 Smoke on acceleration............................................................................................................................3-179
3.1.11 Blue and white smoke..............................................................................................................................3-180
3.1.12 Black smoke..............................................................................................................................................3-181
3.1.13 Lack of power...........................................................................................................................................3-182
3.1.14 Engine does not start...............................................................................................................................3-184
3.1.15 Engine does not stop...............................................................................................................................3-186
3.1.16 Engine dies when moving off.................................................................................................................3-187
3.1.17 Smell of fuel..............................................................................................................................................3-188
3.1.18 Exhaust smells..........................................................................................................................................3-189
3.1.19 Idle speed stuck........................................................................................................................................3-190
3.1.20 Idle unstable ............................................................................................................................................3-191
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DIAGNOSTICS I
TABLE OF CONTENTS
3.1.21 Engine overheat.......................................................................................................................................3-193
3.1.22 Excess engine speed on releasing accelerator pedal............................................................................3-194
3.1.23 Too much power......................................................................................................................................3-195
3.1.24 Flat spot on acceleration..........................................................................................................................3-196
4. CHECKS
4.1 Description Of The Checks.......................................................................................................................................4-197
4.1.1 Electrical supply circuit check.................................................................................................................4-197
4.1.2 Checking the air inlet circuit....................................................................................................................4-197
4.1.3 Checking the LP circuit.............................................................................................................................4-198
4.1.4 Looking for HP leaks................................................................................................................................4-198
4.1.5 Checking engine parameters...................................................................................................................4-198
4.1.6 Checking the C2I conformity...................................................................................................................4-200
4.1.7 Checking the injectors and the HP pump...............................................................................................4-200
4.1.8 Checking the ECU.....................................................................................................................................4-200
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II APPENDIX
TABLE OF CONTENTS
5. APPENDIX
5.1 Component Location.................................................................................................................................................5-201
5.2 Wiring Diagrams.......................................................................................................................................................5-202
5.2.1 Switching on the ECU..............................................................................................................................5-202
5.2.2 Ancillaries (vehicle)..................................................................................................................................5-203
5.3 Controller Pin Configuration....................................................................................................................................5-204
5.3.1 96 way engine connector layout (X1).....................................................................................................5-204
5.3.2 54 way vehicle connector layout (X2).....................................................................................................5-206
5.4 Resistance Values......................................................................................................................................................5-208
5.5 Abbreviations Used In This Manual........................................................................................................................5-210
6. FAULT CODE INDEX
6.1 Fault code index........................................................................................................................................................6-212
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DIAGNOSTICS I
DIAGNOSTIC TOOL FUNCTIONS
1.1 Reading The Fault Codes
1.1.1 Principle
This function is used to read the data relating to the faults recorded in the DCU memory. This data consists of:
• The number of faults stored in the DCU memory.
• The diagnostic trouble code (DTC).
• The status.
• Permanent (current and historic code recorded with environmental data).
• Historic (historic code recorded with environmental data).
• Current (current code recorded with no environmental data).
• The environmental data.
Information relating to a fault is erased automatically if the fault is not detected again within 40 operating cycles.
The DCU memory can only contain ten separate faults.
1.1.2 Environmental data

Environmental data gives information on the operating conditions of the system when the fault appeared (fault
context).
CAUTION
Care must be taken when interpreting the environmental data as this information is recorded in the memory at
the same time as the fault. This means that the environmental data does not describe the engine operating
conditions the first time the fault was detected but instead the n th time (n being the number of detections needed
to register the fault in the memory). In addition, as the fault was already present when it was saved in the memory,
the environmental data may be corrupt, in this case sometimes the linearised data is used which is obtained by
converting the raw signal, which provides the first set of useable data available in the DCU.
Variable Definition Units

Inlet air temperature Measurement of the manifold air temperature. °C
Atmospheric pressure Measurement of the atmospheric pressure: mbar
• Sensor integrated into the DCU.
Boost pressure Measurement of the boost pressure. mbar
Battery voltage Measurement of the validated battery voltage. V
Raw battery voltage Measurement of the raw battery voltage. V
Coolant temperature Measurement of the engine coolant temperature. °C
Engine speed Engine speed measured over a complete cycle (720 degrees). rpm
Estimated air flow Estimation of the air flow. mg/st
Engine state • Off/Stopped. No units
• Cranking.
• Engine running.
• Engine has stalled.
Diesel temperature Measurement of the fuel temperature inside the pump. °C
Gear • 0: Neutral. No units
• 1 to 5: Gear selected.
• 8: Default value with vehicle speed sensor fault.
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I DIAGNOSTICS

Ignition position • Ignition on. No units
• Ignition off.
5V Sensor supply (Vext 1) Measurement of the external reference voltage 1. V
5V Sensor supply (Vext 2) Measurement of the external reference voltage 2. V
IMV control output • 0% = Fully open (IMV not energised). %
• 100% = Closed (Maximum current to the IMV).
Measured rail pressure Measurement of the rail pressure. bar
Glow plug relay • Deactivated. No units
• Activated.
Air conditioning request • Yes = A/C button pressed and air conditioning circuit pressure correct. No units
• No = No air conditioning request.
Measured rail pressure Measurement of the rail pressure. bar
Glow plug relay • Deactivated. No units
• Activated.
Air conditioning request • Yes = A/C button pressed and air conditioning circuit pressure correct. No units
• No = No air conditioning request.
Torque request Indicated engine torque demand. Nm
Vehicle speed Vehicle speed measured. km/h
1.2 Reading Dynamic Parameters
Dynamic parameters are used to check the system status in real time.
Note: Some variables can be represented in three different ways:

• Gross (raw) value.
• Linearised value.
• Physical value.
The figure below represents the processing sequence of an analog signal with the various associated variable
representations.
Measurement
and Raw Conversion Filtering
Sensor signal conversion value Linearised value Physical value
SENSOR x 0.1 - 50
0...1023 degC, rpm... degC, rpm...
V
V
Analogue - digital
converter
Software
ECU
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DIAGNOSTICS I

1.2.1 The gross value
(e.g: gross atmospheric pressure, gross air flow,

gross diesel temperature, etc). V
The gross value is the image, supplied by the Vext
analog-digital converter of the voltage transmitted
by the sensor to the DCU input. This value is difficult
to interpret, but allows a sensor or DCU fault
(analog-digital converter) or a fault on the harness
to be detected.
This value is typically between 0 and 1023. In certain
cases, it can also be converted into a physical value
by the diagnostic tool (°C, bar etc.). 0
0 1023
Raw value
1.2.2 The linearised value

(e.g: linearised atmospheric pressure, linearised air flow, linearised diesel temperature, etc).
The linearised value of a variable is the gross value returned by the sensor, to which a conversion function has
been applied to obtain a physical value representing the measured variable. For example, values in degrees
centigrade, rpm, etc. are obtained.
1.2.3 The physical value

(e.g: atmospheric pressure, requested air flow, diesel temperature, etc).
This is a "default" value of a variable used in the various system strategies. Under normal conditions, the linearised
value and the physical value are practically the same.
When a fault appears on a sensor (e.g OC or SC+), the physical value associated to the sensor takes into account
a limp home value and the linearised value displays a corrupt value.
1.2.4 List of parameters

Fault LED status Indicates the status of the fault LED control: No units
• Deactivated (LED off).
• Activated (LED on).
Engine state • Off/Stopped. No units
• Cranking.
• Engine running.
• Engine has stalled.
Air conditioning control • AC allowed. No units
output • AC not allowed.
Air conditioning cooling • No. No units
request • Yes.
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I DIAGNOSTICS

Brake switch • Open. No units
• Closed.
Injection speed Measurement of the engine speed over one injection (180 degrees). rpm
Glowplug status This is the status of the glowplug LED control: No units
• Deactivated (LED off).
• Activated (LED on).
Engine stalled Specifies whether the engine stopped without being requested to do so by No units
the driver:
• Yes (appears when the engine has stalled or when the ignition is
switched back on during the power latch phase).
• No (no engine stalling detected).
Coolant temperature Measurement of the coolant temperature. The linearised value corresponds °C
linearised to converting the signal transmitted to the DCU input to a physical value.
Air temperature linearised Measurement of the air temperature. The linearised value corresponds to °C
converting the signal transmitted to the DCU input to a physical value.
Fuel temperature linearised Measurement of the fuel temperature. The linearised value corresponds to °C
Fuel temperature Measures the temperature of the fuel being supplied. °C
Gear • 0: Neutral. No units
• 1 to 5: Gear selected.
• 8: Default value for vehicle speed fault.
Glowplug relay control Glowplug relay status: No units
• Activated.
• Deactivated.
Air mass flow linearised Measurement of the air mass flow. The linearised value corresponds to °C
Raw air flow Measurement of the air flow after the air filter. The raw value corresponds No units
to the conversion of the analog signal transmitted to the DCU input to a digital
signal. Correspondence between the digital value displayed and the voltage
from the air flowmeter.
Coolant temperature Measurement of the engine coolant temperature. °C
Raw coolant temperature Measurement of the engine coolant temperature. The raw value corresponds °C
to converting the analog signal transmitted to the DCU input to a physical
value.
Air temperature Measurement of the manifold air temperature. °C
Raw air temperature Measurement of the inlet air temperature after the air filter. The raw value °C
corresponds to converting the signal transmitted to the DCU input to a physical
value.
Diesel temperature Measurement of the fuel temperature in the pump. °C
Raw diesel temperature Measurement of the fuel temperature in the pump. The raw value corresponds No units
to converting the signal transmitted to the DCU input to a physical value.
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DIAGNOSTICS I

Atmospheric pressure Measurement of the atmospheric pressure (the sensor is integrated into the mbar
DCU).
Linearised atmospheric Measurement of the atmospheric pressure (the sensor is integrated into the mbar
pressure DCU). The linearised value corresponds to converting the signal transmitted
to the DCU input to a physical value.
Raw rail pressure Measurement of the rail pressure. The raw value corresponds to converting No units
the signal transmitted to the DCU input to a physical value.
Injector 1 cylinder 1 - rise Measurement of the time required for the current applied to the injectors to µs
time reach its maximum value.
Rail pressure linearised Measurement of the boost pressure. The linearised value corresponds to bar
Battery voltage Measurement of the battery voltage. V
Accelerator pedal Measurement of the accelerator pedal position. %
Raw pedal position track 1 Position of the accelerator pedal measured by track 1. The raw value %
corresponds to converting the analog signal transmitted to the DCU input.
Raw pedal position track 2 Position of the accelerator pedal measured by track 2. The raw value %
corresponds to converting the analog signal transmitted to the DCU input.
Idle reference speed Idle speed request determined by the DCU as a function of: rpm
• Engine temperature and the gear engaged (idle setting reduces as
the engine temperature increases).
• Activation of the air conditioning.
• The battery voltage.
Engine speed Engine speed measured over a complete cycle (720 degrees). rpm
Pedal sensor 2 raw supply Measurement of the pedal sensor 2 supply voltage. The raw value No units
voltage corresponds to converting the signal transmitted to the DCU input to a physical
value.
Sensor supply voltage Measurement of the voltage applied to the terminals of the sensors. V
Vehicle speed Measurement of the vehicle speed. km/h
Main fuel demand Injected fuel demand (for main injection) determined by the DCU as a function mg/st
of the engine operating conditions.
Sensor supply voltage Measurement of the voltage applied to the terminals of the sensors. V
Pilot fuel demand Injected fuel demand (for pilot injection) determined by the DCU as a function mg/st
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I DIAGNOSTICS

Main timing demand Advance demand (for main injection) determined by the DCU as a function engine degrees
Note: Positive = Before TDC.

Pilot timing demand Advance demand (for pilot injection) determined by the DCU as a function of engine degrees
the engine operating conditions.
Note: Positive = Before TDC.

IMV control of PWM drive Value specifying the duty cycle ratio of the IMV: %
• 0% = Fully open (IMV not energised).
• 100% = Closed (Maximum current to the IMV).
Clutch switch status Indicates if the clutch has been activated. No units
PPH control state This consists of the control status of the pre-heating warning light: No units
• Off (the DCU has connected terminal CH A1 to +batt).
• On (the DCU has earthed terminal CH A1).
Water heater This consists of the control status of the water heaters: No units
• On (the DCU has earthed terminals CME H4).
• Off (the DCU has connected terminal CMH H4 to +batt).
Fan 1 drive 1 This consists of the status of fan high speed control circuit: No units
• On (the DCU has earthed control circuit 1).
• Off (the DCU has connected control circuit 1 to +batt).
Fan 2 drive 2 This consists of the status of fan high speed control circuit 2: No units
• On (the DCU has earthed control circuit 2).
• Off (the DCU has connected control circuit 2 to +batt).
When fan 2 drive 2 is on, the engine cooling fan must operate at high speed.
EGR control Indicates if the EGR is activated. No units
Ignition key Ignition switch status. No units
EGR valve PWM drive This is the PWM ratio applied to the EGR solenoid valve. %
Air mass flow Measurement of the air mass flow. mg/st
Air mass flow linearised Measurement of the air mass flow. The linearised value corresponds to g/s
MDP number of updates - Number of updates for MDP for cylinder 1. No units
cylinder 1
cylinder 2
cylinder 3
cylinder 4
PN switch Specifies the position of the selector lever (automatic transmission). No units
• D/R (when the lever is in position "D" (drive), "R" (reverse), 2 or L).
• P/N (when the lever is in the parking position "P" or neutral "N".
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DIAGNOSTICS I

Gear ratio Indicates the gear ratio of the particular gear. No units
Key OFF engaged Specifies whether the key is in ON or OFF position. No units
Transponder status (key) This consists of the status of the ignition key transponder: No units
• Not available. Displayed when the DCU cannot access the status
which is memorised in its EEPROM or if the DCU does not have the
engine immobiliser function.
• Coded. Shows that the transponder has been successfully
programmed with vehicle specific data (VSD).
• Blank. Transponder status at the end of production line.
• Invalid. Signifies that the key data is not same as the data recorded
in the DCU (this occurs when the key is coded and the DCU is blank).
DCU - status This is the status of the engine immobiliser function of the DCU: No units
• Not available. Displayed when the DCU cannot access the status
which is memorised in its EEPROM or if the DCU does not have the
immobiliser function.
• Coded. Shows that the DCU has successfully programmed at least
one key.
• Blank. DCU status at the end of production line or before delivery. A
DCU remains blank for as long as it has not been programmed.
• Deactivated. When all keys memorised in the DCU and the vehicle
specific data (VSD) has been erased using the "DEACTIVATE DCU"
function. When the DCU is in this status, only the programming phase
can be performed.
• Locked. If an incorrect user password or vehicle specific data is sent
three times in succession, the DCU is locked for one hour and prevents
the engine from being started. When the DCU is locked, the functions
linked to the engine immobiliser (programming phase, DCU
deactivation, define/modify password and active limp home mode)
are no longer useable.
Immobiliser lamp Indicates if the immobiliser lamp is activated. No units
Raw atmospheric pressure Measurement of the atmospheric pressure. The raw value corresponds to No units
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I DIAGNOSTICS
1.3 DCU Identification
This service is used to identify:

• The DCU calibration and software version.
DCU identification Meaning

SOFTWARE VERSION (5 characters) N Indicates the type of DCU
N => Common Rail 32 bits 2nd generation DCU
(Delco)
X Identifies the vehicle manufacturer
A Indicates the software type (takes into account
the vehicle or engine application)
09 Indicates the modification level applied to the
software.
Note: The identification above is given as an example only. To display the identification, select 'DCU IDENTIFICATION'
in the diagnostic menu of the tool.
1.4 Actuator Control
The diagnostic tool allows the status of certain DCU outputs to be controlled.
Output Verification conditions Normal consequences on the system

Fault LED Ignition on, pre-starting The fault LED flashes
Preheating LED Ignition on, pre-starting The preheating LED flashes
Fuel filter LED Ignition on, pre-starting The fuel filter LED flashes
Supply relay Ignition on, pre-starting The relay oscillates between the two states
Pre-post heating relay Ignition on, pre-starting The relay oscillates between the two states
Air conditioning relay Ignition on, pre-starting The relay oscillates between the two states
Inlet metering valve(IMV) Ignition on, pre-starting The IMV piston vibrates(low level noise)
Injector - cylinder 1 Ignition on, pre-starting The valve of the injector for cylinder 1 vibrates
Injector - cylinder 2 Ignition on, pre-starting The value of the injector for cylinder 2 vibrates
To select an actuator, observe the following procedure:

• Select menu 1: "DIAGNOSTIC MENU".
• Select menu 3: "ACTUATORS".
Note: After testing the actuators a full power down of the DCU for 10 seconds is required for resetting.
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DIAGNOSTICS I
1.5 Aftermarket Management Of C2I And Programming
1.5.1 Definition of C2I and programming

The C2I has a calibration specific to each injector. It describes the initial specifications of the injector in question.
The C2I is determined during end of line tests on the injector. It is represented by a 16 character hexadecimal code
which is shown clearly on a label affixed to the injector holder body.
Programming values are corrective terms which counteract injector ageing . They are determined using the
accelerometer strategy which provides a closed loop correction of the injector MDP.
The DCU determines the pulse applied to the injector as a function of:
• The target which represents the initial average characteristics of a representative set of injectors.
• The C2I which represents the initial characteristics of each injector.
• The programming values which represent the actual state of each injector (including component wear and
ageing).
The DCU must therefore know the C2I to precisely determine the pulse to be applied to each injector. This condition
is required to ensure optimum operation of the injection system. If the C2I of an injector is not entered into the
DCU, it applies a pulse to the injector which is not corrected as a function of the characteristics specific to the
injector, this may lead to significant and permanent decline in engine operation. In this case, the DCU applies a
"limp home" strategy where the engine speed is set to 1300 rpm without the accelerator pedal being pressed.
Likewise, the DCU must learn the APC trims relative to each injector. If these trims are lost, the pulse applied to
each injector will not take into account the ageing of the components and this will temporarily lead to a significant
drop in engine performance.
Refer to the CR - Principles Of Operation manual (DDGX131) for more information.
In the aftermarket:
• When replacing an injector the C2I of this injector must be entered into the DCU. The DCU automatically
reinitialises the programming values linked to this injector when the C2I is entered.
• When replacing the DCU enter the C2I values into the new DCU.
Enter the VIN:
Note: It is not possible to copy the learnt APC trim values from the faulty DCU into the new DCU. The new
DCU therefore uses neutral programming values to determine the pulse to be applied to each injector.
Vehicle performance is therefore likely to be seriously affected for the first few miles after the repair.
However, this downgraded operation is quickly corrected by the accelerometer strategy which acquires the
actual characteristics of the injectors as corrections are applied.
• When replacing the system, it is not necessary to re-initialise the programming values for this application.
Special functions have been defined in the diagnostic tool to allow operations to be performed easily within the
after-sales network.
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I DIAGNOSTICS

1.5.2 Replacing an injector
When replacing an injector, the C2I of the new injector must be entered into the DCU. Perform the following
sequence to do this:
• Select menu: "SPECIAL FUNCTIONS".
• Select menu: "C2I".
• Select the cylinder to calibrate. The diagnostic tool displays the cylinder arrangement.
CAUTION
When writing a new C2I, it is extremely important to check that the new C2I is entered for the cylinder number
on which the injector has been replaced.
• Enter the C2I as shown on the label of the new injector. When the last character of the C2I has been entered,
validate the C2I using the "NEXT" button.
Note: The C2I are shown in relation to the cylinder number and not the injector number.
Note: The C2I includes a checksum which is used to detect any input errors. This checksum is the result of a
calibration performed on all the values contained in the C2I. The DCU performs the same calculation when it
receives a new C2I. If the result is identical to the checksum contained in the C2I, this indicates that the values
entered by the operator are correct. In this case, the DCU saves the C2I in its memory and returns a positive
response "The injector calibration is successful". An input error must have occurred if the result is different. In
this case, the DCU returns a negative response: "Write error". The operator must restart the operation from the
beginning.
To check that the C2I's entered have been saved, the DCU memory can be consulted. To do this, simply follow
the instructions below:
• In the diagnostic menu, click on the "SPECIAL FUNCTIONS" button.
• Click on the "C2I" button.
• On the "C2I menu" screen, click on the "READ A C2I" button. The "READ C2I" screen appears with a photo
of the engine in the lower part giving an overview of the cylinder arrangement. The C2I of each injector is
shown in the upper part of the screen. Check that the C2I saved in the DCU memory is identical to the number
on the labels of the injectors. If they do not match, correct the data saved in the DCU memory using the "C2I
MENU".
1.5.3 Replacing a DCU

When a DCU is faulty and prior to replacing it, an attempt must be made to retrieve the data relating to the injection
system "learnt parameters" saved in the DCU so that it can be copied into the new DCU. If it is not possible to
communicate with the faulty DCU, this data must be entered manually.
• Copying the C2I
In certain cases, despite the fault in the DCU, it is still possible to recover this data so that is can be copied
over into the new DCU. To do this, perform the following operations:
• Click on the "DCU" button.
• Click on the "CHANGE DCU" button, the "REPLACE DCU" screen appears.
• Follow the instructions given by DIAMAND.
Click on "READ C2I" button to check that the values are not corrupt. If the C2I's are corrupt, quit the
procedure and copy the C2I's manually into the new DCU, otherwise continue.
• Click on "START PROCEDURE" to transfer the C2I's from the faulty DCU to the tool's memory. If the
transfer fails, check the connections and the ignition switch and start the procedure again. Otherwise
continue.
© Delphi
1-10 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

• Follow the instructions given by DIAMAND:
Switch off the ignition for at least 30 seconds.
Remove the faulty DCU.
Fit the new DCU.
Switch on the ignition.
• Once the ignition is on, click on "START PROCEDURE" to transfer the C2I's from the faulty DCU into
the new DCU. If the transfer fails, follow the instructions given by DIAMAND. If the problem persists,
click on "REPEAT WHOLE PROCEDURE". If the transfer is performed successfully, continue
• Follow the instructions given by DIAMAND:
Check the C2I by clicking on "READ C2I's. Check the conformity of the C2I's saved in the DCU
memory with the labels on the injectors.
Erase the diagnostic trouble codes by clicking on "FAULT CODES".
• Entering the C2I manually
In certain cases it is impossible to communicate with the faulty DCU. The C2I for each injector must then be
entered manually, seeSection 1.5.2.
Note: If no C2I are saved, the DCU uses default values. The negative effect on vehicle performance will be
both significant and permanent. Activation of the limp home strategy (engine speed set to 1300 rpm
regardless of pedal position".
• Writing the VIN
After copying or manually entering the C2I into the new DCU, enter the vehicle VIN, see Section 1.7.
1.5.4 Replacing the system

If the whole injection system (pump, injectors, HP pipes, etc) except the DCU has been replaced, the C2I values
of the four injectors have to be entered manually, see Section 1.5.2.
Reset the VLC.
Note: When replacing the system, it is not necessary to copy out the learnt parameter values for the application.
Problem
The combination of parameters such as fuel temperature, internal part wear, filter condition etc. means that the
injection system may reach its limit during operation. In this case, the pressure demand in the rail cannot be
maintained due to a lack of capacity in the system and the DCU will generate a fault. The diagnosis of such a
system then becomes very difficult and may lead to unjustified replacement of components.
Description of the VLC principle
The change in most of the parameters mentioned above is not known by the DCU or is difficult to evaluate. In
order to avoid a fault being generated, the DCU will reduce the fuel requested to a value which allows it to
maintain and check the pressure in the rail i.e. it will adjust - within certain limits, in a dynamic manner the
operation of the injection system as a function of the operating peak (fuel temperature, engine speed...).
This strategy is known as VLC (Variable Limit Capacity).
In concrete terms, this strategy is seen in the calculation of 2 offsets.
The VLC offsets may be read using the diagnostic tool.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 1-11

I DIAGNOSTICS

Diagnostics of an under-capacity system
In the event of a complaint for an under-capacity system, 2 causes may arise:
1. Appearance of fault code (correction of fuel that is too high - VLC strategy).
If a trouble code is raised by the DCU on a vehicle with the VLC strategy, this indicates that the system has
operated beyond the operating zone for this strategy (i.e more fuel than the maximum authorised has been
taken).
In this case, there is a real fault in one or more components.
2. No faults is raised by the DCU.
In this case the fault is of the "lack of performance" type. This symptom may have 2 causes:
1. Change the VLC mode.
2. Fault in one or more components which may affect the engine performance.
Follow the diagnostic procedure below:

a. Condition under which the symptom appears:
Intermittent fault.
Fuel level near to minimum.
Hot conditions.
b. Diagnosis of the following elements:
Turbo.
Counter pressure at the exhaust.
3. Reading the VLC offsets using the diagnostic tool:
If the offsets are zero, the VLC strategy has not been activated. In this case, follow the conventional
procedure for the high pressure circuit.
If the offsets are not zero, the strategy has been activated. In this case, there are no faulty components
and the under capacity of the system is "normal".
Using the reset service
Follow the procedure below:
• Read the fault codes.
• Carry out a system diagnosis.
• Replace the faulty component (pump, injector,...).
• Carry out a reset using the service.
Note: This service must be used if the high pressure pump is replaced.
© Delphi
1-12 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
1.6 Test Routines
The test routines are pre-defined services which can be launched using an external tool (diagnostic tool or end of line
calibration tool): DIAMAND offers one test routine:
• Leak detection cycle.
1.6.1 Leak detection cycle
A) Principle
After working on the high pressure circuit, a check must be performed to ensure there are no high pressure leaks.
To avoid having to perform a road test the DCU has a leak detection cycle which allows the injection system to
be operated at high speed.
The leak detection cycle consists of performing four no load accelerations, during which the pressure request is
forced up to a value close to the maximum pressure authorised by the system (1600 rpm) for approximately five
seconds. This cycle can only be activated when the following conditions are met.
• Engine running.
• The coolant temperature is greater than 60°C.
• The gearbox is in neutral (manual gearbox) or the P/N position (automatic transmission).
• The system has not detected any faults.
This cycle can be launched using the diagnostic tool.
CAUTION
In order to avoid any risk of injury from a jet of high pressure diesel, it is recommended that this test be carried
out with the bonnet closed. DELPHI DIESEL SYSTEMS does not accept any liability sustained during a leak
detection cycle.
B) Procedure
• Apply leak detector solution to the connectors removed during the operation.
• Start the engine.
• Let the engine idle until the coolant temperature exceeds 60°C.
• Close the bonnet.
• In the diagnostic menu, select "ROUTINES".
• Click on the "START button to activate the leak detection cycle.
• If the conditions required to authorise the start of the cycle are met, the engine will perform four no load
accelerations.
• Wait a few seconds then switch off the ignition.
• Open the bonnet and visually check for diesel leaks shown up by the leak detector solution previously applied
to the connectors removed during the operation.
• Clean off the leak detection solution using a solvent of the "CARECLEAN" type.
CAUTION
If there are leaks it is absolutely essential to remove all traces of leak detection solution very thoroughly before
opening the high pressure circuit, since particles of leak detection solution may pollute the injection system.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 1-13

I DIAGNOSTICS
1.7 Reading / Writing The VIN
1.7.1 Principle
The VIN (Vehicle Identification Number) is the vehicle chassis number. When a DCU is replaced, agents are
required to enter the chassis number into the new DCU. This operation can be carried out using the diagnostic
tool.
1.7.2 Procedure
To reach the READ/WRITE VIN screen:
• Select the "DCU" button.
• Click on the "READ/WRITE VIN" button.
If no VIN is saved in the DCU, a "WRITE VIN" button is available.
Enter the VIN and click on the "WRITE VIN" button.
1.8 Vehicle Configuration Options
This service allows the vehicle configuration options to be read when fitting a new DCU.
© Delphi
1-14 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
TROUBLE CODES AND CHECKS
2.1 Diagnostic Charts / Trouble Codes

Rail Pressure Control Error Fault
Diagnostic Diagnostic tool title Detection
trouble code
P0087 Rail pressure fails to build at cranking Less than 100 bar rail pressure.
speed.
Fault LED Recovery mode
MIL OFF/CEL ON • Disable accelerometer strategy.
• Turns diagnostic lamp ON.
• Disable discharge on injector 1.
• Disable EGR control (airflow).
• Disable cylinder balancing strategy.
• Limit rail pressure demand.
Symptoms
• Engine stops.
• Rushing noise when reaccelerating after a no load position.
• Engine noisy.
• Idle unstable.
• Lack of performance.
Electrical faults Diagnostic tool title
OC on 59 Rail pressure signal fault.
SC - on 59 Rail pressure signal fault - low.
SC + on 59 Rail pressure signal fault - high.
OC on 84 Rail pressure ground fault.
OC on 86 Rail pressure supply fault.
SC - on 86 Rail pressure supply fault - low.
SC + on 86 Rail pressure supply fault - high.
Rail pressure Vref

86
Rail pressure signal ECU

59
Rail pressure ground

P 84
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-15

I DIAGNOSTICS
Fault chart (Code P0087)

Stage Operation / Decision Result
1 Is the trouble code P0087 present? Disconnect the sensors supplied one by one and check if the fault
disappears. If the fault is no longer present the sensor which was
disconnected was at fault. If the fault is still present after replacing
the sensor, then check the resistance and electrical insulation of
the disconnected line.
2 Check the connection of the sensor. Carry out the repairs required.
Is there a connection problem?
3 Visually inspect the sensor. Change the rail and sensor assembly.
Is there a sensor problem?
4 Check the resistance and the electrical insulation of the wiring Carry out the repairs required.
harness.
Is there a wiring harness problem?
5 Check the connection of the DCU. Carry out the repairs required.
6 Replace the sensor/rail assembly. Change the DCU.
Does the problem persist?
7 The problem is resolved.
© Delphi
2-16 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Rail Pressure Error Fault

trouble code
P0088 Rail pressure error (Over pressure). Greater than 1800 bar.
MIL OFF/CEL OFF • None.
Symptoms
• None.
Rail pressure Vref

86

59

P 84
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-17

I DIAGNOSTICS

1 Is the trouble code P0088 present? Disconnect the sensors supplied one by one and check if the fault
disappears. If the fault is no longer present the sensor which was
disconnected was at fault. If the fault is still present after replacing
the sensor, then check the resistance and electrical insulation of
the disconnected line.
harness.
6 Replace the sensor/ rail assembly. Change the DCU.
© Delphi
2-18 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Air Mass Flow Signal Fault

trouble code
P0101 AMF plausibility fault - Low. At idle with EGR OFF airflow is between 300 and 400 bar.
P0101 AMF plausibility fault - High. At idle with EGR ON airflow is between 200 and 250 bar.
MIL ON/CEL OFF • Disable AMF plausibility diagnostic.
Symptoms
• None.
SC + on 70 AMF sensor signal fault - high.
SC - on 70 AMF sensor signal fault - low.
OC on 70 AMF sensor signal fault.
OC on 61 AMF sensor ground fault.
SC + on 31 Inlet air temperature signal fault - high.
SC - on 31 Inlet air temperature signal fault - low.
OC on 31 Inlet air temperature signal fault.
Temperature & Mass

air flow sensor
Mass Air Flow Signal

QL 70
Mass Air Flow Ground

61
Inlet Air temp. Signal ECU

31
Inlet Air Temp. Signal (HFM6)

54
t°
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-19

I DIAGNOSTICS
Fault chart (Code P0101 - P0101)

1 Is the trouble code P0101 present? Disconnect the sensor one by one and check if the fault disappears.
If the fault is no longer present, the sensor which was disconnected
was at fault. If the fault is still present after replacing the sensor,
then check the resistance and electrical insulation of the
disconnected line.
3 Visually inspect the sensor. Replace the sensor.
harness.
6 Replace the sensor. Change the DCU.
7 The problem is solved.
© Delphi
2-20 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Air Mass Flow Sensor Fault

trouble code
P0102 AMF sensor fault (Low). AMF sensor Min 0.131V
P0103 AMF sensor fault (High). AMF sensor Max 4.75V
P1100 AMF sensor fault (Vext).
Symptoms
• None.
Temperature & Mass

air flow sensor

QL 70

61

31

54
t°
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-21

I DIAGNOSTICS
Fault chart (Code P0102 - P0103 - P1100)

1 Is trouble code P0102 present? Disconnect the sensor one by one and check if the fault disappears.
disconnected line.
harness.
© Delphi
2-22 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Air Mass Flow Gradient Fault

trouble code
P0104 AMF gradient sensor fault. Noisy or intermittent signal.
Symptoms
• None.
Temperature & Mass

air flow sensor

QL 70

61

31

54
t°
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-23

I DIAGNOSTICS

1 Is trouble code P0104 present? Disconnect the sensors and check if the fault disappears. If the fault
is no longer present, the sensor which was disconnected was at
fault. If the fault is still present after replacing the sensor, then
check the resistance and the insulation of the disconnected line.
harness.
© Delphi
2-24 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Atmospheric Pressure Sensor Fault

trouble code
P0107 Atmospheric pressure sensor fault (Low). Inlet pressure less than 50 mbar
P0108 Atmospheric pressure sensor fault (High). Inlet pressure less than 1.15 bar
P1105 Atmospheric pressure sensor fault (Vext). Analogue/digital fault
P0109 Atmospheric pressure sensor fault (GRAD).
Symptoms
Temperature & Mass

air flow sensor

QL 70

61

31

54
t°
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-25

I DIAGNOSTICS
Fault chart (Code P0107 - P0108 - P1105 - P0109)

1 Is trouble code P0107 present? Disconnect the sensors supplied by Vext one by one and check if
the fault disappears. If the fault is no longer present, the sensor
which was disconnected was at fault. If the fault is still present
after replacing the sensor, then check the resistance and electrical
insulation of the disconnected line.
2 Check the condition of the air inlet circuit (tightness of clips, Carry out the repairs required.
contamination, incorrect fitting...).
Is there an air line problem?
harness.
© Delphi
2-26 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Inlet Air Temperature Sensor Fault

trouble code
P0112 Inlet air temperature sensor fault Inlet air temperature less than -35°C.
(electrical) S2LO.
P0113 Inlet air temperature sensor fault Inlet air temperature greater than 128°C.
(electrical) S2HI.
P1110 Inlet air temperature sensor fault Analogue/digital fault.
(electrical) EX.
Symptoms
• None.
Temperature & Mass

air flow sensor

QL 70

61

31

54
t°
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-27

I DIAGNOSTICS

1 Is trouble code P0112 present? Disconnect the sensors one by one and check if the fault disappears.
disconnected line.
3 Measure the characteristics (voltage or resistance) at the sensor Replace the sensor.
terminals.
Is there a characteristic problem?
harness.
7 Problem is resolved.
© Delphi
2-28 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Coolant Temperature Sensor Fault

trouble code
P0116 Coolant sensor fault (plausibility). Coolant temperature between -30°C and 130°C.
MIL OFF/CEL OFF • AC can not be turned ON.
• Reduction of level of detection of engine over temperature to turn on the fans.
• Reduced torque request.
Symptoms
OC on 57 Coolant temperature signal fault.
SC - on 57 Coolant temperature signal fault - low.
SC + on 57 Coolant temperature signal fault - high.
OC on 56 Coolant temperature ground fault.
Coolant temperature sensor
Coolant Temp. Signal

57
Coolant Temp. Ground

ECU
earth
t°
56
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-29

I DIAGNOSTICS

terminals.
harness.
© Delphi
2-30 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Coolant Temperature Sensor Fault

trouble code
P0115 Coolant sensor fault (global = electrical OR 5V supply fault or analog / digital converter fault.
plausibility).
MIL ON/CEL ON • A/C can not be turned on.
• Turns diagnostic lamp on.
• Reduction of level of detection of engine over temperature to turn on the fans.
Symptoms

57

ECU
earth
t°
56
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-31

I DIAGNOSTICS

terminals.
harness.
Does the problem still persist?
© Delphi
2-32 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Coolant Sensor Fault

trouble code
P0118 Coolant sensor fault (electrical)HI. If the coolant temperature is greater than 130°C.
P0117 Coolant sensor fault (electrical)LO. If the coolant temperature is greater than -30°C.
P0119 Coolant sensor fault (electrical)GRAD. Analogue/ digital fault.
P1115 Coolant sensor fault (electrical)Vext. Analogue/ digital fault.
MIL OFF/CEL OFF • Deactivation of accelerometer strategy.
Symptoms

57

ECU
earth
t°
56

2 Measure the characteristics ( voltage or resistance) at the sensor Replace the sensor.
terminals.
harness.
Does the problem still persist?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-33

I DIAGNOSTICS
Pedal Sensor Signal Fault

trouble code
P0120 Pedal sensor track 1 supply – triggers limp 5V supply fault or analog / digital converter fault.
home mode.
MIL ON/CEL ON • Turns diagnostic lamp ON.
• Limp home mode activation.
Symptoms
OC on 24 Pedal sensor track 1 supply fault.
SC - on 24 Pedal sensor track 1 supply fault - low.
SC + on 24 Pedal sensor track 1 supply fault - high.
OC on 25 Pedal sensor track 1 signal fault.
SC - on 25 Pedal sensor track 1 signal fault - low.
SC + on 25 Pedal sensor track 1 signal fault - high.
OC on 26 Pedal sensor track 1 ground fault.
Pedal sensor
Pedal 1 signal
25
Pedal 1 supply (5V)

Track 1 24
Pedal 1 ground
26
ECU
Pedal 2 signal
13
Pedal 2 supply (5V)

Track 2 10
Pedal 2 ground
14
© Delphi
2-34 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Is trouble code P0120 present? Disconnect the sensors supplied by Vext 1 and Vext 2 one by one
and check if the fault disappears. If the fault is no longer present,
the sensor which was disconnected was at fault. If the fault is still
present after replacing the sensor, then check the resistance and
electrical insulation of the disconnected line.
harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-35

I DIAGNOSTICS
Pedal Sensor Fault Track 1

trouble code
P0122 Pedal sensor fault (electrical, track 1)Low. Information for track 1 less than 5%.
P0123 Pedal sensor fault (electrical, track 1)High. Information for track 1 greater than 93%.
P1120 Pedal sensor fault (electrical, track 1)Vext. analogue/ digital fault.
MIL OFF/ CEL OFF • None.
Symptoms
OC on 26 Pedal sensor track 1 ground fault
Pedal sensor
Pedal 1 signal
25
Pedal 1 supply (5V)

Track 1 24
Pedal 1 ground
26
ECU
Pedal 2 signal
13
Pedal 2 supply (5V)

Track 2 10
Pedal 2 ground
14
© Delphi
2-36 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-37

I DIAGNOSTICS
Fuel Temperature Sensor Fault

trouble code
P0182 Fuel temperature sensor faultS2LO. If the fuel temperature is less than -45°C.
P0183 Fuel temperature sensor faultS2HI. If the fuel temperature is greater than 140°C.
P1180 Fuel temperature sensor faultEX. Analogue/ digital fault.
MIL OFF/CEL OFF • Disable RPC trim fault detection.
Symptoms
• None.
OC on 8 Fuel temperature signal fault.
SC - on 8 Fuel temperature signal fault - low.
SC + on 8 Fuel temperature signal fault - high.
OC on 32 Fuel temperature ground fault.
Fuel Temperature sensor

Fuel Temp. signal
8
DCU ECU
earth
Fuel Temp. ground
t° 32
© Delphi
2-38 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Are the fault codes present? Disconnect the sensors supplied by Vext one by one and check if
terminals.
harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-39

I DIAGNOSTICS
Rail Pressure Sensor Fault

trouble code
P0192 Rail pressure sensor fault (out of range or Rail pressure less than 112 bar.
ADC or vref) Low.
P0193 Rail pressure sensor fault (out of range or Rail pressure greater than 1912 bar.
ADC or Vref) High.
P1190 Rail pressure sensor fault (out of range or Rail pressure >90 bar for several successive key ons (sensor drift upwards).
ADC or Vref)Vext.
P0194 Rail pressure sensor fault (out of range or
ADC or Vref)DROP.
MIL ON/CEL ON • Disable accelerometer strategy.
• Temporised engine stop.
• Disable RPC trim fault detection.
• Disable high pressure leak detection strategy.
• Full opening demand of IMV.
• Deactivation of the over rail pressure test.
• Disables the RPC build measurement.
• Disables the rail pressure control fault detection.
Symptoms
• Engine stops.
• Engine noisy.
• Idle unstable.
© Delphi
2-40 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Rail Pressure Sensor Fault

Rail pressure Vref

86

59

P 84

2 Check the high pressure circuit (presence of leaks). Carry out the repairs required.
Are any leaks detected?
4 Visually inspect the sensor. Replace the sensor / rail assembly.
harness.
7 Replace the sensor/ rail assembly. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-41

I DIAGNOSTICS
Cylinder 1 - Open Circuit Fault

trouble code
P0201 Open circuit fault (Cylinder 1). The current rise time in the cylinder is too high.
• Disable cylinder 1 pulse width correction based on current measurement, this correction is based on battery voltage and
coolant temperature.
Symptoms
• Engine noisy.
• Engine running on 3 cylinders.
• Engine stalls.
OC on 25 Cylinder 1 - open circuit.
HSD
25
Cylinder 1 ECU
74
LSD
© Delphi
2-42 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Switch off the engine and wait for 10 seconds. Disconnect the Carry out the repairs required.
injectors and check the injector connection.
2 Check the electrical resistance between the two injector terminals Replace the injectors.
using a multimeter.
Open circuit ?
3 Check the electrical resistance of the wiring harness. Change the wiring harness.
5 Replace the injectors. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-43

I DIAGNOSTICS

trouble code
P0202 Open circuit fault (Cylinder 2). The current rise time in the cylinder is too high.
Symptoms
• Engine noisy.
• Engine stalls.
HSD
2
Cylinder 2 ECU
49
LSD
© Delphi
2-44 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Switch off the ignition and wait for 10 seconds. Disconnect the Carry out the repairs required.
injector and check the injector connection.
2 Check the electrical resistance between the two injector terminals Replace the injector.
using a multimeter.
Open circuit?
5 Replace the injector. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-45

I DIAGNOSTICS

trouble code
P0203 Open circuit fault (cylinder 3). The current rise time in the cylinder is too high.
Symptoms
• Engine noisy.
• Engine stalls.
HSD
26
Cylinder 3 ECU
51
LSD
© Delphi
2-46 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

using a multimeter.
Open circuit?
4 Check the connection of the DCU. Change the wiring harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-47

I DIAGNOSTICS

trouble code
P0204 Open circuit fault (cylinder 4). The current rise time in the cylinder is too high.
Symptoms
• Engine noisy.
• Engine stalls.
HSD
3
Cylinder 4 ECU
4
LSD
© Delphi
2-48 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

using a multimeter.
Open circuit?
3 Check the connection of the DCU. Change the wiring harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-49

I DIAGNOSTICS
High Current Fault On Cylinder 1 & 3 (Bank 1)

trouble code
P0216 Current too high on cylinder 1 & 3 (bank 1). None.
• Disable discharge on cylinder 1.
• Disable cylinder 1.
Symptoms
• None.
OC on 25 High current on cylinder 1.
SC - on 25 High current on cylinder 1 - low.
SC + on 25 High current on cylinder 1 - high.
OC on 74 High current on cylinder 1
OC on26 High current on cylinder 3
© Delphi
2-50 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
HSD
25
Fuel injector
Cylinder 1 74
LSD
ECU
HSD
26
Fuel injector
Cylinder 3
51
LSD

1 Key off and check injector connections. Carry out the repairs required.
2 Disconnect injectors and key on. Check injector connections.
Is the problem still present?
3 Clear default then key off then reconnect ONE injector then key on. Change correspondent injector - Do not forget to update (C2l) in
Is the problem still present? DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-51

I DIAGNOSTICS
Pedal Sensor Fault Track 2

trouble code
P0222 Pedal sensor fault (electrical, track 2) Low. Information for track 2 less than 3%.
P0223 Pedal sensor fault (electrical, track 2) High. Information for track 2 more than 49%.
P1220 Pedal sensor fault (electrical, track 2) Vext. Analogue/digital fault.
Symptoms
Pedal sensor
Pedal 1 signal
25
Pedal 1 supply (5V)

Track 1 24
Pedal 1 ground
26
ECU
Pedal 2 signal
13
Pedal 2 supply (5V)

Track 2 10
Pedal 2 ground
14
© Delphi
2-52 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Are the trouble codes present? Disconnect the sensors supplied by Vext one by one and check if
that was disconnected was at fault. If the fault is still present after
replacing the sensor, then check the resistance and electrical
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-53

I DIAGNOSTICS
Manifold Pressure Sensor Fault

trouble code
P0236 Manifold pressure sensor fault None.
(Plausibility).
MIL OFF/ CEL ON • Disable EGR control (airflow).
• Disabled Turbo.
Symptoms
• Engine stops.
• Engine noisy.
• Idle unstable.
OC on 60 Boost pressure supply fault.
SC - on 60 Boost pressure supply fault - low.
SC + on 60 Boost pressure supply fault - high.
OC on 63 Boost pressure signal fault.
SC + on 63 Boost pressure signal fault - high.
SC - on 63 Boost pressure signal fault - low.
OC on 83 Boost pressure ground fault.
Boost Air Pressure

Boost pressure Vref
60
Boost pressure signal

P 63 ECU
Boost pressure ground

t° 83
© Delphi
2-54 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check the IMV connection. Carry out the repairs required.
2 Measure the characteristics (voltage or resistance) at the IMV Change the IMV.
terminals.
5 Replace the IMV. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-55

I DIAGNOSTICS

trouble code
P0237 Manifold pressure sensor fault (Electrical) Manifold pressure voltage is less than 0.39V.
Low.
P0238 Manifold pressure sensor fault (Electrical) Manifold pressure voltage is more than 4.8V.
High.
P1235 Manifold pressure sensor fault (Electrical) Analogue/ digital fault.
Vext.
P1236 Manifold pressure sensor fault (Electrical) None
GRAD.
MIL OFF/ CEL ON • Disable EGR control (airflow).
• Disabled Turbo.
Symptoms
• Engine stops.
• Engine noisy.
• Idle unstable.
SC - on 60 Boost pressure supply fault - low.
SC + on 60 Boost pressure supply fault - high.
SC + on 63 Boost pressure signal fault - high.
SC - on 63 Boost pressure signal fault - low.
Boost Air Pressure

Boost pressure Vref
60

P 63 ECU

t° 83
© Delphi
2-56 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

terminals.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-57

I DIAGNOSTICS
IMV Drive Fault

trouble code
P0251 IMV drive fault (electrical) SC. Short circuit or short circuit to +ve.
P0253 IMV drive fault (electrical) SC2G. Short circuit to earth.
P0255 IMV drive fault (electrical) OC. Open circuit.
MIL ON/ CEL ON • Disable accelerometer strategy.
• CEL is flashing.
Symptoms
• Engine stops.
• Engine noisy.
• Idle unstable.
OC on 76 Inlet metering valve control.
SC- on 76 Inlet metering valve control - low.
SC+ on 76 Inlet metering valve control - high.
© Delphi
2-58 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Inlet metering
valve actuator
Inlet metering valve out

76 ECU

terminals.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-59

I DIAGNOSTICS
Turbo Actuator Drive Fault

trouble code
P0245 Turbo actuator drive fault (Signal) SC2G. None.
P0246 Turbo actuator drive fault (Signal) SC2 None.
Vbatt.
MIL ON/CEL OFF • Turns diagnostic lamp ON.
• Disabled Turbo.
Symptoms
SC- on 60 Boost pressure supply fault - low.
SC+ on 60 Boost pressure supply fault - high.
SC+ on 63 Boost pressure signal fault - high.
SC- on 63 Boost pressure signal fault - low.
Boost Air Pressure

Boost pressure Vref
60

P 63 ECU

t° 83
© Delphi
2-60 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Is the trouble code P0245 present? Disconnect the sensors supplied by Vext one by one and check if
2 Check the actuator connection Do the necessary repair.
3 Check resistance of actuator. Change the actuator.
Is there a resistance problem?
6 Replace the actuator. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-61

I DIAGNOSTICS
Cylinder Balancing Fault

trouble code
P0263 Cylinder balancing fault (cylinder 1): injector Large drift in cylinder 1 injector (it is providing less fuel, with the extreme case
is stuck closed. being that the injector is blocked in the closed position). This fault is raised by the
cylinder balancing strategy.
MIL OFF/CEL ON • Turns diagnostic lamp ON.
• Disable accelerometer strategy.
• Torque limitation on full load points.
• Deactivation of accelerometer strategy.
Symptoms
• Engine noisy.
OC on 25 Cylinder balancing fault.
SC+ on 25 Cylinder balancing fault - high.
SC- on 25 Cylinder balancing fault - low.
HSD
25
Cylinder 1 ECU
74
LSD
© Delphi
2-62 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check the inlet ducts. Clean the inlet ducts and check the operation of the EGR.
Are the inlet ducts contaminated?
2 Refer to the pressure checking fault section for injector diagnosis. Replace the injector.
Is the injector faulty?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-63

I DIAGNOSTICS

trouble code
P0266 Cylinder balancing fault (cylinder 2):injector Large drift in cylinder 2 injector (it is providing less fuel, with the extreme case
MIL OFF/ CEL ON • Turns diagnostic lamp ON.
• Torque limitation on full points.
Symptoms
• Engine noisy.
OC on 2 Cylinder balancing fault .
SC + on 49 Cylinder balancing fault - high.
SC - on 49 Cylinder balancing fault - low.
HSD
2
Cylinder 2 ECU
49
LSD
© Delphi
2-64 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-65

I DIAGNOSTICS

trouble code
Symptoms
• Engine noisy.
HSD
26
Cylinder 3 ECU
51
LSD
© Delphi
2-66 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-67

I DIAGNOSTICS

trouble code
• Torque limitation on full load position.
Symptoms
• Engine noisy.
HSD
3
Cylinder 4 ECU
4
LSD
© Delphi
2-68 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-69

I DIAGNOSTICS
Turbo Boost Fault

trouble code
P0299 Turbo control error on boost pressure fault. None.
MIL ON/ CEL ON • Turns diagnostic lamp ON.
• Disable Turbo.
Symptoms
OC on 83 Boost pressure ground fault
Boost Air Pressure

Boost pressure Vref
60

P 63 ECU

t° 83
© Delphi
2-70 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Is the trouble code P0299 present? Disconnect the sensors one by one and check if the fault disappears.
disconnected line.
2 Check the connection of the sensors. Carry out the repairs required.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-71

I DIAGNOSTICS
Accelerometer Decode Fault

trouble code
P0325 Accelerometer decode fault(signal / noise Detecting the fault relies on detecting combustion. When idling, the detection
ratio too low at idle). window is shifted to the combustion caused by the main injection. If the ratio
increases this indicates that the accelerometer is operating correctly, if not, a fault
is raised to indicate a faulty sensor.
MIL OFF/ CEL ON • Disable discharge on injector 1.
Symptoms
• Engine noisy.
OC on 46 Accelerometer signal fault (no signal at idle speed).
SC - on 46 Accelerometer signal fault - low (no signal at idle speed).
SC + on 46 Accelerometer signal fault - high(no signal at idle speed).
SC - on 47 Accelerometer signal fault - low(no signal at idle speed).
Combustion noise sensor 1

CNS 1 positive
46
CNS 1 negative
47 ECU
43
CNS 1 shield
© Delphi
2-72 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

First deal with any faults relating to the coolant, air, fuel and atmospheric pressure sensors. A fault on these sensors
may lead to a false diagnosis of the accelerometer.
1 Check the accelerometer connection. Carry out the repairs required.
4 Replace the accelerometer. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-73

I DIAGNOSTICS
Crankshaft Signal Loss Fault

trouble code
P0335 Crankshaft signal fault (signal lost). None.
Symptoms
• Engine stalls.
OC on 87 Crankshaft signal loss fault.
SC+ on 87 Crankshaft signal loss fault - high.
SC- on 87 Crankshaft signal loss fault - low.
OC on 88 Crankshaft signal loss fault.
SC + on 88 Crankshaft signal loss fault - high.
SC - on 88 Crankshaft signal loss fault - low.
CPS positive
87
88 ECU
CPS negative
81
Crank position sensor CPS shield
(VR)

4 Change the sensor. Change the DCU.
© Delphi
2-74 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Crankshaft Signal Fault

trouble code
P0336 Crankshaft signal fault (gap lost). None
Symptoms
• Engine stalls.
OC on 87 Crankshaft signal fault.
SC + on 87 Crankshaft signal fault - high.
SC - on 87 Crankshaft signal fault - low.
CPS positive
87
88 ECU
CPS negative
81
(VR)

Is the problem resolved?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-75

I DIAGNOSTICS

trouble code
P0337 Crankshaft signal fault (engine speed lost). None
Symptoms
• Engine stalls.
CPS positive
87
88 ECU
CPS negative
81
(VR)

© Delphi
2-76 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Camshaft Signal Fault

trouble code
P0340 Camshaft signal fault (missing event). None.
Symptoms
• Engine stalls.
OC on 38 Camshaft signal fault.
SC- on 38 Camshaft signal fault - low.
SC+ on 38 Camshaft signal fault - high.
OC on 37 Camshaft supply fault.
SC- on 37 Camshaft supply fault - low.
SC+ on 37 Camshaft supply fault - high.
OC on 14 Camshaft ground fault..
Camshaft Camshaft Vref

sensor 37
Brake
Camshaft signal
38 ECU
Sensor ground
14
n
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-77

I DIAGNOSTICS

2 Visually inspect the sensor. Change the sensor.
5 Check the target. Replace the target.
Is there a line problem?
6 Check the timing / pump setting. Set the timing / pump setting.
Is there a setting problem?
© Delphi
2-78 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Camshaft Signal Fault

trouble code
P0341 Camshaft signal fault (CAM not None.
synchronised with CRANK).
Symptoms
• None.
OC on 38 Camshaft signal fault.
SC- on 38 Camshaft signal fault - low.
SC+ on 38 Camshaft signal fault - high.
OC on 37 Camshaft supply fault.
SC- on 37 Camshaft supply fault - low.
SC+ on 37 Camshaft supply fault - high.
OC on 14 Camshaft ground fault.
Camshaft Camshaft Vref

sensor 37
Brake
Camshaft signal
38 ECU
Sensor ground
14
n
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-79

I DIAGNOSTICS

2 Visually inspect the sensor. Change the sensor.
5 Check the target. Replace the target.
6 Check the timing / pump setting. Set the timing / pump setting.
Is there a setting problem?
© Delphi
2-80 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
P0371 Crank signal fault (Edges too close). None.
Symptoms
• Engine stalls.
CPS positive
87
88 ECU
CPS negative
81
(VR)

2 Check the resistance and electrical insulation of the wiring harness. Carry out the repairs required.
Is the fault resolved?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-81

I DIAGNOSTICS
Crank Signal Fault

trouble code
P0372 Crank signal fault (missing tooth). None.
Symptoms
• Engine stalls.
CPS positive
87
88 ECU
CPS negative
81
(VR)

© Delphi
2-82 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Flame Glow Drive Fault

trouble code
P0380 Flame glow drive fault. None.
MIL OFF/CEL OFF • Glow plug lamp flashes.
Symptoms
• Engine noisy.
SC - on 68 Glow plug driver fault - low.
SC + on 68 Glow plug driver fault - high.
OC on 68 Glow plug driver fault.
Glow plug relay drive
Actuator fuse
Glow plug output
68 ECU

1 Check the electrical connections of the Glow Plugs. Carry Out the repairs required.
4 Replace the Glow Plug. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-83

I DIAGNOSTICS
EGR Control Error Fault

trouble code
P0400 EGR Control error on airflow. None.
• Disabled Turbo.
Symptoms
OC on 33 EGR position sensor supply fault.
SC+ on 33 EGR position sensor supply fault - high.
SC- on 33 EGR position sensor supply fault - low.
OC on 82 EGR position sensor signal fault.
SC+ on 82 EGR position sensor signal fault - high.
SC- on 82 EGR position sensor signal fault - low.
OC on 9 EGR position sensor ground fault.
OC on 48 EGR output fault.
SC - on 48 EGR output fault - low.
SC + on 48 EGR output fault - high.
External gas recirculation

valve position
EGR feedback 5V
33
EGR feedback signal

82
ECU
EGR feedback ground
9
EGR out
48
Exhaust gas recirculation

valve
© Delphi
2-84 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check the pneumatic connections of the EGR circuit. Carry out the repairs required.
2 Check the vacuum at the EGR solenoid valve. Carry out the repairs required.
Is there a vacuum problem?
3 Check the condition of the EGR valve. Replace the EGR valve.
Is there a valve problem?
4 Check the air and exhaust lines. Carry out the repairs required.
5 Check the flowmeter. Carry out the repairs required.
Is there a flowmeter problem?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-85

I DIAGNOSTICS
EGR Actuator Fault

trouble code
P0489 EGR actuator fault SC2G. None
P0490 EGR actuator fault SC2 VBATT. None
MIL ON/ CEL ON • CEL is flashing.
• Disabled Turbo.
Symptoms
OC on 33 EGR position sensor supply fault.
SC+ on 33 EGR position sensor supply fault - high.
SC- on 33 EGR position sensor supply fault - low.
OC on 82 EGR position sensor signal fault.
SC+ on 82 EGR position sensor signal fault - high.
SC- on 82 EGR position sensor signal fault - low.
OC on 9 EGR position sensor ground fault.
OC on 48 EGR output fault.
SC - on 48 EGR output fault - low.
SC + on 48 EGR output fault - high.
External gas recirculation

valve position
EGR feedback 5V
33
EGR feedback signal

82
ECU
EGR feedback ground
9
EGR out
48
Exhaust gas recirculation

valve
© Delphi
2-86 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check the pneumatic connections of the EGR circuit. Carry out the repairs required.
2 Check the vacuum at the EGR solenoid valve. Carry out the repairs required.
Is there a vacuum problem?
3 Check the condition of the EGR valve. Replace the EGR valve.
Is there a valve problem?
4 Check the air and exhaust lines. Carry out the repairs required.
5 Check the flowmeter. Carry out the repairs required.
Is there a flowmeter problem?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-87

I DIAGNOSTICS
Vehicle Speed Fault

trouble code
P0500 Vehicle speed fault (global). None.
Symptoms
• Poor drive ability.
OC on 18 Vehicle speed output fault.
SC - on 18 Vehicle speed output fault - low.
SC + on 18 Vehicle speed output fault - high.
Vehicle speed output

n 18 ECU

1 Check source of vehicle speed signal. Carry out the repairs required.
harness.
© Delphi
2-88 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Vehicle Speed Fault

trouble code
P0501 Vehicle speed sensor fault (plausibility). None.
P0503 Vehicle speed sensor fault (Speed too high). None.
MIL OFF/CEL OFF • Turns diagnostic lamp ON.
Symptoms
• Poor drivability.

n 18 ECU

harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-89

I DIAGNOSTICS
Vehicle Speed Fault

trouble code
P0502 Vehicle speed sensor fault (signal lost). None.
MIL OFF/CEL OFF • Turns diagnostic lamp ON.
Symptoms
• Poor drive ability.

n 18 ECU
© Delphi
2-90 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

2 Check presence of electrical default on water sensor. Carry out the necessary repairs.
Is there an electrical problem?
3 Check the water sensor connection. Carry out the necessary repairs.
4 Check the water sensor resistance. Carry out the repairs required.
harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-91

I DIAGNOSTICS
Battery Voltage Monitoring Fault

trouble code
P0562 Battery voltage monitoring fault - low. Battery voltage less than 6 Volts.
P0563 Battery voltage monitoring fault - high. Battery voltage greater than 18 Volts.
P1560 Battery voltage monitoring fault - ADC. Analogue/ digital fault.
MIL ON/ CEL ON • A/C can not be turned ON.
Symptoms
• Starting impossible.
• Engine noisy.
© Delphi
2-92 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check the battery voltage at Key On. Check the battery and charge it.
Is the voltage too low?
2 Check the battery terminals and the tightness of the clamps. Carry out the repairs required.
Is there a terminal or clamp problem?
4 Check the charging circuit. Carry out the repairs required.
Is there a charging problem?
5 Replace the sensors. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-93

I DIAGNOSTICS
Brake Signal Sensor Error

trouble code
P0571 Brake signal fault error. None.
Symptoms
• None.
OC on 23 Brake switch 1 sensor fault.
SC + on 23 Brake switch 1 sensor fault - high.
SC - on 23 Brake switch 1 sensor fault - low.
OC on 39 Brake switch 2 sensor fault.
SC + on 39 Brake switch 2 sensor fault - high.
SC - on 39 Brake switch 2 sensor fault - low.
Brake switch 1 signal

23
ECU
39
© Delphi
2-94 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check switch connection. Carry out the repairs required.
2 Check the 12V switch supply. Check the supply for continuity and the corresponding fuse.
Is there a supply problem?
3 Check the contractor functioning. Change the contractor.
Is there a contractor problem?
harness.
Is there a connection problem?.
6 Replace the sensor Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-95

I DIAGNOSTICS
DCU Watchdog Fault

trouble code
P0606 DCU watchdog fault. The watchdog cannot carry out a main microprocessor reset.
Symptoms
• Engine stops.

1 Check the DCU earth. Carry out the repairs required.
Is there an earth problem?
2 Check the connections of the DCU Change the DCU
© Delphi
2-96 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
5V Supply 1 Fault
trouble code
P0642 5V supply 1 faultLow. Supply is less than 4.75V.
P0643 5V supply 1 faultHigh. Supply is more than 5.3V.
P1641 5V supply 1 faultADC. Analogue/ digital fault.
• Disable the rail pressure control fault detection.
Symptoms
• Engine stops.
• Engine noisy.
• Unsteady idle.
SC- on 24 5V sensor supply (Vext1) - low.
SC+ on 24 5V sensor supply (Vext1) - high.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-97

I DIAGNOSTICS

harness for all sensors supplied by Vext1 or Vext2.
3 Check the connection of the ECU. Carry out the repairs required.
4 Replace the sensor. Change the ECU.
© Delphi
2-98 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Air Conditioning Drive Fault

trouble code
P0646 Air conditioning drive fault SC2G. None.
P0647 Air conditioning drive fault SC. None.
P1646 Air conditioning drive fault OC. None.
Symptoms
• A/C cannot be activated.
OC on 29 AC pressure sensor supply fault.
SC + on 29 AC pressure sensor supply fault - high.
SC - on 29 AC pressure sensor supply fault - low.
OC on 51 AC pressure signal fault.
SC + on 51 AC pressure signal fault - high.
SC - on 51 AC pressure signal fault - low.
OC on 30 A/C demand ground fault.
AC pressure sensor
AC pressure Vref
29
AC pressure signal ECU

51
AC pressure ground
P 30
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-99

I DIAGNOSTICS

1 Check the relay connection. Carry out the necessary repairs.
harness.
4 Check the relay (run ISO cycle). Change the relay.
Is the relay ok?
5 Replace the sensor Change the ECU.
© Delphi
2-100 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
5V Supply 1 Fault
trouble code
P0652 5V supply 2 faultLow. Supply is less than 4.75V.
P0653 5V supply 2 faultHigh. Supply is more than 5.30V.
P1651 5V supply 2 faultADC. Analogue/ digital fault.
MIL ON/ CEL ON • Disable accelerometer strategy.
• Disable pilot and post injections.
Symptoms
• Engine stops.
• Engine noisy.
• Unsteady idle.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-101

I DIAGNOSTICS
5V Supply 1 Fault

1 Check the connection of the sensors supplied by Vext1 or Vext2 Carry out the repairs required.
( boost pressure sensor, temperature sensor, pedal sensor, rail
pressure sensor, cam sensor).
2 Visually inspect each sensor. Replace the sensor.
harness for all sensors supplied by Vext1 or Vext2.
5 Replace the sensors. Change the ECU.
© Delphi
2-102 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
MIL Fault
trouble code
P0650 MI lamp fault. None.
Symptoms
• None.
OC on 40 MI lamp indicator fault.
SC + on 40 MI lamp indicator fault - high.
SC - on 40 MI lamp indicator fault - low.
Malfunction Indicator
40 ECU
F2
Instrumentation fuse [15] (10A)

2 Check the sensor resistance (checking if it is coherent with the Replace the sensor.
vehicle conditions) if applicable.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-103

I DIAGNOSTICS
Unexpected State Of Main Relay

trouble code
P0685 Unexpected state of main relay (high). The supply relay is open without an order from the ECU.
Symptoms
• Engine stalls.
OC on 44 ECU supply control - relay open.
SC+ on 44 ECU supply control - relay high.
SC- on 1, 3 or 5 ECU supply control - relay low.
OC on 1, 3 or 5 ECU supply control - relay open.
OC on relay supply ECU supply control - relay open.
Supply ECU supply

1
relay
F3
30A ECU supply
3
ECU supply
F4 5 ECU
5A
Supply control
44
Battery
+IGN
19
F5
12V Earth

1 Check the connection of the supply relay. Carry out the repairs required.
harness.
4 Replace the relay. Change the ECU.
© Delphi
2-104 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Electrical Fan Drive Fault (Type 1)

trouble code
P0691 Electrical fan drive fault (Type 1)SC2G. None.
P0692 Electrical fan drive fault (Type1) SC. None.
P1691 Electrical fan drive fault (Type1) OC. None.
MIL OFF/CEL OFF • A/C can not be turned ON.
• Engine temperature required to activate cooling fans reduced.
Symptoms

1 Check the connection of the relay. Carry out the repairs required.
harness.
4 Change the relay (run ISO cycle). Change the ECU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-105

I DIAGNOSTICS
Electrical Fan Drive Fault (Type 2)

trouble code
P0693 Electrical fan drive fault (Type2) SC2G. None.
P0694 Electrical fan drive fault (Type 2) SC. None.
P1693 Electrical fan drive fault (Type 2) OC. None.
MIL OFF/ CEL ON • A/C can not be turned on.
• Engine temperature required to activate cooling fans reduced.
Symptoms

1 Check the connection of the relay. Carry out the repairs required.
harness.
4 Change the relay (run ISO cycle). Change the ECU.
© Delphi
2-106 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
5V Sensor
trouble code
P0698 5V Sensor supply Vext 2 aux fault Low. Supply voltage less than 4.75V.
P0699 5V Sensor supply Vext 2 aux fault High. Supply voltage more than 5.30V.
P1697 5V Sensor supply Vext 2 aux faultADC. Analogue/ digital fault.
Symptoms
• No drive ability.
OC on 44 ECU supply control - 5V sensor fault.
SC + on 44 ECU supply control - 5V sensor fault.
SC - on 1,3 or 5 ECU supply control - 5V sensor fault.
OC + on 1,3 or 5 ECU supply control - 5V sensor fault.
OC on relay supply ECU supply control - 5V sensor fault.
Supply ECU supply

1
relay
F3
30A ECU supply
3
ECU supply
F4 5 ECU
5A
Supply control
44
Battery
+IGN
19
F5
12V Earth
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-107

I DIAGNOSTICS

1 Is the trouble code P0698 present? Disconnect the sensors supplied by the Vext one by one and check
if the fault disappears. If the fault is no longer present, the sensor
insulation of the disconnected wiring harness. If none is found
faulty, check short circuit and isolation of Vext lines on the harness.
harness.
© Delphi
2-108 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Clutch Switch Fault

trouble code
P0704 Clutch switch electrical fault None
MIL OFF/ CEL OFF None.
Symptoms
Poor drive ability.
OC on 27 Clutch switch 1 electrical fault.
SC + on 27 Clutch switch 1 electrical fault - high.
SC - on 27 Clutch switch 1 electrical fault - low.
OC on 34 Clutch switch 2 electrical fault.
SC + on 34 Clutch switch 2 electrical fault - high.
SC - on 34 Clutch switch 2 electrical fault - low.
Clutch switch #1
Clutch switch 1 signal

27
Clutch switch #2 (auto cruise) ECU

Clutch switch 2 signal
34
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-109

I DIAGNOSTICS

1 Is the trouble code P0704 present. Disconnect the sensors and check if the fault disappears. If the fault
is no longer present, the sensor which was disconnected was at
fault. If the fault is still present after replacing the sensor, then
check the resistance and electrical insulation of the disconnected
wiring harness. If none is found faulty, check short circuit and
isolation of Vext lines on the harness.
3 Check the 12V switch supply. Check supply continuity and corresponding fuse.
Is there a supply problem?
4 Check contractor functioning. Change the contractor.
Is there a contractor functioning problem?
harness.
© Delphi
2-110 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Atmospheric Pressure Signal

trouble code
P1101 Generic atmospheric pressure signal fault. Diagnostic trouble codes P1105, 1107, 1108.
MIL OFF / CEL ON • Turns diagnostic lamp ON.
• Disabled Turbo.
Symptoms
• None.
Inside the ECU

1 Change the ECU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-111

I DIAGNOSTICS
Atmospheric Pressure Sensor

trouble code
P1107 Atmospheric pressure sensor - Global None.
atmospheric pressure fault.
MIL OFF / CEL OFF • None.
Symptoms
• None.
Inside the ECU.

1 Change the ECU.
© Delphi
2-112 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Pedal Sensor Fault

trouble code
P1123 Pedal sensor - correlation between track 1 5% bottom end - 10% top end.
and track 2 Pedal 1 over 2.
P1223 Pedal sensor - correlation between track 1 5% bottom end - 10% top end.
and track 2Pedal 2 over 1.
Symptoms
See diagnostic trouble codes P0120, P0122, P0123 & P0220, P0222, Pedal sensor - correlation track 1&2 (1 > 2)or pedal sensor - correlation track
P0223 1&2 (2 > 1).
Pedal sensor
Pedal 1 signal
25
Pedal 1 supply (5V)

Track 1 24
Pedal 1 ground
26
ECU
Pedal 2 signal
13
Pedal 2 supply (5V)

Track 2 10
Pedal 2 ground
14

1 See diagnostic fault codes P0120, P0122, P0123 P0220, P0222,
P0223.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-113

I DIAGNOSTICS
Pedal Sensor Fault

trouble code
P1121 Pedal sensor fault (triggers reduced torque Difference between the information given by tracks 1 and 2 of the pedal sensor.
mode)(2>1).
Symptoms
See diagnostic trouble codes P0120, P0122, P0123 & P0220, P0222, Pedal sensor - correlation track 1&2 (1 > 2) or Pedal sensor - correlation track
P0223 1&2 (2 > 1).
Pedal sensor
Pedal 1 signal
25
Pedal 1 supply (5V)

Track 1 24
Pedal 1 ground
26
ECU
Pedal 2 signal
13
Pedal 2 supply (5V)

Track 2 10
Pedal 2 ground
14

1 See diagnostic fault codes P0120, P0122, P0123 P0220, P0222,
P0223. © Delphi
2-114 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Cylinder 1 - MDP Below Minimum Limit

trouble code
P1171 Cylinder 1 - MDP absolute below the This fault is raised when the APC correction stored in the non-volatile memory has
minimum limit. reached the lower threshold (injector drift).
MIL OFF / CEL ON • Disable accelerometer strategy.
Symptoms
• Engine noisy.
SC+ on 25 Cylinder 1 - loss of signal (high).
SC- on 25 Cylinder 1 - loss of signal (low).
OC on 25 Cylinder 1 - loss of signal.
HSD
25
Cylinder 1 ECU
74
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-115

I DIAGNOSTICS

1 Write the C2I of the corresponding injector using the diagnostic The problem is resolved.
tool, erase the faults then switch the ignition off then on again.
2 Replace the injector and enter the new C2I into the ECU. Change the ECU.
© Delphi
2-116 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
Symptoms
• Engine noisy.
HSD
2
Cylinder 2 ECU
49
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-117

I DIAGNOSTICS

© Delphi
2-118 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
Symptoms
• Engine noisy.
HSD
26
Cylinder 3 ECU
51
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-119

I DIAGNOSTICS

© Delphi
2-120 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
• disable discharge on injector 4.
Symptoms
• Engine noisy.
HSD
3
Cylinder 4 ECU
4
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-121

I DIAGNOSTICS

© Delphi
2-122 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Rail Pressure Sensor fault

trouble code
P1191 Rail pressure sensor fault (out of range at (sensor drift upwards).
key-on)Med TEST.
P1192 Rail pressure sensor fault (out of range at (sensor drift downwards).
key-on) low.
P1193 Rail pressure sensor fault (out of range at (sensor drift downwards).
key-on) high.
MIL ON / CEL ON • Disable accelerometer strategy.
Symptoms
• Rushing nosie when reaccelerating after a no load position.
• Engine noisy.
• Unsteady idle.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-123

I DIAGNOSTICS
Rail Pressure Sensor fault

SC+ on 86 Rail pressure supply fault - high.
SC- on 86 Rail pressure supply fault - low.
SC+ on 59 Rail pressure signal fault - high.
SC- on 59 Rail pressure signal fault - low.
Rail pressure Vref

86

59

P 84

harness.
5 Replace the sensor / rail assembly. Change the ECU.
© Delphi
2-124 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Cylinder 1 - Short Circuit HSD To LSD

trouble code
P1201 Short circuit HSD to LSD (cylinder 1). The injector for cylinder 1 is not controlled. The other injectors are controlled
normally.
• Deactivates the ISO test mode for the injector.
• Disables RPC trim fault detection.
Symptoms
• Engine noisy.
• Unsteady idle (random check at low fuelling).
SC between LSD and HSD or SC on the coil for cylinder 1 Cylinder 1 - short circuit SC between LSD and HSD.
HSD
25
Cylinder 1 ECU
74
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-125

I DIAGNOSTICS

1 Switch off the ignition and check the injector connection. Carry out the repairs required.
2 Disconnect the injector. Injector faulty, replace the injector.
3 Check the electrical resistance of the wiring harness. Carry out the repairs required.
© Delphi
2-126 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
normally.
Symptoms
• Engine noisy.
HSD
2
Cylinder 2 ECU
49
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-127

I DIAGNOSTICS

© Delphi
2-128 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
normally.
Symptoms
• Engine noisy.
HSD
26
Cylinder 3 ECU
51
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-129

I DIAGNOSTICS

© Delphi
2-130 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
normally.
Symptoms
• Engine noisy.
HSD
3
Cylinder 4 ECU
4
LSD
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-131

I DIAGNOSTICS

© Delphi
2-132 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
High Current On Cylinder 2 & 4

trouble code
P1216 Current too high on cylinder 2 & 4. None.
• Disable injector 2.
Symptoms
• None.
SC+ on 2 High current fault on cylinder 2 & 4 - high.
SC- on 2 High current fault on cylinder 2 & 4 - low.
OC on 2 High current fault on cylinder 2 & 4.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-133

I DIAGNOSTICS
HSD
2
Fuel injector
Cylinder 2
49
LSD
ECU
HSD
3
Fuel injector
Cylinder 4
4
LSD

2 Disconnect the injectors and key on. Check injector connections.
3 Clear default then key off then reconnect ONE injector then key on. Change correspondent injector- do not forget to update the {Cxl} in
Is the problem still present? ECU.
5 Check connection to the ECU. Carry out the repairs required.
© Delphi
2-134 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

trouble code
P1237 Manifold pressure sensor fault - low. None.
P1238 Manifold pressure sensor fault - high. None.
• Disabled Turbo.
Symptoms
OC on 60 Boost pressure supply fault .
Boost Air Pressure

Boost pressure Vref
60

P 63 ECU

t° 83
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-135

I DIAGNOSTICS

1 Are the trouble codes present? Disconnect the sensor supplied by vext one by one and check if the
fault disappears. If the fault is no longer present, the sensor which
was disconnected was at fault. If the fault is still present after
replacing the sensor, then check the resistance and electrical
2 check the condition of the air inlet circuit (tightness of clips, Carry out the repairs.
contamination, incorrect fitting...).
Is there an air line problem?
harness.
© Delphi
2-136 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Rail Pressure Control Error

trouble code
P1253 Rail pressure control (loop activation/ Rail pressure loop difference(50 bar).
pressure error too high)NEG.
P1254 Rail pressure control (loop activation/ Rail pressure loop difference(50 bar).
pressure error too high)POS.
Symptoms
• Engine noisy.
SC + on 86 Rail pressure control supply fault - high.
SC - on 86 Rail pressure control supply fault - low.
OC on 86 Rail pressure control supply fault.
SC + on 59 Rail pressure control signal fault - high.
SC - on 59 Rail pressure control signal fault - low.
OC on 59 Rail pressure control signal fault..
OC on 84 Rail pressure control ground fault.
Rail pressure Vref

86

59

P 84
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-137

I DIAGNOSTICS

1 Carry out the electrical diagnosis of the IMV. Carry out the repairs required.
2 Carry out the diagnosis of the HP sensor. Carry out the repairs required.
Is there a HP sensor problem?
3 Check the LP circuit. Carry out the repairs required.
Is there a LP circuit problem?
4 Check the HP circuit. Carry out the repairs required.
Is there a HP circuit problem?
5 Check the injectors. Carry out the repairs required.
Is there an injector problem?
6 Check the HP pump. Carry out the repairs required.
Is there a HP pump problem?
7 Change the ECU.

1 Check the low pressure circuit: Fill the tank.
Check there is fuel in the fuel tank.
Is the tank dry?
2 Visually inspect the fuel supply and return hoses: Carry out the repairs required.
• Look for leaks.
• Check the connections.
• Check the quick release connections.
Is there a hose problem?
3 Check there is no air in the low pressure circuit. Place a container under the venturi. Disconnect the pump return
Is there air in the low pressure circuit? hose at the venturi and prime the circuit using the priming bulb.
4 Check the diesel filter reference. Replace the filter with an original part.
Is the filter reference incorrect?
5 The low pressure circuit is correct.

1 Check the high pressure circuit: Carry out the repairs required.
Start the HP leak detection cycle.
2 The high pressure circuit is correct.
© Delphi
2-138 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

1 Check the injectors and the HP pump:
Refer to the high pressure diagnostic section.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-139

I DIAGNOSTICS
Rail Pressure Check

trouble code
P1256 Rail pressure control - trim low and fuel low. The rail pressure is slightly less than the demand. The checking device tries to
open the IMV by progressively reducing the current applied to the actuator. When
the current correction arrives at the minimum threshold a fault is raised to indicate
that the system is not able to reach the pressure demand.
P1257 Rail pressure control - trim low and fuel high. The rail pressure is slightly less than the demand. The checking device tries to
open the IMV by progressively reducing the current applied to the actuator. When
the current correction arrives at the minimum threshold a fault is raised to indicate
P1258 Rail pressure control - trim high and fuel low. The rail pressure is higher than the demand. The checking device tries to close the
IMV by progressively increasing the current applied to the actuator. When the
current correction arrives at the maximum threshold a fault is raised to indicate
P1259 Rail pressure control - trim high and fuel The rail pressure is higher than the demand. The checking device tries to close the
high. IMV by progressively increasing the current applied to the actuator. When the
current correction arrives at the maximum threshold a fault is raised to indicate
Symptoms
• Engine noisy.
• Rushing noise when reaccelerating after a no-load position.
SC+ on 86 Rail pressure control supply fault - high.
SC- on 86 Rail pressure control supply fault - low.
OC on 86 Rail pressure control supply fault.
SC+ on 59 Rail pressure control signal fault - high.
SC- on 59 Rail pressure control signal fault - low.
OC on 59 Rail pressure control signal fault.
OC on 84 Rail pressure control ground fault.
© Delphi
2-140 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Rail pressure Vref

86

59

P 84

1 Carry out the electrical diagnosis of the IMV (See codes P0251, Carry out the repairs required.
P0253 and P0255).
2 Carry out the diagnosis of the HP sensor. (See codes P0192 and Carry out the repairs required.
P0193).
Is there a HP sensor problem?
3 Check the LP circuit. Carry out the repairs required.
Is there a LP circuit problem?
4 Check the HP circuit. Carry out the repairs required.
Is there a HP circuit problem?
5 Check the injectors. Carry out the repairs required.
Is there an injector problem?
6 Check the HP pump. Carry out the repairs required.
Is there a HP pump problem?
7 Change the ECU.

1 Check the low pressure circuit: Fill the tank.
Check there is fuel in the fuel tank.
Is the tank dry?
2 Visually inspect the fuel supply and return hoses: Carry out the repairs required.
• Look for leaks,
• Check the connections,
• Check the quick release connections.
Is there a hose problem?
3 Check there is no air in the low pressure circuit. Place a container under the venturi. Disconnect the pump return
Is there air in the low pressure circuit? hose at the venturi and prime the circuit using the priming bulb.
4 Check the diesel filter reference. Replace the filter with an original part.
Is the filter reference incorrect?
5 The low pressure circuit is correct.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-141

I DIAGNOSTICS

1 Check the high pressure circuit: Carry out the repairs required.
Start the HP leak detection cycle.
2 The high pressure circuit is correct.

1 Check the injectors and the HP pump:
Refer to the high pressure diagnostic section.
© Delphi
2-142 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Cylinder Harness Resistance

trouble code
P1286 Cylinder 1 - resistance too low. Cylinder 1 harness too low.
P1287 Cylinder 1 - resistance too high. Cylinder 1 harness too high.
• Disable pulse width correction based on the current.
• Disable dynamic discharge on all injectors.
Symptoms
• Engine noisy.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-143

I DIAGNOSTICS
Cylinder Harness Resistance

SC+ on 25 Cylinder 1 resistance fault - high.
SC- on 25 Cylinder 1 resistance fault - low.
OC on 25 Cylinder 1 resistance fault.
SC- on 51 Cylinder 3 resistance fault -low.
© Delphi
2-144 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
HSD
25
Fuel injector
Cylinder 1
74
LSD
HSD
2
Fuel injector
Cylinder 2
49
LSD
ECU
HSD
26
Fuel injector
Cylinder 3 51
LSD
HSD
3
Fuel injector
Cylinder 4
4
LSD
CAUTION
• Limit the number of times the injectors are disconnected as far as possible.
• If an injector has to be replaced, the C2I for the new injector must be entered into the ECU.
Fault chart (Code P1286 - P1287 - P1288 - P1289 - P1290 - P1291 - P1292 - P1293)
using a multimeter.
Open circuit?
3 Check the electrical resistance of the wiring harness. Change the wiring harness
5 Replace the injector. Change the ECU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-145

I DIAGNOSTICS
Accelerometer Functional Check Fault

trouble code
P1325 Accelerometer functional check fault. None
MIL OFF/ CEL ON • Disable discharge on injector 1.
Symptoms
• Engine noisy.
SC - on 46 Accelerometer signal fault - low (no signal at idle speed).
SC - on 47 Accelerometer signal fault - low(no signal at idle speed).
Combustion noise sensor 1

CNS 1 positive
46
CNS 1 negative
47 ECU
43
CNS 1 shield © Delphi
2-146 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I

First deal with any faults relating to the coolant, air, fuel and atmospheric pressure sensors. A fault on these sensors
may lead to a false diagnosis of the accelerometer.
1 Check the accelerometer connection. Carry out the repairs required.
4 Replace the accelerometer. Change the DCU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-147

I DIAGNOSTICS
Flame Fuel Drive Fault

trouble code
P1380 Flame fuel drive fault. None.
MIL OFF/CEL OFF • Glow plug lamp flashes.
Symptoms
• Engine noisy.
SC - on 68 Glow plug driver fault - low.
SC + on 68 Glow plug driver fault - high.
OC on 68 Glow plug driver fault.
Actuator fuse
Glow plug output
68 ECU

1 Check the electrical connections of the Glow Plugs. Carry Out the repairs required.
4 Replace the Glow Plug. Change the DCU.
© Delphi
2-148 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Brake Light Signal Fault

trouble code
P1571 Brake light signal fault (safety). None.
P1572 Brake light signal fault (light). None.
Symptoms
• None.
SC+ on 23 Brake switch 1 fault - high.
SC- on 23 Brake switch 1 fault - low.
OC on 23 Brake switch 1 fault.
SC+ on 39 Brake switch 2 fault - high.
SC- on 39 Brake switch 2 fault - low.
OC on 39 Brake switch 2 fault.

23
ECU
39

1 Check the connection of the switch. Carry out the repairs required.
2 Check the 12V switch supply. Carry out the repairs required for connection continuity and
Is there a supply problem? corresponding fuse.
3 Check contractor functionality. Change the contractor.
Is there a contractor problem?
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-149

I DIAGNOSTICS
ECU Watchdog Fault

trouble code
P1600 ECU watchdog fault (watchdog trip) Noise None.
injector shut down.
P1601 ECU watchdog fault (watchdog trip) CPU- None.
CPU clock.
P1602 ECU watchdog fault (watchdog trip) TPU- None.
TPU clock.
Symptoms
• Engine stops.

1 Check the ECU earth. Carry out the repairs required.
2 Change the ECU.
© Delphi
2-150 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
ECU Memory Fault

trouble code
P1603 ECU memory integrity fault CODE One or more cells of the random access memory (RAM) are faulty.
INTEGRITY.
P1604 ECU memory integrity fault CAL One or more cells of the random access memory (RAM) are faulty.
INTEGRITY.
P1605 ECU memory integrity fault RAM One or more cells of the random access memory (RAM) are faulty.
INTEGRITY.
MIL OFF/ CEL OFF • Immediate stop of the engine.
Symptoms
• Engine stops.

2 Change the ECU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-151

I DIAGNOSTICS
ECU Watchdog Fault

trouble code
P1607 Internal ECU fault. Watchdog injector Injector cut out impossible.
shutdown fault.
MIL OFF/ CEL ON • None.
Symptoms
• None.

2 Change the ECU.
© Delphi
2-152 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
ECU Watchdog Fault

trouble code
P1608 ECU watchdog fault (injector unlock during None.
start-up).
MIL OFF/ CEL ON • None.
Symptoms
• Engine stops.

2 Change the ECU.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-153

I DIAGNOSTICS
ECU Non Volatile Memory Fault

trouble code
P1614 ECU non volatile memory fault C2l, MDP. The non volatile memory of the ECU is damaged.
P1615 ECU non volatile memory fault RP, PL, STE. The non volatile memory of the ECU is damaged.
P1616 ECU non volatile memory fault WDOG. The non volatile memory of the ECU is damaged.
P1606 ECU non volatile memory fault CAN, KW. The non volatile memory of the ECU is damaged.
P1617 ECU non volatile memory fault SMC. The non volatile memory of the ECU is damaged.
P1620 ECU non volatile memory fault ICV, Inj. The non volatile memory of the ECU is damaged.
Cnt..
P1621 ECU non volatile memory fault FM. The non volatile memory of the ECU is damaged.
P1622 ECU non volatile memory fault APP. The non volatile memory of the ECU is damaged.
MIL ON/ CEL OFF • A/C can not be turned ON.
Symptoms
• Engine noisy.
• Unstable idle (random check at low fuelling).
Fault chart (Code P1614 - P1615 - P1616 - P1606 - P1617 - P1620 - P1621 - P1622)
2 Change the ECU.
© Delphi
2-154 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Check Engine Lamp Fault

trouble code
P1650 Check engine lamp fault. Open circuit.
Symptoms
• Starting difficult or impossible.
• Engine noisy.
• Smoke.
OC on 45 Check engine lamp fault.
SC + on 45 Check engine lamp fault - high.
SC - on 45 Check engine lamp fault - low.
Check Engine Indicator
45 ECU
F2

2 Check the sensor resistance ( checking it is coherent with vehicle Replace the sensor.
conditions) if applicable.
harness.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-155

I DIAGNOSTICS
Glowplug Relay
trouble code
P1678 Glowplug Drive - open circuit. Open circuit.
P1679 Glowplug Drive - short circuit. Short circuit.
P1680 Glowplug Drive - short circuit to earth. Short circuit to earth.
Symptoms
• Starting difficult or impossible.
• Engine noisy.
• Smoke.
OC on 68 Glowplug relay drive fault.
SC - on 68 Glowplug relay drive fault - low.
SC + on 68 Glowplug relay drive fault - high.
Actuator fuse
Glow plug output
68 ECU

1 Check the connection of the Glowplugs. Carry out the repairs required.
2 Check the resistance and the electrical insulation of the wiring Repair the wiring harness.
harness.
4 Replace the Glowplug. Change the ECU.
© Delphi
2-156 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Exhaust Brake Fault

trouble code
P1681 Exhaust break drive fault. None.
Symptoms
OC on 29 Exhaust brake demand switch fault
SC+ on 29 Exhaust brake demand switch fault - high
SC- on 29 Exhaust brake demand switch fault - low
OC on 91 Exhaust brake actuator relay fault
SC+ on 91 Exhaust brake actuator relay fault - high
SC- on 91 Exhaust brake actuator relay fault - low
Exhaust brake demand

switch
F3 Exhaust break demand
switch
29
ECU
F4
Exhaust break out
91
Exhaust brake actuator

relay
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-157

I DIAGNOSTICS

harness.
© Delphi
2-158 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Main Relay Sensor State

trouble code
P1685 Main relay unexpected high/low state. None.
Symptoms
OC on 44 ECU supply control - unexpected high/ low state.
SC+ on 44 ECU supply control - unexpected high/ low state.
OC+ on 1,3 or 5 ECU supply control - unexpected high/ low state.
SC- on 1,3 or 5 ECU supply control - unexpected high/ low state.
OC on relay supply ECU supply control - unexpected high/ low state.
Supply ECU supply

1
relay
F3
30A ECU supply
3
ECU supply
F4 5 ECU
5A
Supply control
44
Battery
+IGN
19
F5
12V Earth
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-159

I DIAGNOSTICS

1 Is the trouble code P1685 present? Disconnect the sensors supplied by the Vext one by one and check
if the fault disappears. If the fault is no longer present, the sensor
insulation of the disconnected line. If none is found faulty, check
short circuit and isolation of Vext lines on the harness.
harness.
© Delphi
2-160 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Injector Bank 1 Fault

trouble code
P2147 Injector bank 1 fault (shorted to ground or None.
to Vbatt) - LOW
to Vbatt) - HIGH
Symptoms
• None.
OC on 25 High current on cylinder 1.
OC on26 High current on cylinder 3
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-161

I DIAGNOSTICS
HSD
25
Fuel injector
Cylinder 1 74
LSD
ECU
HSD
26
Fuel injector
Cylinder 3
51
LSD

2 Disconnect injectors and key on. Check injector connections.
3 Clear default then key off then reconnect ONE injector then key on. Change correspondent injector - Do not forget to update (C2l) in
Is the problem still present? DCU.
© Delphi
2-162 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Injector Bank 2 Fault

trouble code
to Vbatt) - LOW
to Vbatt) - HIGH
Symptoms
• None.
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 2-163

I DIAGNOSTICS
HSD
2
Fuel injector
Cylinder 2
49
LSD
ECU
HSD
3
Fuel injector
Cylinder 4
4
LSD

2 Disconnect the injectors and key on. Check injector connections.
3 Clear default then key off then reconnect ONE injector then key on. Change correspondent injector- do not forget to update the {Cxl} in
Is the problem still present? ECU.
5 Check connection to the ECU. Carry out the repairs required.
© Delphi
2-164 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTICS I
Water In Fuel Sensor

trouble code
P2269 Water in fuel detected None
MIL OFF/ CEL OFF • Engine speed limitation requested.
• Increase the idle target speed.
Symptoms
OC on 9 Water in fuel sensor fault.
SC + on 9 Water in fuel sensor fault - high.
SC - on 9 Water in fuel sensor fault - low.
Water in Fuel Indicator
09 ECU
F2

1 Is there water detected in the fuel? Unscrew the sedimenter and drain the sedimenter of water.
harness.
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I DIAGNOSTICS
Pedal Sensor Fault

trouble code
P2299 Pedal sensor fault (Electrical, pedal stuck). If pedal action is greater than 10% and brake is applied.
Symptoms
• lack of performance.
SC - on 25 Pedal sensor track 1 signal fault – low.
SC + on 25 Pedal sensor track 1 signal fault – high.
SC - on 13 Pedal sensor track 2 signal fault – low.
SC + on 13 Pedal sensor track 2 signal fault – high.
Pedal sensor
Pedal 1 signal
25
Pedal 1 supply (5V)

Track 1 24
Pedal 1 ground
26
ECU
Pedal 2 signal
13
Pedal 2 supply (5V)

Track 2 10
Pedal 2 ground
14
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DIAGNOSTICS I

harness.
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I DIAGNOSTICS
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DIAGNOSTICS I
NON DETECTABLE FAULTS
3.1 List of Faults / Symptoms

These are the faults which cannot be detected by the injection ECU auto-diagnostic function.
3.1.1 Irregular acceleration / deceleration

1 Pedal sensor fault. • Sensor mounting.
• Sensor movement.
• Consistency of the pedal signal (0 to 100%).
2 Drift in rail pressure sensor not detected. Read the rail pressure value when cranking.
3 Intermittent wiring fault. • Injector connectors.
• Rail pressure sensor connector.
• IMV connector.
4 Conformity of engine oil. • Conformity of oil quality.
• Conformity of oil level.
• Oil diluted by fuel.
• Condition of the oil vapour recycling circuit.
• Condition of turbo bearings.
5 Intermittent wiring fault. • Injector connectors.
• IMV connector.
• Accelerometer connector.
6 Fuel problem. Conformity of the fuel.
7 Check the exhaust system. • Exhaust outlet.
• Catalytic converter is free of debris.
• Catalytic converter clogged.
8 Software bug. Download ECU then change ECU if problem persists.
© Delphi
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I DIAGNOSTICS

3.1.2 Engine hesitation
CAUTION
Follow the cleanliness standards during all operations.

1 Is the vehicle out of fuel? • Presence of fuel in the tank / fuel level sender unit /
priming pump.
• Fuel level unit operation.
• Condition of the fuel (petrol, water...) take a sample.
2 • Continuity (cut, blocked,...) of the injector return circuit.
• Pump supply hose split or blocked.
Check the fuel supply circuit.
• Sealing/clogging of the fuel filter.
• LP connection inverted.
• Fuel filter clogged.
• Incorrect fuel filter (reference).
• LP fuel circuit blocked.
• Air leak in LP circuit.
• Pump return circuit blocked.
• Tank sealing / breather.
3 Engine mounting. Condition of the engine and transmission mountings.
4 Check the mechanical and electrical systems. • Alternator charging.
• Battery voltage.
• Air conditioning compressor.
• Automatic transmission.
• Power assisted steering.
5 C2I conformity. Conformity cylinder by cylinder.
6 Sensor drift. • Read the coolant temperature.
• Read the vehicle speed.
• Read the clutch pedal switch status.
• Read the accelerator pedal setting.
7 Intermittent connection fault. Known method (test the connector, wire, resistance,
harness,...).
8 Glow Plugs. Conformity of the Heater unit.
9 Engine compression. Known method.
10 • Injector contaminated.
• Needle stuck.
Injector problem.
• Sealing washer (missing, double or incorrect).
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DIAGNOSTICS I

3.1.3 Engine stop / stalling
CAUTION

1 Check the immobiliser function. Immobiliser function diagnosis (immobiliser and ECU).
2 Immobiliser function diagnosis (immobiliser and ECU). • Fuses.
• Relay.
• ECU earth.
• Harness connections.
• Battery and charging circuit.
3 • Presence of fuel in the tank / fuel level sender / priming
pump.
Check fuel conformity. • Sender unit operation.
• Conformity of the fuel (petrol, water...) take a sample.
4 • Injector return circuit conformity.
• Pump supply hose cut or blocked.
• Sealing / clogging of the fuel filter.
5 • Visual.
• Smell.
Is there an HP leak?
6 Condition of the exhaust system. • Exhaust outlet.
7 Check:
(Using the Delphi High Pressure diagnostic tool (H3PI)).
HP circuit. • The pump.
• The injectors (if stuck open).
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I DIAGNOSTICS

3.1.4 Rushing noise
CAUTION

2 Rail pressure sensor offset not detected. Read the rail pressure value when cranking.
3 Coolant temperature sensor offset not detected. Measurement of the ambient value read.
4 Intermittent connection fault. • Injector connectors.
• IMV connector.
• Accelerometer connector.
5 • OCR control.
• Verification of requested rail pressure/measured rail
IMV. pressure.
• Presence of pollution.
6 Conformity of the injector / engine.
Unsuitable injector.
8 Software bug. Download the ECU then change ECU if problem persists.
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DIAGNOSTICS I

3.1.5 Noise interference
CAUTION

1 Noise on injector. • Injector "buzzer" noise (discharge from the injectors).
• Compare with the actuator test.
• Incorrect injector flange fitting.
2 Noise from mechanical and electrical equipment. • Alternator.
• Clutch.
• Auto transmission.
• Turbo.
• Other.
3 Air noise. • Air filter.
• Condition of the air line (manifold, intercooler).
• Turbo.
4 Exhaust noise. • Exhaust outlet.
• Catalytic converter.
5 Accessories noise. Auxiliary heating.
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I DIAGNOSTICS

3.1.6 Engine knocking / engine noisy
CAUTION

4 Airflow sensor offset. Read the air flow value in comparison with a nominal value.
5 Injector return circuit. Check the conformity of the return circuit:
• Condition of the hoses.
• Condition of the venturi.
6 Glow Plugs. • Glow Plugs wiring condition.
8 • Conformity of the injector / engine.
• Sealing washer on the cylinder head.
• Needle stuck.
Injector problem.
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DIAGNOSTICS I

3.1.7 Excessive fuel consumption
CAUTION

1 Vehicle conformity. • Conformity of the tyres.
• Accessories (roof rack etc.).
• Parking brake.
• Equipment...
3 Check the mechanical and electrical consumers. • Alternator charging.
4 • Injector return hoses cut.
• Pump return circuit cut.
5 Check the fuel quality. • Conformity of the fuel (presence of petrol, water..).
• Take a sample.
6 • Visual.
• Smell.
Is there a leak?
7 Condition of the air inlet system. • Altitude.
• Condition of the turbo.
• Turbo air filter (exchanger, ducts...).
• Conformity of the line.
• Operation of the air throttle (if present).
8 Conformity of oil level. Oil level too high.
11 Injector problem. Conformity of the injector / engine.
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I DIAGNOSTICS

3.1.8 Engine difficult to start when hot
CAUTION

1 Check fuel conformity. • Presence of fuel in the tank / fuel level sender unit /
priming pump.
• Sender unit operation.
2 Check the battery starter. Charging/ battery voltage.
3 Battery or starter US? Replace.
4 • Conformity (cut, blocked, ...) of the injector return circuit.
• Pump supply hoses cut or leak.
5 • Visual.
• Smell.
Is there a major HP leak?
6 ECU supply US? • Relay/s.
• ECU earths oxidised.
7 Condition of the air inlet system. • Air filter.
11 • Rail pressure on starting.
• IMV.
IMV partially blocked.
12 Known method (test the connector, wire...).
Intermittent connection fault.

• Needle stuck.
Injector problem.
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DIAGNOSTICS I

3.1.9 Engine starts then stalls
CAUTION

1 Is the tank dry? • Presence of fuel in the tank / fuel level sender / priming
pump.
• Condition of the fuel (petrol, water...) take a sample.
2 Check the battery starter? Charging/ battery voltage.
Check the fuel supply circuit?
5 • Visual.
• Smell.
6 ECU supply US? • Relay/s.
7 Condition of the air inlet system? • Air filter.
12 CRANK signal lost after starting. Conformity of the CRANK signal (engine speed).
13 • Rail pressure on starting.
• IMV.
Pump problem.
14 Intermittent connection fault. Known method (test the connector, wire...).
15 Glow Plugs. Conformity of the harness/heater.
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I DIAGNOSTICS

17 Injector problem. • Injector contaminated.
• Needle stuck or blocked open.
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DIAGNOSTICS I

3.1.10 Smoke on acceleration
CAUTION

1 Driving conditions. Ask:
• Driving conditions during the phenomenon (town,
altitude, speed, towing...).
2 Driving conditions. Conformity cylinder by cylinder.
3 Airflow sensor offset. Read the air flow value in comparison with a nominal value.
5 Boost pressure sensor offset not detected. Read the boost pressure value in comparison with a nominal
value.
6 Atmospheric pressure sensor offset not detected. Read the atmospheric pressure value in comparison with a
nominal value.
8 Read the OCR value in comparison with a nominal value. Known method (test the connector, wire...).
Intermittent connection fault.
• Line sealing.
10 Engine conformity. • Coolant consumption.
• Oil level (too high).
• Oil vapour circuit.
• Turbo bearings.
• Injector flange fitting.
• Cylinder compression.
• Injector sealing washer / cylinder head.
11 • Presence of water in the filter.
• Conformity of the fuel (mix, quality).
Conformity of the fuel.
• Inappropriate additive.
12 Condition of the exhaust system. Catalytic converter clogged.
13 • Conformity of the injector / engine.
• Sealing washer on the cylinder head.
• Needle stuck.
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I DIAGNOSTICS

3.1.11 Blue and white smoke
CAUTION

1 Conformity of the fuel. • Presence of water in the filter.
• Conformity of the fuel (mix, quality).
• Inappropriate additive.
2 Engine conformity. • Coolant consumption.
• Turbo bearings.
3 Condition of the air inlet system. - Air filter.
- Line sealing.
- Operation of the air throttle (if present).
4 Condition of the exhaust system. Catalytic converter clogged.
5 Glow plugs circuit conformity.
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DIAGNOSTICS I

3.1.12 Black smoke
CAUTION

1 C2I conformity. • Conformity of the C2I.
• Consistency of the allocation / cylinder numbers.
2 Coolant temperature sensor offset not detected. Read the coolant temperature value.
3 Rail pressure sensor offset not detected. Read the rail pressure value.
4 Inlet air sensor offset. Read the inlet air value.
• Line sealing.
6 Condition of the exhaust system. • "Town" type driving.
• Going down a hill.
7 Check using the Delphi High Pressure diagnostic tool (H3PI).
"Drifting" injector.
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I DIAGNOSTICS

3.1.13 Lack of power
CAUTION

1 Vehicle conformity. • Conformity of the tyres.
• Accessories (roof rack).
• Parking brake.
• Equipment...
• Conformity of the pedal signal (0 to 100%).
5 Sensor drift. • Read the flowmeter value.
• Read the boost pressure.
• Read the accelerator pedal setting.
6 • Pump supply hoses pinched or leak.
• Fuel reheating.
7 • Visual.
• Smell.
8 Condition of the air inlet system? • Altitude.
• Leak downstream from the turbo (exchanger, ducts...).
• Air filter (clogged & conformity).
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DIAGNOSTICS I

• Needle stuck.
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I DIAGNOSTICS

3.1.14 Engine does not start
CAUTION

1 Check the immobiliser function. Immobiliser function diagnosis (immobiliser and ECU).
2 Is vehicle out of fuel? • Presence of fuel in the tank / fuel level sender unit /
priming pump.
• Conformity of the fuel.
3 Check the battery/starter. Charging/ battery voltage.
5 • Pump supply hose cut.
6 • Visual.
• Smell.
7 ECU supply US? • Fuse.
• Relay/s.
• ECU earths.
8 Condition of the air inlet system? • Air filter.
• Line sealing.
9 Condition of the exhaust system? • Exhaust outlet.
10 C2I conformity? Conformity cylinder by cylinder.
11 Coolant temperature sensor offset not detected? Measurement of the ambient value read.
13 Cam and CRANK signals missing at the same time. (when cranking).
• CAM signal conformity.
• CRANK signal conformity.
14 IMV.
IMV stuck closed?

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DIAGNOSTICS I

15 Take a fuel sample from the tank.
Fuel quality (presence of water)?

16 Intermittent connection fault? Known method (test the connector, wire...).
17 Engine compression? Known method.
18 Transfer pump US? Measure the pump return flow (if possible).
19 HP pump US? Check using the Delphi High Pressure diagnostic tool (H3PI).
Injector US?
21 Software bug? Download the ECU then change ECU if problem persists.
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I DIAGNOSTICS

3.1.15 Engine does not stop
CAUTION

1 Conformity of the electrical wiring. Conformity of key information to the ECU (short circuit to
"positive" on this line).
2 • Oil quality.
• Conformity of oil level.
Conformity of engine oil.
• Oil diluted by fuel.
• Condition of the oil vapour recycling circuit.
• Condition of turbo bearings.
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DIAGNOSTICS I

3.1.16 Engine dies when moving off
CAUTION

3 Boost pressure sensor offset not detected. Read the boost pressure value in comparison with a nominal
value.
• Brakes stuck.
• Conformity of the air line (flowmeter; exchanger...).
• Catalytic converter "released".
9 • Coolant consumption.
Engine condition.
• Turbo bearings.
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I DIAGNOSTICS

3.1.17 Smell of fuel
CAUTION

1 • Condition of the tank (filler neck; breather
connections...).
Condition of the LP fuel circuit. • Condition of the fuel filter (type; quick release
connections; heater...).
• Condition of the pump (quick release connections).
• Condition of the venturi / fuel temperature sensor (type;
quick release connections; sensor flange fitting...).
• Condition of the priming bulb.
• Condition of the injector return circuit.
• Condition of the auxiliary heating (if present).
2 Conformity of the HP fuel circuit. • Condition of the pump (IMV; limiter; HP pipes...).
• Condition of the rail / pressure sensor (type; thread...).
• Condition of the injector (flange fitting; connections...).
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DIAGNOSTICS I

3.1.18 Exhaust smells
CAUTION

2 Turbo problem. Condition of the turbo bearings.
• Particle filter - catalytic converter clogged.
• Catalytic converter sealing.
4 Injector problem. • Conformity of the injector / engine.
• Sealing washers (conformity, double or missing).
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I DIAGNOSTICS

3.1.19 Idle speed stuck
CAUTION

1 Coolant temperature sensor offset not detected. • Conformity of the ambient value.
• Check the sensor circuit (resistance; connector;
continuity).
• Bleed the cooling circuit.
2 Offset for fuel injected at idle speed. Consistency of the fuel injected (high residual torque).
4 Battery US? Replace.
5 Check the accelerator function. • Sensor mounting.
• Pedal travel.
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DIAGNOSTICS I

3.1.20 Idle unstable
CAUTION

1 Check fuel conformity. • Presence of fuel in the tank / fuel level / priming pump.
• Auto.
3 Battery US? Replace.
4 • Condition (cut, blocked...).
• Pump supply hose cut or blocked.
5 • Visual.
• Smell.
6 Harness not correct . • Relay/s.
• Connections.
11 Accelerometer circuit. Conformity of the sensor tightness.
12 IMV. • Verification of requested rail pressure/measured rail
pressure + IMV parameters (current loop...).
• HP pump US.
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I DIAGNOSTICS

15 • Injector flange fitting.
• Injector contaminated.
Injector problem.
• Needle stuck.
16 Software bug. ECU download then change ECU if problem persists.
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DIAGNOSTICS I

3.1.21 Engine overheat
CAUTION

1 Check fuel conformity. • Fuel quality.
• Conformity of the fuel (petrol, water...).
• Take a sample.
3 Coolant temperature sensor offset not detected. • Conformity of the ambient value.
• Check the sensor circuit (resistance; connector;
continuity).
• Bleed the cooling circuit.
4 Condition of the cooling system. • Fans.
• Harness.
6 Glow Plugs. Conformity of the heater supply.
7 • Coolant consumption.
Engine conformity.
8 Software bug. ECU download then change ECU if problem persists.
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I DIAGNOSTICS

3.1.22 Excess engine speed on releasing accelerator pedal
CAUTION

1 Clutch problem. • Clutch condition.
• Mechanism adjustment.
• Wear.
3 Accelerator pedal sensor fault. • Sensor mounting.
4 Clutch pedal sensor fault. • Sensor mounting.
• Signal conformity (on/off).
7 Conformity of the injector / engine.
Injector problem.
8 Turbo problem. ECU download then change ECU if problem persists.
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DIAGNOSTICS I

3.1.23 Too much power
CAUTION

2 Turbo problem. • Conformity of the turbo.
4 Injector problem. Conformity of the injector / engine.
5 Software bug. ECU download then change ECU if problem persists.¦
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I DIAGNOSTICS

3.1.24 Flat spot on acceleration
CAUTION

1 Condition of the air inlet system. Sealing of the air line (all components).
2 Boost pressure problem. Comparison of the setting and feedback.
3 Pedal sensor fault. • Low pressure circuit.
• Sensor mounting. • Clogging of the fuel filter.
• Sensor movement. • Air leak in LP circuit.
• Conformity of the pedal signal (0 to 100%). • Tank sealing / breather.

5 Engine compression. Compression at each cylinder.
6 • Visual.
• Smell.
Is there an HP leak in the transitory phase?
7 • OCR control.
• Verification of requested rail pressure/measured rail
IMV. pressure.
• Presence of pollution.
8 Condition of the exhaust system. Condition of the exhaust system (catalytic converter).
Injector problem.
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DIAGNOSTICS I
CHECKS
4.1 Description Of The Checks
4.1.1 Electrical supply circuit check

1 Checking the electrical supply: Check the battery charge and Carry out the repairs required.
the correct operation of the alternator:
Is there a charging circuit problem?
2 Check the fuses. Carry out the repairs required.
Is there a fuse problem?
3 Check the correct operation of the supply relay. Replace the supply relay.
Is there a supply relay problem?
Is there a ECU earth problem?
5 Electrical supply circuit OK.
4.1.2 Checking the air inlet circuit

1 Check the air inlet circuit: Check there are no leaks. Carry out the repairs required.
Are there any leaks?
2 Check the condition of the air filter. Replace the air filter with a new component.
Is there an air filter problem?
3 Ensure the inlet manifold is not blocked (contaminated). Inlet air circuit OK.
Is the inlet manifold blocked?
4 Clean the inlet manifold.
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I DIAGNOSTICS
CHECKS
4.1.3 Checking the LP circuit

1 Check the LP circuit: Check the condition of the connections. Carry out the repairs required.
Are the connections incorrect?
2 Look for leaks at the hoses and quick release connectors. Carry out the repairs required.
3 Check the condition of the diesel filter. Replace the filter with an original part.
Is the filter not correct?
4 Check there are no air leaks (bubbles of air in the fuel). Bleed the LP circuit.
Is there air in the diesel fuel?
5 Check the sealing and breather for the tank. Carry out the repairs required.
Is there a tank problem?
6 LP circuit OK.
4.1.4 Looking for HP leaks

1 Check the HP circuit: Start the HP leak detection cycle. Carry out the repairs required.
Are any HP leaks detected?
2 The HP circuit is OK.
4.1.5 Checking engine parameters

1 Check the consistency of the dynamic parameters using the Carry out the repairs required.
diagnostic tool:
• Parameters within tolerances (see table on the next
page).
• Consistency of the parameter value (ensure there is no
drift).
• Stability of the values.
Are the parameters incorrect?
2 End.
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DIAGNOSTICS I
CHECKS
Dynamic parameters Units Min Max Conditions

terminal terminal
Idle speed setting rpm 750 1400 1400 rpm corresponds to limp home mode. The idle speed setting
reduces as the engine temperature increases.
Accelerator pedal The value displayed should be between 0% and 100%. It increases when the accelerator pedal is pressed.
• Typical value(accelerator pedal released):0%.
• Typical value(accelerator pedal pressed):100%.
Coolant temperature The coolant temperature must be between -40°C and +140°C.
Air temperature The air temperature must be between -40°C and +140°C.
Diesel temperature The diesel temperature must be between -40°C and +140°C.
Battery voltage Volt 12 13 Engine off.
Measured rail pressure bar -5 15 Engine off and cold.
The measured rail pressure Engine off and cold. Engine running.
should follow the rail pressure
demand.
Rail pressure demand bar 230 500 during pre-starting and the starting phase.
230 300 Idling, engine warm.
230 1600 During normal operation.
Vehicle speed kph 0 0 Vehicle stationary.
Atmospheric pressure mbar 500 1050
Main timing demand engine -2.5 10 During pre-starting and the starting phase:
degrees
. Note: A negative value corresponds to a retard (after TDC) and a
positive value corresponds to an advance (before TDC).
-3 12 Engine running
Note: A negative value corresponds to a retard (after TDC) and a

positive value corresponds to an advance (before TDC).
Pilot timing demand engine 2.5 17 During the starting phase.
degrees 10 45 Engine running.
Main fuel demand mg/st 5 10 idling.
0 60 Normal operation
Note: The main fuel demand corresponds to the total fuel less the
pilot fuel demand.
Total fuel demand mg/st 20 70 During the starting phase.
0 60 Engine running.
Note: The total fuel demand corresponds to the pilot fuel demand
plus the main fuel demand.
Pilot fuel demand mg/st 1 9 During pre-starting.
0 4 Engine running.
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I DIAGNOSTICS
CHECKS
Dynamic parameters Units Min Max Conditions

terminal terminal
Linearised sensor Volt 4.8 5.1 Normal operation
supply Vext 1
Linearised sensor Volt 4.8 5.1 Normal operation.
supply Vext 2
Manifold pressure mbar 1000 2000 Idling.
Indicated engine torque Nm 40 300 During normal operation.
40 60 At idle
supply Vext 1
supply Vext 2
Manifold pressure mbar 1000 2000 Idling
Indicated engine torque Nm 40 300 During normal operation
40 60 At idle with all functions off
4.1.6 Checking the C2I conformity

1 Read the C2I stored in the ECU. Write the C2I to the memory using the diagnostic tool.
Does the C2I stored in the memory correspond to the injectors? Take care to ensure the cylinder number is correct.
2 End.
4.1.7 Checking the injectors and the HP pump

1 Refer to the high pressure diagnostic section.
4.1.8 Checking the ECU

1 Check the ECU: Ensure the connectors are correctly locked. Correctly lock the connectors.
Are the connectors incorrectly locked?
2 Replace the ECU.
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APPENDIX II
APPENDIX
5.1 Component Location

The diagnostic socket
The diagnostic socket is of the 16 way OBD type. It is located underneath dashboard on the drivers side
Pin allocation:
Pin no. Description

Pin 4 Bodywork earth
Pin 5 Bodywork earth
Pin 7 Line K
Pin 16 Vbatt
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II APPENDIX
APPENDIX
5.2 Wiring Diagrams
5.2.1 Switching on the ECU
WARNING
Before disconnecting the ECU or any other electronic component of the common rail system (valves, sensors,
injectors), wait for the end of the power latch phase (approximately 10 seconds).
When the ignition on signal appears at terminal 19, the ECU controls the supply relay by earthing terminal 44.
When the relay is closed the components connected to the latched supply are supplied with + Bat.
30
15
F1 F2
86 30
K1
85 87
87a
(Latched
Supply)
PowerSupply_1,2,3
19 T15(keyswitch)
44 MainRelay_out
G1 S1
15
50
0 1 2
30
1
3
5
X2
2
4
6 PowerGround_1,2,3
31
1 Electrical Power Supply
S1 Ignition/Starter switch X2 ECU connector (vehicle)
K1 Power Hold relay F1 system fuse (30A)
G1 Battery F2 Instrumentation fuse [15] (10A)
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APPENDIX II
APPENDIX
5.2.2 Ancillaries (vehicle)
87a
F3 15
F2
S1 S2 B1
K1 K2 K3
p
P
22 AirConDemand_sw
AirConRelay_out
Acpressure_vref
Acpressure_gnd
ACpressure_sig
Flame_Htr_Fuel
Flame_Htr_GP
Brake#2_sw
Brake#1_sw
51
29
23
55
49
30
58
39
X2
22
11
21
27
25
24
26
13
10
14
15
34
Clutch#Bottom_sig
AutoCruise_sig
AutoCruise_gnd
Pedal2_sig
Pedal2_gnd
AutoCruise_Vref
Pedal1_gnd
Pedal1_sig
Pedal1_5V
Clutch#TOP_sig
Pedal2_5V
Low_Fuel_input
S4 S6 S7
X5
B2
31
7 Vehicle Ancillaries
X2 ECU connector (vehicle) S6 Clutch switch #1

F2 Instrumentation fuse [15] (5A) S7 Clutch switch #2 (AutoCruise)
F4 Actuator Fuse (20A) K1 AC Relay Drive (wide open throttle)
S1 Brake switch #1 K2 Flame Heater Fuel Valve Relay
S2 Brake switch #2 (AutoCruise)
K3 Flame Heater Glow Plug Relay
S3 AC Pressure Switch
X5 Low Fuel input B1 AC Pressure Sensor
S4 High Electrical Load Switch B2 Pedal Sensor
S5 Air Con demand switch F2 Instrumentation fuse [15] (5A)
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 5-203

II APPENDIX
APPENDIX
5.3 Controller Pin Configuration
5.3.1 96 way engine connector layout (X1)
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Pins Role Pins Role

1 Not Used 2 Bank 2 High Side, Injector 2
3 Bank 2 High Side, Injector 3 4 Bank 2 Low Side, Injector 3
5 Not Used 6 Not Used
7 Not Used 8 Fuel Temperature, signal
9 EGR feedback, ground 10 Not Used
11 Vehicle Speed, signal 12 Not Used
13 Not Used 14 Camshaft sensor, ground
23 Water in fuel sensor, ground 24 Not Used
25 Bank 1 High Side, Injector 1 26 Bank 1 High Side, Injector 2
29 Exhaust Brake, demand 30 Not Used
31 Inlet Air temperature, signal 32 Fuel temperature, ground
33 EGR feedback, 5V 34 Not Used
35 Vehicle speed sensor, ground 36 Not Used
37 Camshaft sensor, 5V 38 Camshaft sensor, signal
41 Not Used 42 Water in fuel sensor, signal
43 Engine Block Accelerometer 1, 44 Not Used
shield
© Delphi
5-204 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
APPENDIX
Pins Role Pins Role

45 Not Used 46 Engine Block Accelerometer 1,
positive
47 Engine Block Accelerometer 1, 48 Exhaust Gas Recirculation, output
negative
49 Bank 2 Low Side, Injector 2 50 Not Used
51 Bank 1 Low Side, Injector 2 52 Not Used
53 Not Used 54 Inlet Air temperature (HFM6)
55 Not Used 56 Coolant temperature sensor,
ground
57 Coolant temperature sensor, 58 Throttle valve feedback, signal
signal
59 Rail pressure, signal 60 Boost pressure sensor, 5V
61 Air mass flow, ground 62 Not Used
63 Boost pressure sensor, signal 64 Not Used
65 Throttle valve feedback, ground 66 Not Used
67 Throttle valve feedback, 5V 68 Glow relay control, output
69 Not Used 70 Air Mass flow sensor, signal
71 Throttle valve output, output 72 Not Used
73 Not Used 74 Bank 1 Low side, Injector 1
75 Not used 76 Inlet metering valve, output
81 Crankshaft sensor shield 82 EGR feedback, signal
83 Boost pressure sensor, ground 84 Rail pressure sensor, ground
85 Not Used 86 Rail pressure sensor, 5V
87 Crankshaft sensor, positive 88 Crankshaft sensor, negative
91 Exhaust brake, output 92 Not Used
93 Not Used 94 CAN, signal high
95 CAN, signal low 96 Not Used
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 5-205

II APPENDIX
APPENDIX
5.3.2 54 way vehicle connector layout (X2)
5 6 46 47 48 49 50 51 52 53 54 55 56 57 58
33 34 35 36 37 38 39 40 41 42 43 44 45
3 4
20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 7 8 9 10 11 12 13 14 15 16 17 18 19
Pins Role Pins Role

1 Power supply #1 2 Power ground #1
3 Power supply #2 (actuator) 4 Power ground #2
5 Power supply #3 6 Power ground #3
7 Not Used 8 Glow lamp. output
9 Water in Fuel Lamp, output 10 Accelerator pedal 2, 5V
13 Accelerator pedal 2, signal 14 Accelerator pedal 2, ground
15 Cruise demand switch, signal 16 Not Used
17 Not Used 18 Vehicle speed, output
19 T15 (key switch), signal 20 Not Used
21 Not Used 22 A/C demand, signal
23 Brake switch #1, signal 24 Accelerator pedal 1, 5V
25 Accelerator pedal 1, signal 26 Accelerator pedal 1, ground
27 Clutch switch #1, signal 28 Not used
29 AC pressure, supply 30 AC pressure, ground
31 Diagnostic, K-Line 32 Not Used
33 Not Used 34 Clutch switch #2, signal
37 Not Used 38 Low fuel input, signal
39 Brake switch #2, signal 40 MIL, output
43 Engine speed, output 44 Main relay, output
45 Check Engine Lamp, output 46 Coolant gauge drive, output
© Delphi
5-206 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
APPENDIX
Pins Role Pins Role

47 CAN, signal low 48 CAN, signal high
49 Flame Heater glow plug, output 50 Not Used
51 A/C pressure sensor, signal 52 Immobiliser, K-line
55 Flame Heater fuel valve, output 56 Not Used
57 Not Used 58 A/C Relay, output
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 5-207

II APPENDIX
APPENDIX
5.4 Resistance Values
CAUTION
It is impossible to measure resistance less than 1Ω using a conventional multimeter. To measure the injector resistance,
use the KELVIN (4 wire) method.
Components Terminals Resistance values

Sensor ECU
IMV Non- 76 (OCR control) 5.3Ω ± 10%
polarised
HSD LSD Cyl
25 74 1
Non- 26 51 3
Injector 180 mΩ
polarised
3 4 4
2 49 2
Pin 1 59 (measurement)
Rail pressure sensor Pin 2 86 (+5V supply) Integrated circuit (resistance cannot be measured)
Pin 3 84 (earth)
80 (inlet air temp earth)
31 (Inlet air temp, signal)
MAP sensor 61 (Mass air flow ground) Integrated circuit (resistance cannot be measured)
85 (Mass air flow signal)
64 (Mass air flow 5V supply)
Diesel temperature sensor Pin 1 8 (measurement) Function of temperature
Pin 2 32 (earth) 2.8 kΩ ± 6%
Engine speed sensor Pin 1 87 (+ signal) 1090 Ω ± 15%
Pin 2 88 (- signal)
Accelerometer Pin 1 46 (+ signal) Piezo electric sensor
Pin 2 47 (- signal)
Pin A 38 (measurement)
Cam sensor Pin B 14 (earth) Hall effect sensor
Pin C 37 (+5V supply)
Coolant temperature sensor Pin 1 56 (earth) Function of temperature
Vehicle speed sensor Hall effect sensor
Pin 2 35 (earth)
© Delphi
5-208 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
APPENDIX

Temperature (°C) Nominal resistance between sensor Resistance tolerance between sensor
terminals (Ω) terminals (Ω)
-20 15,462 ± 8.83%
0 5,896 ± 7.29%
20 2,498 ± 6.00%
50 833 ± 4.30%
80 323 ± 2.90%
120 113 ± 2.80%
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 5-209

II APPENDIX
APPENDIX
5.5 Abbreviations Used In This Manual
+IGN +Ignition on (battery voltage when the ignition is on)

+Bat or VBATT Battery voltage
ABS Anti Skid Brake System
A/C Air Conditioning
Immob Engine immobiliser
Supp. Power supply
AMF Air Mass Flow
APC Accelerometer Pilot Control
LP Low Pressure
Manual Manual gearbox
C.A.N Controller Area Network
C2I Individual Injector Correction
3D Cartography Three dimensional cartographic map
SC Short circuit
SC- Short circuit to earth
SC+ Short circuit to a positive potential
Ctrl Control
OC Open circuit
ECU Electronic Control Unit
EEPROM Electronically Erasable Programable ROM
EGR Exhaust Gas Recirculation
SV Solenoid valve
Gap The gap represents the two teeth missing from the flywheel
Fan Fan unit
Fan 1 Fan low speed
Fan 2 Fan high speed
Diesel Diesel fuel
Hexadecimal 16 character number base from 0 to F
HP High Pressure
US Unserviceable, off
HSD Controlled by the + of the injector control circuit (High Side Drive)
IDE Identification
IMV Inlet Metering Valve
Info. Information
Key off Ignition off
Key on Ignition on
Limp home Recovery strategy which sets the engine speed to 1300 rpm regardless of pedal position. Used
to drive the vehicle to the nearest car park.
Linearised A linearised value is the conversion of the signal sent to the ECU input into a physical value
LSD Controlled by the earth of the injector control circuit (Low Side Drive)
Max Maximum
MDP Minimum Drive Pulse (minimum pulse required for injection)
Min Minimum
NVM Non Volatile Memory
OBD On Board Diagnostic (diagnostics linked to emissions)
© Delphi
5-210 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
APPENDIX
Pedal 1 Signal supplied on track 1 of the accelerator pedal sensor
Pedal 2 Signal supplied on track 2 of the accelerator pedal sensor
Power latch Phase during which the ECU is set to standby after the ignition is switched off
Pmp Pump
PPH Pre-Post Heating
Prail Rail pressure
RAM Random Access Memory
OCR Open Cycle Ratio (%)
PI regulator Proportional Integral Regulator
RN Random Number
A-S After Sales Department
T° Temperature
TCCU Transfer Case Control Unit
IP Instrument Panel
Temp. Temperature
TMAP Temperature manifold absolute pressure
Numerical value This is the output value from the analogue / digital converter
Vext Sensor supply voltage (approx 5V)
Vext1 First sensor supply (5V)
Vext2 Second sensor supply (5V)
VIN Vehicle Identification Number
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 5-211

APPENDIX II
FAULT CODE INDEX
Diagnostic trouble code Diagnostic tool title Page number

P0087 Rail pressure fails to build at cranking speed. 2-15
P0088 Rail pressure error (Over pressure). 2-17
P0101 AMF plausibility fault - Low. 2-19
P0101 AMF plausibility fault - High. 2-19
P0102 AMF sensor fault (Low). 2-21
P0103 AMF sensor fault (High). 2-21
P0104 AMF gradient sensor fault. 2-23
P0107 Atmospheric pressure sensor fault (Low). 2-25
P0108 Atmospheric pressure sensor fault (High). 2-25
P0109 Atmospheric pressure sensor fault (GRAD). 2-25
P0112 Inlet air temperature sensor fault (electrical) S2LO. 2-27
P0113 Inlet air temperature sensor fault (electrical) S2HI. 2-27
P0115 Coolant sensor fault (global = electrical OR plausibility). 2-31
P0116 Coolant sensor fault (plausibility). 2-29
P0117 Coolant sensor fault (electrical)LO. 2-33
P0118 Coolant sensor fault (electrical)HI. 2-33
P0119 Coolant sensor fault (electrical)GRAD. 2-33
P0120 Pedal sensor track 1 supply – triggers limp home mode. 2-34
P0122 Pedal sensor fault (electrical, track 1)Low. 2-36
P0123 Pedal sensor fault (electrical, track 1)High. 2-36
P0182 Fuel temperature sensor faultS2LO. 2-38
P0183 Fuel temperature sensor faultS2HI. 2-38
P0192 Rail pressure sensor fault (out of range or ADC or vref) Low. 2-40
P0193 Rail pressure sensor fault (out of range or ADC or Vref) High. 2-40
P0194 Rail pressure sensor fault (out of range or ADC or Vref)DROP. 2-40
P0201 Open circuit fault (Cylinder 1). 2-42
P0202 Open circuit fault (Cylinder 2). 2-44
P0203 Open circuit fault (cylinder 3). 2-46
P0204 Open circuit fault (cylinder 4). 2-48
P0216 Current too high on cylinder 1 & 3 (bank 1). 2-50
P0222 Pedal sensor fault (electrical, track 2) Low. 2-52
P0223 Pedal sensor fault (electrical, track 2) High. 2-52
P0236 Manifold pressure sensor fault (Plausibility). 2-54
P0237 Manifold pressure sensor fault (Electrical)Low. 2-56
P0238 Manifold pressure sensor fault (Electrical)High. 2-56
P0245 Turbo actuator drive fault (Signal) SC2G. 2-60
P0246 Turbo actuator drive fault (Signal) SC2 Vbatt. 2-60
P0251 IMV drive fault (electrical) SC. 2-58
P0253 IMV drive fault (electrical) SC2G. 2-58
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 6-212

APPENDIX II
FAULT CODE INDEX

P0255 IMV drive fault (electrical) OC. 2-58
P0263 Cylinder balancing fault (cylinder 1): injector is stuck closed. 2-62
P0266 Cylinder balancing fault (cylinder 2):injector is stuck closed. 2-64
P0299 Turbo control error on boost pressure fault. 2-70
P0325 Accelerometer decode fault(signal / noise ratio too low at idle). 2-72
P0335 Crankshaft signal fault (signal lost). 2-74
P0336 Crankshaft signal fault (gap lost). 2-75
P0337 Crankshaft signal fault (engine speed lost). 2-76
P0340 Camshaft signal fault (missing event). 2-77
P0341 Camshaft signal fault (CAM not synchronised with CRANK). 2-79
P0371 Crank signal fault (Edges too close). 2-81
P0372 Crank signal fault (missing tooth). 2-82
P0380 Flame glow drive fault. 2-83
P0400 EGR Control error on airflow. 2-84
P0489 EGR actuator fault SC2G. 2-86
P0490 EGR actuator fault SC2 VBATT. 2-86
P0500 Vehicle speed fault (global). 2-88
P0501 Vehicle speed sensor fault (plausibility). 2-89
P0502 Vehicle speed sensor fault (signal lost). 2-90
P0503 Vehicle speed sensor fault (Speed too high). 2-89
P0562 Battery voltage monitoring fault - low. 2-92
P0563 Battery voltage monitoring fault - high. 2-92
P0571 Brake signal fault error. 2-94
P0606 DCU watchdog fault. 2-96
P0642 5V supply 1 faultLow. 2-97
P0643 5V supply 1 faultHigh. 2-97
P0646 Air conditioning drive fault SC2G. 2-99
P0647 Air conditioning drive fault SC. 2-99
P0650 MI lamp fault. 2-103
P0652 5V supply 2 faultLow. 2-101
P0653 5V supply 2 faultHigh. 2-101
P0685 Unexpected state of main relay (high). 2-104
P0691 Electrical fan drive fault (Type 1)SC2G. 2-105
P0692 Electrical fan drive fault (Type1) SC. 2-105
P0693 Electrical fan drive fault (Type2) SC2G. 2-106
P0694 Electrical fan drive fault (Type 2) SC. 2-106
P0698 5V Sensor supply Vext 2 aux fault Low. 2-107
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 6-213

II APPENDIX
FAULT CODE INDEX

P0699 5V Sensor supply Vext 2 aux fault High. 2-107
P0704 Clutch switch electrical fault 2-109
P1100 AMF sensor fault (Vext). 2-21
P1101 Generic atmospheric pressure signal fault. 2-111
P1105 Atmospheric pressure sensor fault (Vext). 2-25
P1107 Atmospheric pressure sensor - Global atmospheric pressure fault. 2-112
P1110 Inlet air temperature sensor fault (electrical) EX. 2-27
P1115 Coolant sensor fault (electrical)Vext. 2-33
P1120 Pedal sensor fault (electrical, track 1)Vext. 2-36
P1121 Pedal sensor fault (triggers reduced torque mode)(2>1). 2-114
P1123 Pedal sensor - correlation between track 1 and track 2 Pedal 1 over 2. 2-113
P1171 Cylinder 1 - MDP absolute below the minimum limit. 2-115
P1180 Fuel temperature sensor faultEX. 2-38
P1190 Rail pressure sensor fault (out of range or ADC or Vref)Vext. 2-40
P1191 Rail pressure sensor fault (out of range at key-on)Med TEST. 2-123
P1192 Rail pressure sensor fault (out of range at key-on) low. 2-123
P1193 Rail pressure sensor fault (out of range at key-on) high. 2-123
P1201 Short circuit HSD to LSD (cylinder 1). 2-125
P1216 Current too high on cylinder 2 & 4. 2-133
P1220 Pedal sensor fault (electrical, track 2) Vext. 2-52
P1223 Pedal sensor - correlation between track 1 and track 2Pedal 2 over 1. 2-113
P1235 Manifold pressure sensor fault (Electrical)Vext. 2-56
P1236 Manifold pressure sensor fault (Electrical)GRAD. 2-56
P1237 Manifold pressure sensor fault - low. 2-135
P1238 Manifold pressure sensor fault - high. 2-135
P1253 Rail pressure control (loop activation/pressure error too high)NEG. 2-137
P1254 Rail pressure control (loop activation/pressure error too high)POS. 2-137
P1256 Rail pressure control - trim low and fuel low. 2-140
P1257 Rail pressure control - trim low and fuel high. 2-140
P1258 Rail pressure control - trim high and fuel low. 2-140
P1259 Rail pressure control - trim high and fuel high. 2-140
P1286 Cylinder 1 - resistance too low. 2-143
P1287 Cylinder 1 - resistance too high. 2-143
© Delphi
6-214 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
FAULT CODE INDEX

P1325 Accelerometer functional check fault. 2-146
P1380 Flame fuel drive fault. 2-148
P1560 Battery voltage monitoring fault - ADC. 2-92
P1571 Brake light signal fault (safety). 2-149
P1572 Brake light signal fault (light). 2-149
P1600 ECU watchdog fault (watchdog trip) Noise injector shut down. 2-150
P1601 ECU watchdog fault (watchdog trip) CPU-CPU clock. 2-150
P1602 ECU watchdog fault (watchdog trip) TPU-TPU clock. 2-150
P1603 ECU memory integrity fault CODE INTEGRITY. 2-151
P1604 ECU memory integrity fault CAL INTEGRITY. 2-151
P1605 ECU memory integrity fault RAM INTEGRITY. 2-151
P1606 ECU non volatile memory fault CAN, KW. 2-154
P1607 Internal ECU fault. Watchdog injector shutdown fault. 2-152
P1608 ECU watchdog fault (injector unlock during start-up). 2-153
P1614 ECU non volatile memory fault C2l, MDP. 2-154
P1615 ECU non volatile memory fault RP, PL, STE. 2-154
P1616 ECU non volatile memory fault WDOG. 2-154
P1617 ECU non volatile memory fault SMC. 2-154
P1620 ECU non volatile memory fault ICV, Inj. Cnt.. 2-154
P1621 ECU non volatile memory fault FM. 2-154
P1622 ECU non volatile memory fault APP. 2-154
P1641 5V supply 1 faultADC. 2-97
P1646 Air conditioning drive fault OC. 2-99
P1650 Check engine lamp fault. 2-155
P1651 5V supply 2 faultADC. 2-101
P1678 Glowplug Drive - open circuit. 2-156
P1679 Glowplug Drive - short circuit. 2-156
P1680 Glowplug Drive - short circuit to earth. 2-156
P1681 Exhaust break drive fault. 2-157
P1685 Main relay unexpected high/low state. 2-159
P1691 Electrical fan drive fault (Type1) OC. 2-105
P1693 Electrical fan drive fault (Type 2) OC. 2-106
P1697 5V Sensor supply Vext 2 aux faultADC. 2-107
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 6-215

II APPENDIX
FAULT CODE INDEX

P2147 Injector bank 1 fault (shorted to ground or to Vbatt) - LOW 2-161
P2148 Injector bank 1 fault (shorted to ground or to Vbatt) - HIGH 2-161
P2150 Injector bank 2 fault (shorted to ground or to Vbatt) - LOW 2-163
P2151 Injector bank 2 fault (shorted to ground or to Vbatt) - HIGH 2-163
P2269 Water in fuel detected 2-165
P2299 Pedal sensor fault (Electrical, pedal stuck). 2-166
© Delphi
6-216 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
NOTES
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 7-217

II APPENDIX
NOTES
© Delphi
7-218 DDNX332(EN) - Issue 1 of 07/2008

APPENDIX II
NOTES
© Delphi
DDNX332(EN) - Issue 1 of 07/2008 7-219

II APPENDIX
NOTES
© Delphi
7-220 DDNX332(EN) - Issue 1 of 07/2008

Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range.
All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais
la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd poursuit un programme intensif de conception et de développement qui
peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd se réserve le droit de modifier les spécifications, sans préavis et si
cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits réservés
Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique,
mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.
Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein fortlaufendes Design-
und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produktdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne
Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem
gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopieren, Aufzeichnen oder auf sonstige Art,
übertragen werden.
Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per eventuali
imprecisioni.
Delphi Diesel Systems svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto. Delphi Diesel Systems si riserva
il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini di assicurare le prestazioni ottimali dalla sua gamma di prodotti.
Tutti i diritti riservati
Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo, elettronico,
di fotocopiatura, di registrazione o altro, senza la preventiva autorizzazione di Delphi Diesel Sistems Ltd.
Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd no acepta ninguna responsabilidad legal
por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd se sigue un programa intensivo de diseño e investigación el cual podría
en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd se reserva el derecho de alterar las especificaciones sin
notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.
Todos los Derechos Reservados
No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,
grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.
Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd, não pode aceitar qualquer
responsabilidade legal por inexactidões. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura alterar
as especificações do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario para
assegurar um desempenho óptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desta publicação pode ser reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

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(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung!

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Produced and published by:

DDNX332(EN) - Issue 1 of 07/2008 i

1. DIAGNOSTIC TOOL FUNCTIONS

ii DDNX332(EN) - Issue 1 of 07/2008

DDNX332(EN) - Issue 1 of 07/2008 iii

iv DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS

1.1 Reading The Fault Codes

1.1.2 Environmental data

Variable Definition Units

DDNX332(EN) - Issue 1 of 07/2008 1-1

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1.2 Reading Dynamic Parameters

Note: Some variables can be represented in three different ways:

1-2 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS

(e.g: gross atmospheric pressure, gross air flow,

1.2.2 The linearised value

1.2.3 The physical value

1.2.4 List of parameters

Variable Definition Units

DDNX332(EN) - Issue 1 of 07/2008 1-3

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

1-4 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX332(EN) - Issue 1 of 07/2008 1-5

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

Note: Positive = Before TDC.

Note: Positive = Before TDC.

1-6 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS

Variable Definition Units

DDNX332(EN) - Issue 1 of 07/2008 1-7

DIAGNOSTIC TOOL FUNCTIONS

1.3 DCU Identification

This service is used to identify:

DCU identification Meaning

1.4 Actuator Control

Output Verification conditions Normal consequences on the system

To select an actuator, observe the following procedure:

1-8 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS

1.5 Aftermarket Management Of C2I And Programming

1.5.1 Definition of C2I and programming

DDNX332(EN) - Issue 1 of 07/2008 1-9

DIAGNOSTIC TOOL FUNCTIONS

1.5.3 Replacing a DCU

1-10 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS

1.5.4 Replacing the system

DDNX332(EN) - Issue 1 of 07/2008 1-11

DIAGNOSTIC TOOL FUNCTIONS

Follow the diagnostic procedure below:

1-12 DDNX332(EN) - Issue 1 of 07/2008

DIAGNOSTIC TOOL FUNCTIONS