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ABONNEMENT GMER E F . N o X M 1 4 6 - - 0 0 / 9

.,

AI B ,O S C H V P 3 6 M S A 1 ( . .K S ) U L

I I N , J E ' C IONO t . . Ip e r a I n g p r l n c l p eD i a g n o s i s

..

MAN 158931

AUTOMOBILES CITROE,NDIRECTIION COMMERCE EUROPEDOCUMENrTAT ION APIRES VENTE

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CONTENTS

A~RANID FUEL SIUPPlY -- SUPIERCHARGINGP RIESEINTAT!O N : B O SCH V P:;.ij M SA til FU E : l !NJ EGT~O N _ .. , __ ,. . . . . . . . .3 ,FUNGT1ION~LOCATION: GOMPON E.NT,s ,O F 'THE SYSTEM - -, _. _. r.' - 6OPEIRATINGI PRINCIPLE: BOSCH V1P36,MSA11 FUElllNJIECTION __ _ _. , . 116D.ATA : B O SCH V P36 M SA1 iFUE lINJEG 'TI'O N - - _ . _ - - . r " ,. , " , e 22REPAIRS: ISJOSCH VP36 MSA11 FUEl. ~NJE:CTION r , __ ' 24FAULT F ~ND~NG : 180,se,"" , VP36 MSA 11 [FUEL IINJIECTIO N , " ., __ .._ 26

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A IR : A .ND ' F UEL SUP'PlV - SUPIERCHARGING

PRESENTATION: BOSCH VP36 MSA.1 '1 FUEL INJ IECTIONI1 - PREAMBLEEngine , D K5 ATE i r : l C L ' J . r p o r , a t t e s an '91,~ctronicm a na ge ,m e ra t o f th e in jec!t ion.Adv a nila .g e s o f th e e le c tro n i e m a F t la g E H T lH ~ r i f t : to, comply with th e amiss 1 01 I s tandardsit to impro\i ' \~ the d r i l v e l t l a b iity to ' f J 6 !CUOO censum pt~on.. and opti m iEH~engine 1,)8 rforrnanea

2 .....PRESEINTAf l lONMaln parts constituting t~e system : the ' u n j 1 9etion p u m p" the ' rn jad&o~ E .G . U .

2~1- Injie clioln pu m pThs soseH i1 naction pu m p of the V P3 16 type t Sderived from fh e VE type BO SCH pu m p;The pump m i 8 J j n ~ y ' contains:.' th e' e lliesl,1 'fu !ill 'flow a I ' s c t : n i o a l l ae tua te r (i t replaces:load I s , v 1 3 r~ rods! s p rl n g s ) a n oE IIsd mva hf9 fo r the oontr1oll o f ~njedt io n a d l v e u 1 0 9

2,.2 - In,ieclioln e le c1 ro nic 'co ntro~ u m i tThe, BO SCHI M SA 11 type' E ,.C . U _ checks e ledlricallyth e foil lowing com pone nts :' . i i n je otlo n p u m P ''. ellednJvawe fo r 'tlh e c on tro l of th e E ! H d 1 a . u S ~ . gasr e c i/ e U r n g 'valve pre and pcs1=hea t~n 9 00m l t n ) 1 u n~tThe EC U : 8 1 9 nds the signal :" e n gine spe ~ d l :;:::;:;;> ins trum 9,nt 'c lus t srit ins tantaneous, o o n s ! ! . i ! rnpf ion .:=.:=>, tflip com P l J ~ a r 8 J i r con. :switc:h~o"The E C ~ softw are in te g lra te s :'. the paramete rs ne ce ss ary to check ilnjection andsmiss io 1 1 co ntra Is. , ' th e drl i \ feabi IiW stmtag ias'. th e 'flJlllicti ons of the cru is ,s,acmtral,iii '~heooded am i th e ,H tu n otio n'. th e a 'm a r ge ncy s tra te gie s'. t.h e diaglrlostic with malmo risation o f f , a u 1 lt C O d E H ~ :; there a di n 9 1 is ,c arrie d o ut by mSSJr lS of E r . J T tes t unit or, SOU F i IAU atation

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AIR AND FUEL SUPPLY' - SU'PERCHARGING

3 - SYNOPTIC V~EWO'F INJ 'EC:TION

r " " " I r"""I+' 1 I2~~ ..t /- ~"~

4

17o5 24 'm E - J l o f t - l t1 - I ~ I ' - -1x36

,,,8 , = - ,9

IEUIT10 - , so U IR I A !U I 126A/1r-.',. '",: . . . . . . ...,

21 3 1 1:1. :2 . .3 C-, . . . . . . ~ ~II. .,4 s 1 5-;- .- . . . . . .--1 -: : . , II ' " 5 1- . . . . . . -l' ~I ~ ~ r : . . . : . - r- ~.', -_ , - - - - . - -16

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AIR AND FUEL SU IIPPLY - S IUPEACHA IRG IING

Fit}; IS ;HPOACPPa rts lis t :I Code Componen t I Coda Component

1 Batta'ry I 16 C lu r tch comad swi tch'2 Ig i n i tt i0n sw itc h 17 Inject i on e h~c tr on ic con tro l IJ t1 I it . . -a t rnosphe ru e press u rs 'sa nsor:3 Double injradio,n re lay I 18 Refrigerat ion compressor C\Jt-of f: re~ay4 Aooo Ie ra t er p e da l s e ns or 19 R afiTige raton com p re s s o r c lu tc h5 I TDe sensor 20 Prr@a nd pos t . ..hea t i ng control un iit6 ~n jec1orcarrier l f IumberJ 21 P re - h e ate r I P l u g s(injector w ith ne edle 1 0ftsensor)7 Wate r ' t e 1 m p E : H " a t u l r e , s e ns o r 22 Ptn8,heal ing 'w8lrning la m p I8 Airr trs m p era tu re s e ns or 23 Injwt i0n pum p9 Pre 55u r e s en so r 24 I inject,ors

I 10 Distance's ins e r 25 RrEu:: ; ,yclng 9 1 ac t rova lvsI

A Air cond iti on in g fu n c ti on ,2 6 E xhaust 9 as r r E H , ; y , c ~ i n9 valve11 Avroond it io,ning sw itc h (AC O N). 27 D r . 8 . g nestic w,arning I l a m p12 f'n - e s s o s t a . t : (A C TH ) 28 l achome tEH'B Cruise c o m n ) 1 1 funct ion 29 D ia g n os tlo s o ck e t13 C ru ise co r n t n J l 1switch 30 I Trip compute r1 1 4 Cruise c cn tro l s sls cto r s w itc h 3 '1 Coded a .n ti- the ft k eyi boa rc J1 5 Stop l a m p swi tch

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AIIR AND FUEL SUPPLY - SUPERCHARIGING

F'UNC,'TIO IN ... ..LOCATION: COMPO INE INTS 'O F THE SYSTEMl1 - DOUBLE RELAY'1.,' =Locatten

IF'~I B' i i IHlP09XCloca t,e d : on th e Ft..H , fro nt w h ee l a rch .

1 .:2 ~ F un ;c1 io n'Thedouble re lay enables : t~ e su pp ly of th e inje e tle n E C U the illumination of the pre-healing \l'lfarning lamp,co.ntroUed by the I ir lj ec tion E :. C. U .

2.1 - Location

h ijJ ; 1 8 ~ H P I l ! !i ! CL oca te dl : on th e s cu tU.e pane l a p e rtu re ,! n e xt to th elHM re se r vo ir .

2.,2-lFunclionThs se n s or :, re cords 'th e drive,r~s r eques t (acoelera t ion,decelaraJt ' ion} s en ds ~ nfc ,rma tio n to, injection E auThe, injection ECU act ivates the inject ion pump.ro no 'Mng th e d r i v " 8 l r 's rs Q u a st.

2 .3 , - Cons tl'lU JUonTh e s en sor is li nk sd to th e foot t h r o 1 i t l e peda~b y meanso f a c a lb :l e I it comprise.5, tine f , o l i l o w i ng com p o n s ' n t s , :'. a pote n tr,om e te ,r o f w hich th a i resistance var iesprcportl 0nnafry.with t~e pos it~ on o f the 'foot ' t i t u o . t l I : ( l epedaJl,. a contact w i th 2 p os itio ns ( fo ot ,o ,fflfo ot o n )The oOr l t ad enab l e s th e E CU to ch eck. U1S 'vaJfd! ty O 'fth e imorm'at ion supp l i ed by the, pote ,n t iomets f ( theco ra te d is ,0PEH"I wnen th e pada l is re l l eased) ,

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4 fti NEEDILE l~IFTSENSOR

AIR: AND' FIUEL SUP'PlV - S,UPEIRCHARGING

3" 1 =Locat ion

Fig: 8 1 H PD9ZCL oca.te d : on the cl u tch h ou s i n g l _

9.2 ~ Fu rneUo Iiiliha : S , S ' n l so r is of the' ifl:dUldliv~'type.The sa nse r SIJPP l ies the ECU w ith a signal l a i 8 l , c h timee8CJho f th a 4 \ pe g9,. w h tc h are d is po se d 8 !t 90 g on th efllywh e e l, p a ss .Each ~mpu l s e is produoed ; 5 , Q aite I i " ' ~ h e top de ad C E H " I l ' 9 1 f '(TDO) .T he ~ iig na J snab l1es ,to de te rm i'ns :.. engl~ne rpm.' position ,o f the rEIci proca tllng gSlarNO TlE : The airg a{P bef !N9sn , t he SEmS ,O ' r ' and th e' f l ywhee l \ ; pegs can 't be ~dju sted.

,4 .1 1 - L ,oca t IonTh e se nsor li s in r tsgramd i n t o i nL9dc r ca r ri e rrnu mba r : 3 -

4.2 - Fun CUD nFH)m the :9 S ns er's ,a cti o rii II the E . - G , U. : ceterm ines prec ise ly the beg i F I ning af the in ject ion ca rri 6'S ou t a dyna m ica l c orre ctio n o f the injaGti 0 f' 1advance

4,.3 =Co'o otJ ituUo n

d

F ~ ; B ~ I -l POM I! CInjector canj '. e r n L . I I mbe r3 :'. a : spring b ~ inJector ne ed h i c : m agne t ic core.' d : i'gn~lioncoi l'Ie : :2-w ay conn e ctorThe S~nso r is of: 'the ~ndu dive t ype .'T h e in je c to ll'is n e e d le ls ,e)(j iendreci bV a ccrs .W h e -H 1 th e Ii nje,cto r O pEH'iS : the GO ra c ha n g as ib pOlS i r t i onin th e ce ll ; it creates a m ad ii fi ca ti on of th F 3 mag net lcfisld.,T he , va ria tic n of th 9 magnEtl i C fie lld g e ne r,a te s a curro n tdetect ,sd by th e E .CU_

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5 - W ATER TEM IPER 'ATURE SENSO R5.1 - I1..,Qcarl ionLoca te d : on th e w a ts r outlet hou:s in g,

5.2~ FunotionThe w ate r temp6l l latuH3' sensor infoli l l1s the E .C ,U .abou t th e er1lg~ne coolant t empera tu re ' .Following the t,sm pe r,a tu rre ! th e E .C,U_ ~ adjusts t he , p re-bsaf ng l ti m e adjusts the p os t-h e atin g t'i'm e a dju s,ts t m e starting 'f!ow. . a d j us , ts the iidli'ng speed pe I"m jts ths recy'cl l~ng of exhaust ga.ses. , a d Jus ts th e diesel fuel flow. ' lim its th e 'fuel] injed.lad f low' i f th e temperature o f th eiQoolililQ flu id is c ritic a .l ( ov e rh e a tIn g fu n ctu on )S.3 - Corns1itui l ioi l l iTh e sensa r Inch Jde s a res~ s tQ r o f the NfTG type l(n ega tive te m p e rature coe ff cie nt re s istancs),T~e mer 's the , temperatu re incrsasesI the m ora it srasistencs va lue is reduced.

1 6 - A IR TEMIPERATURE SEINSOR6~1=Locartion

F~ ; ~1H PO A1 CL oc a.te d : o n the a i'l f m l e t d u c t,

6 ,,2 - F u ne llonTh 9 a i I f te m p s ra tu re sensor informs ttl e EC U about th et9 m pe r,a .tu r9 ' o f the a ir ta ks 'n ln .'This mnfoll'mation E H l " I a b l e ' s th e dre ss l 'fu el ftow to beBldj 'usted.

6 .3 - C 'o nst itu tiio nThe sensor ino ludes a re s is tor of the eTN! type(negative te m pe ratu re , coeffici'e nt r'9S Is, lance).The more th e te m p e ra tu re increas. ,es. th e m ore its ,res istancs vaus is reduced ,

7 ,~ P IRESSUR 'IE S,ENSOIR7.1 - Location

~li ;I : 6 "1HPOJ! !EL 'oca te d : on the , scuttre pane l apertu[ 'e, . nex t to ' the,L H M rsss No~r.

7~2 '_ , I Fu ne t ionThe sensor enables the, air pressure in the inletma_n~fold lo be , dete rmin ad,Th is imorm,at l ion enab l e s the adjustment O 'f the d iese lfuel now .

7.3_ ConstitutionThe sensor is. of 'the. pt8zoeledrica.l type, n lisGO m p os sd of a tre ss gaug as.t t 5Ulppl1es at vo~~a.geptOport io f ' !a~ to the, a ir pressu re inth9 ~nle t manifold.

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10 ~,PRE AND POST~HIEATINGCONTROL UNIT

AIR AIND FUEL, SIUPPL Y - SUPERCHARGIN 'G

8 '_ATMOSPHER~C IPRESSUR'IE SEN'SOIR8.1 - Location

oo BOSCH 0r-

o

Fi~ : EJ1lI"D.~C:T he s en so r is COIJp la d '~Oth e, i nj sctic til E .c.U ..Et2 ~ F w ncUonTne sensor unforms the' E C U a bou t ~ha atmosphs ri cpm sslU re ; this parameter is used to determ i ; r r ' l 9in jedeorl advance.9 - VEIHICLE SPEED SIENSORt1- L O c a t 1 1 o l l 1The 51 9 nsor in located on the gearbox.

9 ,,2 '- F u n e tic ,"Th e se nsor i'lnforms th e E . C.lJ . o f th e spee d of ' ~h e ,v9hich~i!' ,t~~s c o:mpon6,n t lis a I:!lHall eHec f ' type sa nsor,5 impu~s9spar meter , 8 , ~mp l Js IS, pG F reve l ut ien.With the ~nformatlon from tha sensor" th6 E,CU : im p roves the ~d116speed of th e v e hic le in mati on optimises th e aoos li e rations' . r e d !l . ! l0 8 s , j e rk s'. e n su re s th e vehic le o ru is e , con~ ro "

10.1 _, LoeaUolillocab3d : at the' front of the, batta ry tray.

1CL2 -= Fu nc1 :lo nThe' control IU r ' I ' i t e1\3C1lFi~al l~t6u'pp~i les tha p rs - h aa ta rIPlugs In p a l rs accoM~ngo th e orders from th e in ject io r1 IE ,C _ U . .1 1 1 e , pre-heating ,a nd p as t-h e atin g tirnas ,aredeterm ined by th e E CU in a cccrdsnce w ith the eng'il i l i j icoolant tam perature _Th e pre hs a.ti 1 1 9 warrr l i tlig l a ! m p is co n t r o l l s d by thein je otion E CU via th e dou ble m la ,y .Th 9 control u tJ 1 it ca n dete ct th e fallIIu ra of a plug {shortci rcuit" btreHlk: iin 00 t i l t i l1uity} I a fauH code ~s the nm em crlse d by th e E ,.G .U.,

1 1 - IN JECT I'O 'N ELIECTR ON tcCONTROL UNliT1 '1 ~1 _ , L , oca iUonLocated : in 'the EGU hou sing.

11.2 - FlUn,ct~onThe E.cU ens ures ,th e e Iact rical checks o f th e fo ll ow i nge ~em !9!nts, :: - inie di o r1 I pu mp" so Ie noid ' V a . I V i 9 fo r the co ntr() l l a,f '~he' exhaust gft!;;.rec.ydJ ng v , a l v 1 eII! prs a nd p os t-h eatt ingl COntrol L !I nitT h e , E .C U sB,nds t h e s 1 9 n a J ; e ng Vrli9 sps e d ! ! ! ! ! ! ~ > , instru m e m d iu ste r'. i 'n s ta n ta n eo lJ s eons IJ mption =~> trip co mplWt@r'. a i r 00n, switch;-offThe IE : CU I :5 'Omtware ime gra te s :.. th e' p aram e !s ll'5 n ie ce s ,s ,a ry t .o check, ~,njection andam i ~ ' S ion cont F O r S, . , ' the drivraabmty stra~egr8 's ," the fundic ns of t he c ru ise con~rd tha coded a n t - it h e f t func~ion the 9'merg ency strat~91~9~5, th le d ~ agn e stle w ith melmonlsat io n of faun cod as : the 'm ad ll i1 g is c arrie d oot by m ea ns 'of ELiT tsst un it o rSO U R IAU 26 A station

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AIR' AIND FU:EL SUPPLY - SUPERCHA,R'GI ING

11.3 =Descri pU o n

I

1 2,.2 - F u n ctlo nTlhe E : .G .U . cornrols th e op~ ration of the alactr'Qrv,alva.line eledraviBJlve links the vacu i ! J I m pu mp a l i i i d t~ ee . )( haus t , g~s f -soycl i F t l g vaJve capsu~e (EG R valv~).The r,ecycl iiiilg is of th e ilaJ~0 r nothing" type.When the ,8 led r,ova~vals su~;r~ilad I the exhal lJ ls t ga;sl86a re re c-yded,INOiE :Ths electr ica l typ9 varuum pump is located atth e, front of "th e R, i F ! , ' front 'wns e la reh

1 ,3 ,- INJ EC TIO N PUMPThe, in ] ec: t~onpump snsu res 3 flu nction s, ~ th e pumping of t~e f ue l1 1 th o m 9 te ri ing of the' f U i , 1 th e dli,s,t~iburtia~ of ' t~e f l u a , ~Pump~ng and d~stributjono,f '~h8ue l a . r 9 , ca rrie d ou t a son a pump of the VE type.Th e fu e l mete ~Ing is can'i ledl ou t v ia th e ru911 Ul:!lWactuator.

o '80SCIH 0'I1

Fig : '1901Hf:t ]!~GT he E 'cU ill1 du ds 's ,: 1 55--w,ay c o : n n e . c t o , r'I! 1 311mosphsric pr '9ssu re sensorIi3 microrm:x:::essors,

112,- RECVCLINIG E,LECTR.OVAlVIE

/ wFI!,;I; E l i ; HPraA!Clocated: o n the engine (near the ,e I1 ig~ile o l I :' fi ll e r neck) _

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AIR: AND' FUIEL SUP 'P IL V - SUP'IEFlCIHIA.R'G~ING

'113"1_,Descrliptilon

P ia l ; 8 1 H l P i1 lA f .O1 : r~gullartit lIg s~~devalve position sen 5. jn9 59nSOL: 2 : ' fu~1 low actuator .3 : h ig lh I P re s su re p is to n.4 : adlvarilce aladroval V9 _S : regulat ing slide valve (sliding b~ook')e : cam plate.7 : rol ler b-ea ri rng r ing"a . : t ran~d91 1"pump .'9 : electric ' f l U 8 1 cut=of solenokt1 0 : advance pist-on.11 ::d ies.e I ~uQI '~@mperatUiresensor,The, ;QlectricaJl ~nm lJ"m atio,nof the injection p um p g o 'th ro l!lg lh a 7 -w a .y black KOSTAL type round oormsetor.Th e, con ne ete r is 9Mched to th e w i ri ng ha rness of ttl e ~ nje ction pu m p ;.I'oca~ion: nsxt to til6 E.G,U - h ou sing.

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AUR AND FUEL S,UPPLY - SUPERCHARGING

12 1 1 5

13F iU :91 l 'l lPO , !\ "C'1 2 : in je ction p u m p ,13 : pu m p e on n ecto r,14~connector of the advance electrcvalvs.1 S : pu Imp w i fing barnsss.

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AIR AND FUEL SUPPL Y _ .SUPER'CHIARGI1NIG

1 3 .2 _ . IF u e l flo w actua tor13.2~1 - ~uru]'i(JfJTh e ~ Iow a ctu etor replace 5 the m gu lator IU In it 'fo rm ee ha ni ca l iI 'lD9C!ion pu mps I it regulates the ' f!ue l f lewi 'nJ~cted.It lis CO:rltroll '@d by the i I 'l Ij e ct :i o n E . C.U. (variab~e eye l lcrattr.orunG F l I t ) . .

F ~ : ! 3 1 IH P !! iA B D1 6 : :5 '0+9 ne ld .1 7 : p erm a ne nt f().t.ary Imagns, t (o n th s a xls ).1S : c on ne ctio n a .x~ e .191 : r e ' Q ' u I ls i n o n s Iid,s valve.Th e flow a ctu a tor ~ sco m p ossd of th e 'fo llow i n g e om p on 9 n ts :.. a rotary mag ne t ,attached '~ O th e regu la tio n s Ii'd e valve a fix,e d so le no id su pp lie d b y a v aJ u ab le ,c yc lic ra ti 0 currentWhen th e n o w a ctu ator is no-t supp l ied th 6 d iese l f u e l 'flo w is , n i~ ( th e ra g u lla ti on slide va lva ls pOSi tio f led to ze rodel1rrv,e b y rs tu rn s prin gs ).

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A IR AND FUEL SUPPLY - SUIPERCHARGING

13.3 = IRe gu la ti rng 51 ide va l ve posUJiom sensingsensor, 3.s. 'I - FunctionTh e, s e ns or supplies the ECU w ith the in fo rm a ti'on :position Q'f'ths, r9gu~abng sl ide va lvs ~ amolUnt 'ofdi '6seIfuel inje ded.If t he pa s itio I ' l l of th e l l ' e g l U lating] s~ ideva lve di",a 1 1 5 f rom ]th e p re-data rm i ned pe s i ~i ol n : th e ' hJe IIflow aetu att 'or isact ivated to move it back to the pre-determlnedpos l t lon.

20

F ~ : E l li H P O A 'D C20 : m sasu ri ng coil Is -21 : meta~~lic ring_Th e sensor is of the inductivB type. it c o rnpris a s . the' fo l lowing components:.. 2 rn sa s u ring coili is... a m e ta l IIc ring moving be fa re the, measurln 9 co iIsTh e m 9tan~C ring is att.a.ch e d to the axte of th e fue l flowa ctu ator ; it e su sss the indu etan 09 of the msasu ringcoils to vary.

13.4 =Di:esel fuel temperaNre sensor

1 ,3 ~ 4 m" ,~ FunctionThe , sensor infol ims tns E O U a bou t the tstlfiparature ofth e d ie s el fu e l; th is in fo rrrla t.ic n e n ab le s . th e d i ' 9 , s , e l fue lflow to be adjusted l EU;COlr,dingto fhs ftLUidityof the fuel.

~ ~ El1 HP iJ AA C

1 3.4 ,,3 ~ O'e8criptio-nThe sensor inc~udes a resistor of the. NTC type(negat ive tsmperatu re coeffici e nt res i s tance } .The m ore the t, emp s ra tu re incrsas 9S~ the mora itsre s is ta nce v alu e ils redu ce d .

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A'IR AND FUEL SUPPLY - :SUPERCHARGING

13.5~t - FunctionT h e s ols no ld valve make s ~tpossib le . to rnodulste thep re s su re ,a ,p plie d o n to , th e a d va n ee p is ,to n ~ co f1 jn e cte dto , the c am p la ;le }i which e na ble s th e injectr,ortl advanceto vary.I~ i s . s u pp.~iJedby a . vary ing c - y c . l i e ra~io C U l ! ' r e ' n t .

13..5~2~ Presentation 01 the',system

22 23

m

24

225 23 22'", .

Fig; BlIfPO,oi.so22: : a d vance pis ton.23 ; m o du la te d p re ss ure ,24 : 811 1 3 t l l " ( ) v a J l v B .,25 : int,s m a l p rs ss u 1 1 ' 6 o f th e ' pu m p.

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A IR AND IFUEl SIUPPILY - SUPIERCHARGI ING

O IP tER .AT ING PR .IINC IIP ILE : BOISCH VP36 M S,A11 F 'UIELI :NJECTION1 - FLOW ADJUISTMENTlPa r ,ame te rswh lch determ l i m e '~hef~ow of f'ue~injection ro:nlr,o;ll,ed by the EC U : r r e q iJ J est o f df~ver m a xilm u m i n jsc t i' on f low taken in amolU nt of air I s , n t e ring the engl~ne m u lillo ad ' O I J ' I D p u !

10 9 8 7 4 3(1) fuel flow actuate r .( 2} o u tle t to w a rd s injector.(3 ) d91liv e ry c ham b e r,(4 ) injecUon p iSUtH'.(5) f 'U 9 I I discharge port

( 1 6 ) r , e g u l a tr lf lg s l~da ' v a f i v e _(7) Gam plate"(8 ) ro l Ie I' b ean ng r ~ n g .~ '9)fu el p u m p .~10) drilve' shan 'of injedton p lU mp,

The i r i l j e c . U o n pump 8haft drives the fdllowiingcompone nts :. , f u a I p u . H n p cam plate< t'':;a m pla te :'.' it re s,m e n the rellsr b e 9 J ' l i FlIgr ing.' ~ tra ns m its ,9 , r I Q 1 t a . t u n g Stu d alta maUn g rn O " I y l " 9 rm am tothe piston

2

16

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A~RANllDFUEL SUPPLY'~ SUIIPER'CHAIRGING

A

6B 3

2Fiji: lSi!HNAED(A ) ph a se ~ ; suct ion.,I3J !)hase 2 : d~ ~w e ry.P h e s s 1 : suct ion.,. th e p is to n moves to fh e le ft., it lncreasee 'the 'VOIUfinS of the ds Iivary chsmbsr i t . pa rm its th e ope ning l of th e, s upply pa ss a ge , a n d t h es uctio n o ,f t~e f 'u i s , 1P hass 2 : de l iVl8 r y . ,~ the p isuon moves to th e lright it 'CIOS,9S, th~ feed 'gaJfe ry i l l enab l es in ject ion by a n Ii ncrsass ~npressurePhas '9 :3 : di:str ibuficn.'. t h e p ~s 1,o nI f' ivots, 0 n its a xle th e piston c on n od s t l 1 , e delivery cnambs'r with aninjec lor outletp~asB 4 ;me~ering.The r!~gu I S i t in g s I ide va lve , posit~oned b ,y b h e 'slidl~'vaw@ a_, duator . varle s, th8' fu e IIde,livary by Im~dTiWyin;gt I M e end of iF i l j ' s c t t f : o n (pal1:~a~obst l l iuct ion of t h ed i : s H : : h a rg e p e ,r t ) _

3

Regula t ing sl ide v , a lV a : w f1en it comp, l, s te l y obs truc ts the d~sc;ha rge port : a .max imum quantity o f 1 '1 . .1 :9 1s. inj'eacled.. w he n it l eav lE i ls~he discha.rge ' c ha n n el compla te lyope 1 1 1 : no f u e l i ls i nj: a ct e dAcco rdling to the in j ;ect i0n flow dsterm i riled by t ~ i 1 3 iE .C .U . :.' 'th e no w a ctu ator ~ s,activatad by a v o~ t'a g e '(the fu:e,1dsl lw 181 fY i'riiCFeaSes < or de cre a se s th rolllgh '~he

m O Y e l m e liit of the r e g u le t i in ,g $ 1 id a v a l J v e ) th e E . C. u .. Mads t h e position o~ th e re gu I l a t i " F : l Q :~dideva lve - p o s W o n : s a nSOT'. ~fth e pas lt ion ,o f th e s I I ~ d s va lva is d i 'f fa re r il l ~rom thsIPrs=dele rlmine d one , th e E . C. U. m ake s a ,00 n n ~ , c t i ' O I i 1( i f n909ssa ry ) by a new a c t i r v , a t i o n O f th e actuator

17

c 5

4 .t].;

( G) p ha se 3 :,d is trib u tio n,( []) phase '" :' me te ning.

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AIR AND FUIEL SUPPLy ....SUPERCHARGI ING

1 .,3 ,- A iU-e b uUiiUo t1 pro l,e c t lonComplementary to th~ optimiisedcooling o.irclLlit~heinje e tlo n E C .U in O ! udss a st rategy de s ,i9 ned to p 're v e nt, the,overh ea ting of the coolantWhen dnivil l lg under S9V1U,B conditions~ in order topr,event ove.rheating , o . f th s 0 0 0 la nt I th e' a mou nt ofi tJ i lj e .ded fue l is r educe .d l wh i ch causes at reduction ofthe vehlicle speed.

2 ....ADVANCE ADJIUSTMENTO n d ie se ll engines, the be ginn ing of th e ~njectionhast ' O I be veri : 5 1 0 that an optilr l l1al combustion of the f lU 91 iso bta in e d w h io h an8!b~es :.. m in im al con$um p ttf:o rnill m i n im l sl IPoHu t~veexhausts. m a :X llm ~m p ow e rThe inj ,edio til s ta rt is ,e nsu re d by th e a uto m atic Um in ga .d va n ce 'd e vic e o f: t h e' ~n j,e cUon pump .

2 .1 - ll nj e cUon pump

11 12 8

O J

12 1114 13F i oj jl : B1li iPoAFD(8 ) ro lla r ooaring rlng,(11) advance piston.(12) mod ula te d p re s su re ,( 13) wlvanoo eledw'QvaJv9.(14) inte m al prs ssu re o~ th e' p . u rnp,

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3 , - RECYCL I'NG i O F ' EXHAU:ST GASESC O f l l d T t i : O I 1 S fo r INii!oyc~if' !gexhaus t : gas as :.' eng i iii!!speed eng i f l l i loa .d cool ant t a m p e r a / t t L l r'a'The Ir,scyclung is o f tn e "a ll o r n oth in gl" ltype,.'The rscycling phases a.re mernorised in the mapsm akl i iig i t poss ib lle ; to deteHlfie ' th e recyel ing phases very p r e cis 9;ly -sm is s lo n s ta n d a rd s to cptimlss the driveabi l~

A.lliR ANIID FUEL SUPPLY - :SUIPERC'HARGING

2 ,. 2 - O lpe raUon~',a.ram9'Wrs which dsterm i rile 'th e th e e re tic al injectionadvanos of h .J e IIreques ted b y 'U1D ECU : e ng ~n9speed [nfo:rmat i 'on fiow ' of i : n j a c t 1 f 3 d f ue l i nj lB 'ct ion l staJrt =r laedle ~ ' i f t :sensor co ola nrt 'ten! p; 9 ra tureDuri 'ng op9r,at~oFl~h e fue l p re s su re ! m o d u ~a te d b ,y th ea dv arlce - e lectrrov8_hrs ~ is ap pl ie d Orr! th e advancepisto n.The ax ia l mOV 1 8 rm e n t of th e advance pi ston,tra ns m itts e llto ' th e ro lie r b ea n ng Iring : m o difie s th e po sillion of '~ h9 ca m p la te in re la tlon 'toth e r , o , I : I E H ' S'. Iifts th e ca m plate dur[ng its rotat ion: bef 'cu'9 hand! offse ts 'from a 08rta "in a ng le th e pos i t ion of th e highprsssure piston from the o~;an 'ksha f tt ~s angu la rposit ionFrom th e tha,oret ical aclvance! determ ined Iby th e'E:CU: the ' ad v an 08' e l i i3!dro'valve is ,adi:vat ,ed by a vo ltag a"M . I ' ! I o "Wit _ ,EIvary i r n g e ye r c m , L lO ths 'f'u~!modulated pressure Qnab les UIQ change ofpas i t!C N " ! of the advance ' pis,ton due , to wh ich th einjie dh':HI i advanc9 va r i 9:S,II! th9 ECU I reCSiV19S in format ion on t lhe injection startw h ich I ! r il a bl e s th e ' actual adv8Ince to be known- - i ' f th e Bo tl lJ a ladvance is d iffe rs n t from the th :H)mt ica la d v a n c e - : th e a O i v a l f 1 o o e l e c t H J V , a f r v e , li s a ctiva te d inSUGh a way a s to obta in th ee re flc al a d vs nc e ;;; :;ctualadwncs 1 1 '9 ' Q CW h en th e a ir condition ing l com pre ssor ls re le ase d I ii tcan be e nga ge d o.n ly ate r a t ime , d e la 'y o f 4 + seconds .6.2 - T'rl'p com pu Ie rThe in jection ECU sends the i ns tan taneouaconsumption Ir' l f-ormatlon in the form af voHageflu ctu atio ns to th e on-board computsr ,

6 ..3 - C od e d ,a nU -'1 h e fi d e lli'o e'ATTE NrTlO NI ,; ~f ' th 9 code of th e coded antRtheft

I device is ~os.t~!h& inj9c.tlon EO U ha s ' to be. re 'P~aoed

2 1 1

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AJI'RAND FUEL :SUPPlY - SUPERCHARGING

IDATA : BOSCH VP361MSA11 FUE,L ~NIJ IECTION1 - liN JE CT llO N E.LEC:TIRONIC CONTRO LUIN~TM ,a ke : B O SCH.Type: MSA , . ' 1 3 A 9 .Refa r e 1 n o e of th:~ M anu f,a dlU re r : 1 8 ) ng ine D KSATE f t1 e rn is s ia n co ntro l IEECQ3. ;,o : 2 8 1 1 001 2 1 1 2 e F I I g in e ' [ ) K5,ATEfY. 6rniss i ' t : H l 00ntrol US87 :o : 2 8 ' 1 001 2 ' 1 1 3: 2 ~ INJECTION PUMP

I M a . k e BOSCHRemarks

I VP36VE [R520535o 46,0404993

I C he ck p is to n Ilift:only : 0.52 m rn r I N at a d l j u s ta :b I eld l ing s p e H '3 id - withQi lJ t al r rondiigoningWith 9ngine hot

P f f i -d!eteIFmjined r ,a t ed v~dUle750 1 rpm (+ 0 l -2:0 rpm)

l i d I i rig spe e d - with , a . ~ rco n O l i t ic nlng'W ith e n gin e , no t 82:0 rpm I N a t a dju s ta ib le

. 5150 rpm Not: a d ju stabi le

D y r n am r . c t t im i ng I a t i id le I 4 ,0With en g i 1 i i i i 1 3 i hot I Not ad]ustabh3'(~) : 'the adjustm an t: r equ i re s the u sa -of the SO liA~AU 26 A statio n O r the EUT tsst unit.ATIll!N TilON I : !B y i t s c f E l 's ig n , th 9 pu rnp only' r equ i 'r estim i ; t J i l g by m ean s of a , dhe cki ng rod (se9 ' the ' r ' 9 1 9 V a ! 1 to pe ra tio n ) ..

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AIR AND FUEL SUP'PlV - SUPtERCHA,RGING

3 - PIRE,AND PO ST HEATING CIIRCUIT-S3..1 - Pre, and post- heati ng control I U I n i - 1IM a ke ~ 8 0'SCH.Re fe re nce of the ' M a nu fa ctu r,sr : 0 28 ,1 003,0041 .

9.2 ~,Pre=heaterplugsRefs re ne e 'o f

Ilime II'lequi- Iintlensiity after Extremi ty Ti 'ghteningM a J k Ia i n Man~fac- Voltage, lFed to reach-6 20 seconds dis. torque.' turer 850 C

80SCI~ 02Sa~01033 11V 4 1.5s 1 9A 6 , mm :2,5 m.daNBEAU 0100226186 1 1 1 ' V 4~ 1.6,s 9A 6 , mm 2 m.da lN

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REPAIRS: IB OSCH 'V P36 MSA11'FUEL I INJIECT~'ONAIR ,A ND FUIE L SUPPLY - SUIPER'CHARGING

1 - IllNJECllON PUMIIPOn t h e f f o 1 1 lo w in g parts, oauy ing l a n r y ope I Il lt icn isprohibited : d iasal r u : s , 1 t19mperatu fa s~nsor. ' f iU l e ' l f~ow'a c t u a t o r, . r e gl iil a ti r ig is I[d's y,a, I ;v,s,os,ut ion 'sensor (s Iiding [b look),. ~..iiU\a-,........,. . : . 1 1 " " ' A 4 reval ....,.II!l.Y,,", .III~Q'![]!I ~uL ~ f!~ Q, . in~ scm i on pump e lec tr[ :c a l harnessATlE N1 fIO N ,; By i ts d i' s ign m 'th e , p u mp 0nly requ~r'9s, t iming by m eans of a. c h e c k i ' I i i Q ro d ( sea t he I r ' ,e , ~ a v ,a .r ii l to p e r a l i ;C l I " i I) .

2.1 =Aecele r,Mor Ipedlal sensa rTh e ch ecks m e , ca rrie d ou t I b y m ea ns 0 ,1E L IT test IJ n itor -sO U RII,AU 26 A station.Chs ck:th e vol l tage' sup~~ied by th e sensor, ~nthe i 1 U ~ 1 1tihroHle'" [posit ion.

F ~ : B ll -1 P ooWCMO\i! \9 the pi n in th e ! l o t c n G S o - f ' the 8JX's l le raton-cab lsto o b t a i J l f ! "a t f u l l throttle, ~I ,8 VQ~ ta g e ' between 3.6 and3.9' volts.ATTENTIO N :: lin t~e case of an j 'nconractad ju s ttmen t, fu I~ r o o d would not ba obta ined.

ATTENT ION i = Th s ch ecks a nd a dju s tm 9nts , mastbec an i:a d o ut: with eng l~ne .hot I ne fault memorised bythe E.C.U"! vehicle a t re s t. r e , f f l i g e r , a f i o nde-activated,

22. 1 - Checks'The l i d i l ing 8p eed l is adjus tab le r It is dets rm inad by thei n , i e c t i: o n E "C .U" B io o o .r d in g t o th e m aps i l n m O lm o r y andthe i n f o l l im a t i ;o t 1 l n ? ; I ; ( ) 9 i V 1 s d _Id ~ ~g spsad, B'ng'iria hot : 7 50 rpm (+O I -20 rpm) .

2.2~2-' Adjustments,ATTIENT~O N : Th is proce dlJ re m ust be used e nlly'u pon n 30 0 r nm s ndat lon (l,f ~he rnanu fa e t u re r or in th eCElS,9 o f s ew i:a u $ d l i s t l U r b a n o e s in th e o j p e r a t . i o n of th e'9 flgine : the 19ngins stalls I noises and vibrat i 0 ns ati 'dl~ing{eng~ne moun t~n g a s sG ,mb~y 'no t :responsible,).The ad jus tmen t Ire'qui res tM usa of: theSO U R I A U 2 10 A s ta tio n o r t~e IEUT test unr~.Possible Irotatiiona~spe e a ~ n ; O r e a . s e by 63, rpm in3 iSteps of 21 rp m .Poss ib le rmat iona! i S l p e e d decrease by 63 rpml i'n'3 steps .o f 21 rpm.

:2 .3 ~ F llo w injeeted on sta rf ngATTIE N T~ O N :Tbe checks ,ana adj u s tm e nm mus , t ba ,carriedout w u t h engine hot ; i f the wat~ r ' ~ e m p e r a . 1 t u U ' " 1 9~sabove 7Q Q O ,

2~3.l' - Checks'Flow ~tnjacted o n s ta rti n g ~ it u s de te rmined by th e~nj"sct: jonE ,C , U . , accor dl ing 't o U~emaps in m em ory andth e i nfoml1 'a t ian r ,sce l ived_F low in je c te d on start~ng~ 35 m g pe r S ' troko .

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ATTENTIO N : Th is proce du r r9 mus t bs use d onliyupon reco ,mrmend la t ion o f th e ' manufa.cJtun~~or ~nthe 'C-aS9 of S9 r iQUS ,d iistlUroancss in the ope ra tio n o f th eeng lna .

3 -INIJE'CIOR CARRIER NIUIMBER3In t~e case of a, failure efths ne e dle lift s ens or, th ecomp~ete i l i i i j ,sdor csrrier has '~Ob e cns rtg a d.Th e sense r=irlitscttor asSI8 m bly is ad lju s 'b8 d in fhe' fader) !" " Eve ,ny mod~f1 lcat ian of adjuS'tm e nt ( f o : r ax .amp~eJlr,essun~1 set t ing) w i Ii causa E H l " i g ' i n9 malfunct ion{w r .o ,n g in f o rrnanon o n ' t h e , b e g in n i 1 ' l I 9 of i r lIJed ion}.

P es sib la incre as e o f' 4 .8 mg pe r stroke . in ' 1 i 5 s te ps of0.3 m g pe r :stroke.Pass i b 1 9d ecre as e o f 4 Aj mg pe r 6~raKs' Ii n 116steps of0 .3 m g p a r s tra ka .l'~e adjustrnent r e q l ! J . irrt9S t h s , use of '~heSO II A [ I A U 26 A staflon or tt~ e E L IT t e , s l uni tATIIE.NiTIO N I : Unt ims,1y co'rJisdi on s Willi hava an [,affect on th~ noise SInd fumas , on s ta li i I1 g , I

2,.4 - fu U [loa d output

2.4.. 1 ~ ChecksF u I I load o U i t p u t : u t i s c :h 3 , t eI fmined by th e c n j ; ectionE.C,U. accord ing '~O the maps ln rna lilu;;ny and thl ii n f O rmat lon rece ived ,Pre-de term~n8d l 1 io im~nalv allile : 4 00,2 : %'-

A TTENT~O N : This procedur ,~ , mus t be use d only.upon racommsnda t lon of th e m a nu fa du rrle r or in th ec a se o f s e rio u s d ~ st:urb a nc e s ~nne ope ra tion of th eeng ina : t~9 iI t1 Ig~nelacks pow,s If, consumpt ion toohigh. fu m e s from t~9 exhaus t ,

A 1TIE _N T~ O N : E v e H ' Y p rasslU re settirtg of injedornu m be r 3 i s p roh i b it ed ,

2 5

P08sib le ~ncr'9,as6 of 2.3, % Ii, a _, 3 irnae,me n~s of0.781 o/~.Poss~b~e de cre ase of ,4_1 %, i -6_, '6 , lncrs m a n J t : s O 'f!O .781 ' 0 / - 0 .Ths ad jus tmen t raqu Ire s the us,s' of theS O U R IA.U 26.A sta tion lor ' the E L IT te st u n~~ ,Ths ad ju s tr n 8nt is fur ttl 9 oper,atiln 9 phases : f lU I I l oad max. speed a oc e le ra J t lo nArr~Nfl'ONI : Th e pe n'O rm ,a ,noo and the rnaxlrnumoutpu t of 'the eng ine are o bta in s d w itn the nom ina lva lu e ; u n li mely cc:rr ,ed~ons Will~have a n e ffe ct on' fue' l o o r u t i , l L im ad and fu m as e m irltsd.

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A IR AND, FUEL SUIIPPLV ,_ SUPER:C,HA.RGIING

FAUL T F IINIDING : B O SCIH V P3,6 M SA 1 1 FUEL INIJEC'T ION1 - D~AGNOSTICT,DOlS

1.1=ELIT test wnU ::4125 ...T

F~ : 83llPOa9CThe tool can be used for : re ad ira gth e fa ult c od es r,o a d t es tiin g l ope ra t~ ng '~h9actuai ' i r n g e e rn pe n e nm., measuring ~h9parameters

1.2 - Test connector box; 4109-T

F i fJ I ; 1 ! 1 11 H P 0 7 4 C(1 ) 1 ~ 5~way wirf lngl h am s ss .(2) ~ test co n nect ar O O I X ,(3 ) - multimehl . l r ,

' 1 m 3 ~ 2 6 A diagnos.t ic station

Fij jj ~S3BP031 CThe tool can be used for: re a din gl the fault cod SIS operaf ng the actuati ng components'. clh e ck in g th e D ia s e ~ inj ';c1jon sys.te,m checking the parameters

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AIR AND FUEL SU IPPLV ....SIUPERCHAIRGING

2 ~ FAULT FINDING CHART2.1 ~ List , o , i fau It codes,NO T E: Th e a utlod ia gnos tlc sys te m w arning lamp wi l llig ht u p, ~ fr ' the ' fo llow ing inc~dentcodes a re disp~a,y9d;37,41 ~54,55,56. '65. ,13 = i n I le t a i r 'te rn pe M ITUre sensor (907).1 4 =engine c oola nt te m p era .tu re s en se F ' (909) ,1 8 ,=powSlr outl a t s h a rt c lrc u it2 1 1 - accelerator p8 d1a~ensor (773).25 =b r,a ke s w itc h (3 1 9).26 - dutch switch (328}.27 =wh~cle speed infonTlwijon ( 1 1 5 4 } ..33=. a ve r pre s S~ra sensor (903).3 6 =d i9 S > 9 1 tuel l t J h e rm ~ a . 1 1 ~ sen so r (9,22).37 - stop electroval~le (429).38- c ru ~ s eIcontrol.41 - i~mgin9speed sensor ( 1160) ,43 - ,a djL Jstm e n t of advance (443) .51 - 's lid i rng b lo ck pos, it ic .m ~166 ).52 ~ 'flow adjustm~ nt (445,),53 =i'lectron iC control uni t (142} (batte, IY voltag:e),54 - , ele ctro n i c control UI"! V I: (142)r.5 , 7 =a tmo sphem 'ic ;,p re s s ur e s e n so r ( 1 4 2) .68 =pre= hea t ing (59).!65 - need Ie Ii f t : s a n so r ('1 (5 ).

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A IR AND FUEL SUPPLY - SUPER'CHARGINIG

L oca tio n o fI co mponen ts

Engine coo-!an~ t '8 m pe ra -b . . ! l f f i sensor(909)(cy l l inderh leadw ate r cu t le ~hous,ingi)

2.3 "':"suit code 14 , (millo'r fault)

lDiagnostHc e qu Ipm ent : Qhmme t e r

IE"C. U , discon ne ctsd :moaasure the, re sis ta nce o f: th e ssn-sor aJC .CQrd~ n o to , th e te mpeH'8 '11W reID ia g no stio e q~ i p men t : voltrn@terIElledr(,H'II: iC ( D n t r o ~ IU n it connecte d ;ig n Itra t1 I sw i tched l on,sansor d i sco rmec t edGhaok '~h8 'sensor SlJlPp~ vo Itags-U~6V

E marge r n c ymcrae

Y e s

n5000!J,4000C30000,~oo' ~ O O O O:;000.i i IOJD3iIl ( !DZ O O D

53=13

Test. Iconnsc-I , m " boxtermi-nels

e.c.u,c o 1 11 11 9 c to rr

Comp0r i lemconJined~ons

1- -IDiseo rmse -ted Green

f '1 Q ,: El11H~

Graph f l o r ch ecl

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A IR AND IFUEil SUPPLY - SUPERCHA.RGIING

2 ~ 4 - f a J U l1 1 1 :o d e 18(111in o r faullt)1

loeatllOri ofc o m p o n e ; H " ! ~ S ,

D- -t'-"*I~~r OWE lh l O IL h_ !; .; i! J.:8hert circu~~( , a t +}Advance,eh;~drovanve(~3)EGA e lectro-vaJve (442}P ra -h s a tin 9w a w n i ' r iig l ampP. 'm~hsat ingcom rol -A i J r c o n e i t i ' c n~ngrelay~22)

IE.CJJ,connector[ )~sconn~Guted

T E H 3 toonnec-to r b o:xte'l imi-nails

10-19

6-19

8-19

9-19

2.5, . . . .IF'aun ' code 21 ( f I T I i inor f,a u I nL oca tio n c ,f

00mp on ~ n ts

A o oe 1 le r a to rp e d a J s e n s o r{77S}(under"the bonnet)

EC III'" .l'Iu.

Connected

Teste cn n sc -tor bQrX'~emTd -nals

CClmponenlc o n l 1 9 d : i o ns Tes t va.lue's

Check 'the vo~ tage ,~i 'g m " !b io n switched o n : U !II!! 112V ;i g l n i t i o t ' 1 l off : U : I I ! > ! 0 V

E ,m ' 8 r Q e ncymode

No

3 3 = 1 1 : 3 ,

COmpO'nl8 lntc o n n e c 1 i : i o : n s

1=4

last values

Mosie rator rs leasedl : U iI!!I 0,.4 VDepr '9ss the pedal 9 raduail ly as falra s it will g o : Illin e HF i~varlatlo t1 I a f thev otta g :e u p to 3 .5 V m~n,

Em,e,rgencymoch~ '

' 2 " 5 l ' 3 ' - ',-,- .I .. .

1 3 - 3 1

1- 4

3-4

4=2

I D ia g no otic e qu iJ p m a n t : o h mm stsrR iI iII 10 00 ,o h lm : sI n t~a acesl e l r a t > l 9 d p o s i t ~ o l f l :R '!til 1 0 0() o hm sA '!I'll 00 : a C C 6 r .e r ato n " re leased

i I D ~ag!'lostie ie qu ipm e n t : v o~ tm e te lr Y e sCheck th e se n sor s l l J P p ~ y \ra fta ge ; Fas t idiliF ig :U jIiIi!' 5 'V 15'00 rpmI ~ - - - ~ ~ ~ - - - - - - - - - - - - ~ ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~13;- :37 I 4 -,2 C heck. th e vol ta.ges as, a f ' L i net ic n of Ai r COriO i, the 00ndit lons land dowlf'i tlon i ' n gc om p rs s-so r ou t= ,o ff

Disco:nnec.. 33-~3ted

1 0 0 0 'o n rn s < : R ;( 2000 o 1 h m is :aces Israt,or re: leass d

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,AIR: AND' F IUE L SUPPIL V - SUPERCHARGING

:2 '.6 - F au n code :2 5 {m~nDr faUl~t)

locat ion ()f I IE"C"u .tampon Bnts con necta rTe s tconnsc-tor box'termi~' I 1 : B J i s

'O o ,mpon e n tc o n n s c t i o ns Tes t v a lu e s Em9rgenoymode,B r a : k ' ! i ' switch(319) 1 0

"l iSconnec-te o '~'1U' -

_j

D UEl'gostic , e ( ~U ipmA9il t' : :V\oltmete rI g n i ti on : s,w i tc h ad 'on, a ha ck th e' V I o l t a g e ,B r ,a k e p~d a~ ~919 :F . :! JS ed : U ji!Ii! 1 2 VBr ,a 'ka psde l depressed : U i ! I i ! I 0 V

2'S,-t e rm ina l Bn1Jke pedal W 'i Ie a se d : III 1;!iI, 0 VI Br,aka pedall dsprasss d : U iI!!I ~ :2 V

I N O

tccation ofoompo,t" i Iems s.c.uTe s t

GOrl I t19C",tor boxterrnl-naJ~sCompone ntco nne-di ems IElmergencymode

C lu tch sw iittc~ . Conne cte d 28 -18(3,2..8 ) D iagnost ic e ,q u~ lP :mEH '1 t:vol~m@te,rI,gr 1 I i t i o n sw itch ed onU iiIil 0 V - llClu lch e ngag:ed~ pe s i ti o nU AF tUlttelry U - ! 't ~U lt ch re lea se d~IPOs~~ i ion

'V'j.,t",~0.0

location , o fco mponeH1ts ~,.C.U,connectorTes~:

I connec-to r b oxterrni-na lsComponentconnsctic ns Test values Eme,tJ"g9ncymods ,

Vehicle spes d's a r is e r ( '154)(on the gear-box)

,F'~n"'''''~''''''d'~'I'II'II![J!II;;r~c

Wh ita Majka sure, that th e s pe e dom ,a te r is ,correctly qpetr.a ti 'ngIgrtili O n switched On ,_,oheck th~sensor S!lJ P iP I y volta ge :U I i ! I I b a t t f E l ' f Y U

2Sl-18

1 ,~..;JI

Diagnost ic e qu ipmenu : vo l tmeter

IR oa d w lh ee l)s ,rn ta tling -(:hedk ' the output vo~tag'9of t~esa nsor : U i! iti 6 V -

3 1 1

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,AIR AND l F IU EL SUPPLY ,_ SUPER'CHARG IING

2.9 ,=Fau It code 33 (minD r faultl)

Locat io f1 I ofcomponen ts E . C . U .connectorTes tconnao-tor b oxte rmi -na ls

Gompon9 nteennee t lons Tes t v a lu e s Emergencymods' O V I I I Fpressu resensor (9013 )

Connected

Brown

Diag ne s tl e e qu ipm e nt : \ 1 1 0 Itms,te r

Ig nitio n s w iltc lh a d o n -- c h s dk theS en so r s up ply vo ltage U 1IIiI ' 5 V

The output volta.'Qe must be ! b e tweeno . 1 V a r n d 4 V -[Engine stoppe d : U ~ 1 .5 V

Btrown

D iagn. osNc eq lL J rpmen~ : ohmrne t a r

S a I1S0 r d T s C Qn n e cted - check an lh~'S6nsor : R Ali 1 360 oh ms I

Yas

IR9pl lace~menlvaJlua:1 00 0 m ba rs

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2 . .1 0 - , IF 'a uIt code 36 (m i nor fauU),

t harmaJsensor (' 9 122){ in 'th e pu m p)

Componen tc on nec ti ona Tes t va lues

Diag ne stic e q u ip rne n t' : vo l tmeter{ ' -"way KOSTAL can in e c to rd is co n ne ctsd

Chec k the se nsor su P PIy vo lt8 .~ :l l I R i : ! JV

Emergencym o d e ,Ye'sIRaplaoo-m i S r rtvalus :4500

ID~6\S61 fUB 1 Connactad 35-13

7-way KOSTAL 00nns (: to t ( towa r r"~ s' ! : ha i1 n je G t 1 Q r r l p u mp}Chec~ ; tihe rG sis la n ,o o A b e tw e e n

Ithe, wa.ys 4 and 7 of the '7 -waycon nec ta r (as e taJl!e be low }

33

Te s t'connec-tor boxtel i 'm i~nalsE..G.U.ocation ofcom p a,n e n ts connector

T '~ C A ohms1 1 1 ~ ) ,378020 25,00so 169040 1110so 8 2 06 0 59070 4308 0 32~)90 2 4 - 01(lO 185

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A R 'AND FUIEL SUPPLY - SUiPERCHIARG,INIG

2 .. 11- F 'aw It, code 37 (se rious "au 1 0Tes t

Locat ion of E,C.lI. cennec- Oo rn pc n lIa nt Emergencytor box Te st va Ju a scomponents connector termi- eonneetons mode . Inels IStop e~actro- Connacted 18-:3 D i ag nostic 'EH:~uipma nt : vo 1l tm6mr Yesvalve (429} Check fha, l i m r m su pply voUage , Eng~rneIJ iIIIl battery U stopped bythe ' h , H ~ 1 1dallivary cutoff

C fsconneo- D ia gnos tiic e qlJ ip me nt . ohmme t e r Ited Check the reslistanc9 cftheIeliectl'U'IIahie . R RII 1 . 5 ohms2 ~1 2 .. ..faurl l t code, a s (m inor f aL l l' lt)

Testloca tn on o f E.C,U, connsc- Gompon~mt Em 9 rgs'n r : : yter box T e st v a lu e scampens ~t:s ccrnsctor ~ " eon nectl on F l, m o d e ,tsrrrn-nelsCru~5econ~ro l D isconnec , 30'-45- D iia gn os tic e qlU ip me nt ohmme te r - Yested 48 Check the continu~ty and in su la t[o liil C ru ris 9of th e 'w~tes,betwee-nr e rn iSB' 00 ntrol control(214) and E,C.U. (1142) stopped

34

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AIR A JND fU 'E L ,9IUPP LV " ",,'SUP'ERCHARG~NG

:2,.113 Fault code 4 ,1 (serious fault)

Location of,component ts . E.C.U.connectorTesteonnae -to r boxt e rm i -nals ,

ComponentI 00ninednons T es t v alu e s E;merg;sncymece

E rilgi File ' speedsensor ( 160 ) Disoonnec-te d [ ) i 'i lgnos ti c equipment : 0 hmme~er

Check the resistance value :R . ; ; : 360 + 45 oh m s

~ 3 2

C - o i i : n s u l la : t e d l from t h e e a r t h R !iii: ee

19-47

Air gap va lu e 0 .,8 to 1 .6 rn rnTh e a ir 9a p is not a dju s1 a'b li e

Use of the6tg ,r ia ] f romth e r U ~ ' Q , d I1 9lift :S S nser

L c u 'J a I! to n o feo,mponents , E.C,U.eonnee to r Oempensntco nne-diane Tes t va luesi

Em~rge_ncy Imode

.A dju stm a ru t o fadvancef 4 43 }(o n the I p ' U rnp)

C o nn ecte d - ,----10=I ts rm i Iila l D i :a,gnost~o e qu ipm,e n it ' : : vo,ltm e te rIgnition switched on,ch e ck th e volta ge : U :!!IiI 1 2 V

Disconnec-ted 1 1 i[)-1 6 ~'10-17~ ,2 11

' Y \ e s ,I R e d u c i t u o nof the ' fuel ld e l r l V l e r ya nd p s r fo r-manesExhaus tgas recy~c l i r n g s t o p e .pedl -

Ie -r:heck th e re s isitalnc9 valua :I IR !II!! '115ohms

3,5

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AIR AND FUE,IL SIUiPPLV - srUPERCHARGI~NG

2.,1 5 ~ Fau It co de 51 I(ssiri OUS fault)

L oca tion ofo O ' l I 1 1 p o n e n t sT e s , tccnnscto r b{H{t r f u T n i -nals

Comlpo rilsntconnect ions Tsst va lues Emer 'gencymode

Slidiing block Cannected 14 -posit ion ' 166 ' ) t E 9 l m 1 n ria l(~nth e pump) "_'"

E,C,U"connector

D iagnest le eq IJ ip lme t i l t : vo I t mete ' r NoI ,g n ifie n sw itc h e d on ~ch eck the . out- E,ng~naput volta.ge of the its m : U iRIf 2.S V stopped~ ~ - - - - - + ~ ~ ~ ~ - - ~ ~ ~ ~ ~ ~ - - ~ - - ~ - - ~ ~ ~ - - ~ ~ ~D~sconnec 39~1,4 Dia9nosl~ce 'qu ipm e nt : ohmmeter

tedl ~.

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A~[R ,AND [ FUEL , SUPPLY ,_SUIPE,R'CHARGING

2.,17- faun code 53 (m~n,orlaldl)- Test

Location o f E.C,U. connse- Gompnoent Emergencyto r box T e s t ' ' 1 1 , 1 3 . 19.Se< rmponen ts connector terml- oonnections moder n a sI E . I C . U . C o rf I t1I9cled I 16- ,18 " Diagnostic equ i ipment .vol tmeter I Ves.(bette ry ve I ~ 17-=18'~ag9) ( ' 142) 16-1'9 . Ignition swi tc lhed 1 0 ! i i i ~ R,9p~ac.e-17-1'9' check the supp~yvo lta ge ' o f 'the men tE.C"U. U Ii!i 1 2 V value 0~W I ~ 8,3 V

'TestILocat tOr l i of : E . C , . U . , cormec- 'Component Ema[f 'g~r iCY

tor box Test valuesc om P0 riS n its 00rmecte r terrmi= connectfnns modenals~.C.U,(142) Other fauH codes presen t ? r epw r 9S,the faulty functions

T he ,e ng in e runs ,Ajlf c o n =ch eck the E...U. 'supply and 8'al i lh. swlitch-oH.othsr .wuse . E .C .U . not Op8[rati 'ng CruiseI

co n t r , o l lstoppsd2.1'9 - Fallin code 5,7 (m inor fau II:)

1 7 e s , t Iocnnsc-tor boxt e rm i -nals I

Tes t. v a~ue s Emarg;e~oy'[modelocation ofcomponents Componemt00nnect ionsE,C.U.connector

I Ye ss in g .s OU R I lAU 2SA s ta tlo n 01 "I~[JT test unit, cneck th e va lu s o fthe a tm ,0 6p he ri c p r es su lie =m9.aSUN~ parametersEng in e s to p ped , ignition on,preSSU[f'I;3 read ing -e 6 50 m b ars or>1015 mbars !!!!!! 59nsor n o t op e ratingl~ , re pia ce rns nt: o f th e EeU

AtmospherL'Cp rs ss u re .senaor (142)( incorporatedU1 th e E .,C .U .} Raplacs-

montva lu e :1 00 0 m b ars,

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AIIR AND FUEl. SUPPLY - SUPEIRCHARGING

:;1'.20.....F au lt oode sa I (m i or fault)1 7 e s t

Locatr,orll of : E,C. . l I . eonnsc- Component Em 9. rg ,9.ncy'tor box Test valuescomponents connecter terrmii , '00 til noa ions modsnelsPrr,e-heafn g Connact,ed ,8-18 D ia g no stic e qu ipm e nt ';voltmeter No(59} Check the control 'v,oltage of thepre-heater 00ntroll uni t -U ". lbat teuy U

Tihe p , h . J ' Q S alii s.upp~r,ad by twos .~the E.C, lL rnon ltors th e d ifF ere n e e inCIJ rrs n t : bem ,ean the 2 units,

I The te st is carried out if U :> . 9 volts2.'21- ,'aulll code 65 (.serlous, fault)

Tes tconnsc-tor IDO'l::t emn i -~B~S

T~H;tvalues ! E l m s rge,ncymode ,E . I C - U _ronnecitorlocat~ortlofromlponents Ce rn po n sn tCOin nections

CCl1n~c. ted Y e s ,eed le lins en so r (1 65 )on e y l indsr :3,5=12 I D ia gn os ti.o e qu ip m en t v o~ tm 9 te r< L W2: 1

Wh ite Ignition sw itch ed on,check the, sensor ISUpp~ vo I tags;U~3,5VDiagnostic equipment: ohmmets'uCheck the res i 'stance value :A ~ 10 0 + 1 0 ohm s a t :20 g c

D i E conn sc-ted