Bosch Hdi Edc15c2 Injection System

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PEUGEOT

CITROËN

CITROËN

DEALER QUALITYDEVELOPMENT DIVISION

DOCUMENT REF N°: 1.6.243 August 2000

TECHNICAL TRAINING

BOSCH HDI EDC 15C2INJECTION SYSTEM AND

PARTICLE FILTER



NOTE TO READERS

This documet cot!is i"o#m!tio o" ! co"ideti!$ !tu#e%It is the#e"o#e st#ict$& #ese#'ed "o# the use o" CITRO(N t#!ie#s !d m!& ot

)e dist#i)uted to *eo*$e outside the #e$e'!t de*!#tmets%



BROCHURE SUMMARY

BOSCH EDC 15C2 HDI SYSTEM H!"# $%&''(%&D!&'&) I*+&,-!*/

COMBINED 0ITH A PARTICLE FILTER SYSTEM

The !im o" this )#ochu#e is to de"ie the com*ositio !d o*e#!tio o" ! +O,CH EDC-. C2 HDI diese$ egie m!!gemet s&stem/ com)ied ith ! *!#tic$e "i$te# s&stem/ i#e$!tio to the D1-2 Diese$ egie%

This de'ice cosists o" ! ECU hich !!$&ses the i"o#m!tio "#om the '!#iousseso#s/ !d the o*e#!tes the iecto#s !t the co##ect momet% It !$so cot#o$s !*#essu#e #egu$!to#/ the e3h!ust g!s #ec&c$ig e$ect#o'!$'e !d the tu#)och!#gig*#essu#e modu$!tig e$ect#o'!$'e%

The "o$$oig su)ects !#e de!$t ith i this documet:

4 Gee#!$ det!i$s !d s&stem *#eset!tio/

4 Desc#i*tio !d o*e#!tio o" the com*oets o" the '!#ious "uctios/ o# the"uctios themse$'es/

4 Desc#i*tio o" the o*e#!tig *h!ses:

• o" the iectio s&stem/

• o" the *!#tic$e "i$te# s&stem%

4 Notes o m!ite!ce/

4 The e$ect#ic!$ ci#cuit%

A



CONTENTSCITRO(N%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-

CITRO(N%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-

CHAPTER 1 DEALER QUALITY...............................................................1

CHAPTER 2 GENERAL DETAILSHDI DIRECT INJECTION SYSTEM.............................................................1

I 4 FORE1ORD%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-

II 4 5RINCI5LE OF HDI%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%6

III 4 5ARTICLE FILTRATION 5RINCI5LE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.

I7 4 ,AFET8 IN,TRUCTION,%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9

CHAPTER 3 GENERAL LAYOUTHDI SYSTEM

CHAPTER 4 FUEL SUPPLY FUNCTION................................................13

I 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-

II 4 COM5ONENT, COMMON 1ITH DOCUMENT ;+O,CH EDC -.C2 HDI IN<ECTION,8,TEM;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-.

III 4 ,5ECIFIC COM5ONENT,%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-.

I7 4 ELECTRIC FUEL HEATER =-2>9?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-9

7 4 LO1 5RE,,URE 5UM5 ,U55L8 CUT4OFF%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-9

CHAPTER 5 AIR SUPPLY FUNCTION....................................................1

I 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%->

II 4 COM5ONENT, COMMON 1ITH DOCUMENT ;+O,CH EDC -.C2 HDI IN<ECTION,8,TEM;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%20

III 4 ,5ECIFIC COM5ONENT, %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%20

I7 4 7ACUUM RE,ER7E%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2-

7 4 7ARIA+LE GEOMETR8 TUR+OCHARGER%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%22

7I 4 7ARIA+LE ;,1IRL;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%29

7II 4 ,1IRL CONTROL ELECTRO7AL7E =-296?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% 2>

7III 4 FEATURE: INLET MANIFOLD 5RE,,URE ,EN,OR =--2?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2@

CHAPTER 6 EHAUST GAS RECYCLING FUNCTION.........................2

I 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2

II 4 COM5ONENT, COMMON 1ITH DOCUMENT ;+O,CH EDC -.C2 HDI IN<ECTION,8,TEM;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2

III 4 ,5ECIFIC COM5ONENT,%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2

I7 4 1ATERBEHAU,T GA, ECHANGER =EGR?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2

+



7 4 THROTTLE HOU,ING =EGR?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%2

7I 4 THROTTLE HOU,ING CONTROL ELECTRO7AL7E =EGR? =-29?%%%%%%%%%%%%%%%%%%%%%%%

CHAPTER HDI SYSTEM......................................................................35

I 4 COM5ONENT, COMMON 1ITH DOCUMENT ;+O,CH EDC -.C2 HDI IN<ECTION,8,TEM;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.

II 4 ,5ECIFIC COM5ONENT,%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9

III 4 DOU+LE IN<ECTION RELA8 =+,M? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9

I7 4 COOLANT TEM5ERATURE ,EN,OR =-220? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%>

7 4 FUEL TEM5ERATURE ,EN,OR =-22-? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

7I 4 +RAE ,1ITCH =2-00? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%60

7II 4 CRUI,E CONTROL +RAE 5EDAL ,1ITCH =>0@? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%60

7III 4 CLUTCH ,1ITCH =>09? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%60

I 4 7EHICLE ,5EED ,EN,OR 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%60

4 IN<ECTION ECU =-20? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%6-

CHAPTER PREPOST HEATING FUNCTION......................................4

I 4 COM5ONENT, COMMON 1ITH DOCUMENT ;+O,CH EDC -.C2 HDI IN<ECTION,8,TEM;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%6>

II 4 5REHEATER 5LUG, =--90? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%6>

CHAPTER ENGINE COOLING FUNCTION FRIC/INCORPORATED INTO THE INJECTION ECU/......................................4

I 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.0

II 4 FAN UNIT =-.-0?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.2

III 4 COOLANT TEM5ERATURE ,EN,OR =-220?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.6

I7 4 5O,T 7ENTILATION%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.6

7 4 DO1NGRADED MODE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.6

CHAPTER 17 COOLING REQUIREMENTS FOR THE AIRCONDITIONING BRAC/ INCORPORATED INTO THE

INJECTION ECU/.......................................................................................55I 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.9

II 4 AIR CONDITIONING 5RE,,URE,TAT =@00>?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.@

III 4 FAN UNIT =-.-0?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%90

I7 4 DO1NGRADED MODE %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%90

CHAPTER 11 PARTICLE FILTER FUNCTION.......................................61

I 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9-

II 4 5ARTICLE FILTER%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9.

III 4 CATAL8TIC CON7ERTER%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9>

C



I7 4 EHAU,T GA, TEM5ERATURE ,EN,OR =U5,TREAM OF THE CATAL8TICCON7ERTER? =-66?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9@

7 4 EHAU,T GA, TEM5ERATURE ,EN,OR =DO1N,TREAM OF THE CATAL8TICCON7ERTER? =-6?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9

7I 4 DIFFERENTIAL 5RE,,URE ,EN,OR =-6-?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%>0

7II 4 AIR TEM5ERATURE ,EN,OR =--0?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%>2

7III 4 AIRB1ATER HEAT ECHANGER =HEATING OF THE INLET AIR?%%%%%%%%%%%%%%%%%%%%%%>

I 4 INLET AIR HEATER THROTTLE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%>

4 THROTTLE HOU,ING CONTROL ELECTRO7AL7E =HEATING OF THE INLET AIR? =-2@.?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% >6

I 4 THROTTLE HOU,ING CONTROL ELECTRO7AL7E =EGR? =-29?%%%%%%%%%%%%%%%%%%%%%%%>>

II 4 +UILT4IN ,8,TEM, INTERFACE =+,I-?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%>>

III 4 IN<ECTION ECU =-20?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@-

CHAPTER 12 FUEL ADDITIVE FUNCTION............................................3

I 4 ADDITI7E%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@

II 4 ADDITI7E TAN %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@6

III 4 ADDITI7E IN<ECTION 5UM5 =-2@?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@.

III 4 LO1 ADDITI7E LE7EL ,EN,OR =-2@?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@9

I7 4 ,AFET8 7AL7E %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@>

7 4 ADDITI7E IN<ECTOR =-2@6?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%@

7I 4 FUEL FILLER CA5 5RE,ENCE ,EN,OR =620?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%0

7II 4 FUEL ,ENDER =-2--?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-

7III 4 +UILT4IN ,8,TEM, INTERFACE =+,I-?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

I 4 FUEL ADDITI7E ECU =-2@2?%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

CHAPTER 13 OPERATING PHASESHDI DIRECT INJECTION SYSTEM...........................................................5

I 4 COM5ONENT, COMMON 1ITH DOCUMENT ;+O,CH EDC -.C2 HDI IN<ECTION,8,TEM;%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%.

II 4 ,5ECIFIC COM5ONENT,%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9

III 4 TUR+OCHARGING 5RE,,URE REGULATION 4 FEATURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%9

I7 4 EHAU,T GA, REC8CLING REGULATION%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%>

7 4 5RE45O,T HEATING%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

7I 4 5REHEATING O5ERATION %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

7II 4 HEATING OF THE 5LUG, 1HIL,T CRANING%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

7III 4 5O,THEATING O5ERATION %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

I 4 ADDITIONAL HEATING%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-00

4 AIR CONDITIONING COM5RE,,OR CUT4OFF%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-06

I 4 ENGINE IMMO+ILI,ER FUNCTION%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-06

D



II 4 DI,5LA8ING FAULT,: DO1NGRADED MODE, O5ERATION%%%%%%%%%%%%%%%%%%%%%%%%%%-0.

III 4 COOLANT TEM5ERATURE 1ARNING LED =76020? 4 FEATURE%%%%%%%%%%%%%%%%%%%%%-0>

I7 4 CRUI,E CONTROL%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-0@

CHAPTER 14 OPERATING PHASES

PARTICLE FILTRATION..........................................................................17I 4 GENERAL 5RINCI5LE %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-0

II 4 DIAGRAM%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%--0

III 4 5ARTICLE FILTER LOAD LE7EL MONITORING FUNCTION%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%--2

I7 4 REGENERATION A,,I,TANCE MANAGEMENT FUNCTION%%%%%%%%%%%%%%%%%%%%%%%%%%%%%--9

7 4 EFFECT, OF ACTI7ATING REGENERATION A,,I,TANCE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-20

7I 4 FUEL ADDITI7E FUNCTION %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-2.

7II 4 DI,5LA8ING FAULT, 4 DO1NGRADED O5ERATING MODE,%%%%%%%%%%%%%%%%%%%%%%%%-2>

7III 4 DRI7ER, INFORMATION FUNCTION%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-2

CHAPTER 15 MAINTENANCEHDI INJECTION SYSTEM........................................................................131

I 4 RECOMMENDED FUEL %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%--

II 4 ,AFET8 IN,TRUCTION,%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-2

III 4 MAINTENANCE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-.

I7 4 RE5LACING 5ART,: O5ERATION, TO +E 5ERFORMED%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%->

7 4 1ARRANT8 RETURN 5ROCEDURE%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-60

CHAPTER 16 0IRING DIAGRAM.........................................................141

I 4 LA8OUT DIAGRAM %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-6-

II 4 5ART, LI,T%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%-62

E



C#8$-&% 1

GENERAL DETAILSHDI DIRECT INJECTION SYSTEM

N-& ,ome items metioed i this documet !#e commo to the )#ochu#e: ;HDIiectio s&stem; =doc -%9%-.?% Re"e#ece shou$d )e m!de to thisdocumet he#e ecess!#&%

N-& A$$ '!$ues s*eci"ied i this documet !#e gi'e !s guide$ies o$&% Re"e# tothe documet!tio co##es*odig to the 'ehic$e%

I FORE0ORD

The HDI s&stem "itted to the e D1-2 TED6 egie is )!sed o the s&stem"itted to the D1-0 egie !d ic$udes the "o$$oig !dditio!$ "e!tu#es:

• c&$ide# he!d ith -9 '!$'es =6 '!$'esBc&$ide#?/

• dou)$e com*$e3 sh!*e !i# i$et ducts i the c&$ide# he!d ='!#i!)$e si#$?/

• '!#i!)$e geomet#& tu#)och!#ge#

The HDI s&stem is used to "u$"i$ the #eui#emets o" the cu##et st!d!#ds#eg!#dig the "o$$oig:

• de*o$$utio/

• d#i'ig *$e!su#e/

• "ue$ s!'ig/

• mech!ic!$ #e$i!)i$it&%

I !dditio to these "e!tu#es/ ! *oe#"u$ *o$$ut!t *!#tic$e "i$t#!tio s&stem h!s)ee de'e$o*ed%

BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER

-



C#8$-&% 1

A 4 DE5OLLUTION

Fue$ com)ustio c!uses the emissio o" the "o$$oig *o$$ut!ts:

• c!#)o dio3ide =CO2?/

• c!#)o moo3ide =CO?/

• u)u#ed h&d#oc!#)os =HC?/

• it#oge o3ide =NO3?/

• c!#)o *!#tic$es%

Ati*o$$utio #egu$!tios !#e )eig tighteed u* !d $e!d to the "o$$oigde'e$o*mets:

• ist!$$!tio o" ! e3h!ust g!s #ec&c$ig de'ice =EGR? to #educe it#ogeo3ide emissios =NO3? =!te# coo$ed?/

• ist!$$!tio o" ! th#ott$e housig =EGR? to im*#o'e e3h!ust g!s #ec&c$ig%

Fittig ! c!t!$&tic co'e#te# #educes the "o$$oig *o$$ut!ts:

• c!#)o moo3ide =CO?/

• u)u#ed h&d#oc!#)os =HC?/

• c!#)o *!#tic$es%

Fittig ! -9 '!$'e c&$ide# he!d #educes the "o$$oig *o$$ut!ts:

• it#oge o3ides =NO3?/

• c!#)o *!#tic$es%

The du!$ it!e !i# i$et ducts i the c&$ide# he!d he$* to #educe *o$$ut!t*!#tic$es%

The "i$te# s&stem #emo'es )$!c smoe !d *o$$ut!t *!#tic$es !t "u$$ $o!d o#du#ig t#!sito#& o*e#!tio/ thus he$*ig to *#otect the e'i#omet%


2



C#8$-&% 1

+ 4 MAIN DE,IGN OF THE D1-2 TED6 ENGINE

U* uti$ o/ diese$ egies "itted to tou#ig c!#s h!'e used idi#ect iectio%

I idi#ect iectio/ the "ue$ is iected ude# ! m!3imum *#essu#e o" 00 )!#

ito ! com)ustio *#ech!m)e#%

I di#ect iectio/ the "ue$ is iected di#ect$& oto the to* o" the *isto%

Egie e""iciec& is im*#o'ed due to:

• )ette# u!$it& o" the !i#B"ue$ mi3tu#e/

• #eductio i he!t $osses/

• di#ect com)ustio i the c&$ide#s%

Fe!tu#es o" the e c&$ide# he!d desig o" the D1-2 TED6 egie:

• c&$ide# he!d ith -9 '!$'es/

• s*eci"ic $oc!tio o" the diese$ iecto#s =cet#!$ !d 'e#tic!$/ o*timis!tio o"!i#B"ue$ mi3tu#e?/

• dou)$e com*$e3 sh!*e !i# i$et m!i"o$ds i the c&$ide# he!d ='!#i!)$esi#$?/

• o *#ecom)ustio ch!m)e#/

• s*eci"ic $oc!tio o" the he!te# *$ugs =o the #e!# o" the c&$ide# he!d?%

Modi"ic!tios used to im*#o'e the e""iciec& o" the D1-2 TED6 egies:

• '!#i!)$e geomet#& tu#)och!#ge# =highe# tu#)och!#gig *#essu#e !t $oegie s*eeds?/

• o*timis!tio o" the i$et !d e3h!ust m!i"o$ds/

• #o$$e# '!$'e #oce#s $imitig $osses c!used )& "#ictio/

• eight #eductio%

Note: The above modifications also help to reduce pollutant emissionsdirectly.




C#8$-&% 1

II PRINCIPLE OF HDI

The de'ice/ de'e$o*ed i co$$!)o#!tio ith +O,CH/ is used to o# out ! ide!$iectio $!%

Iectio is *e#"o#med !t 'e#& high *#essu#e usig ! iectio #!i$ hich iscommo to the e$ect#oh&d#!u$ic iecto#s =c!$$ed commo #!i$?%

The commo iectio #!i$ is m!it!ied !t ! 'e#& high *#essu#e%

The iectio *#essu#e m!& #e!ch -.0 )!# !t high egie s*eed%

The iectio ECU iteg#!tes the "o$$oig *!#!mete#s:

• egie s*eed/

• coo$!t tem*e#!tu#e/

• !i# tem*e#!tu#e/

• "ue$ tem*e#!tu#e/

• "ue$ *#essu#e/

• *#essu#e i the i$et m!i"o$d/

• !tmos*he#ic *#essu#e/

• *ositio o" the !cce$e#!to# *ed!$/

• !i# "$o%The iectio ECU:

• o#s out the iectio time "#om the "ue$ *#essu#e/

• cot#o$s/ i" ecess!#&/ ! *#e4iectio =to #educe com)ustio oise? !d them!i iectio/

• cot#o$s the "ue$ "$o iected )& the e$ect#oh&d#!u$ic iecto#s%

Ad'!t!ges o" the e$ect#oic m!!gemet s&stem:

• d#i'ig *$e!su#e =.0 !dditio!$ to#ue !t $o egie s*eeds !d 2. mo#e*oe#?/

• ic#e!se i egie e""iciec& =!#oud 20 "ue$ s!'ig?/

• #eductio o" *o$$ut!t emissios =CO2/ CO/ HC/ !d c!#)o *!#tic$es?%


6



C#8$-&% 1

III PARTICLE FILTRATION PRINCIPLE

The !im o" the "i$t#!tio s&stem is to #educe emissios o" *!#tic$es #e$e!sed itothe !tmos*he#e =)$!c smoe #e$e!sed !t "u$$ $o!d o# du#ig t#!sito#& o*e#!tio?%

A *!#tic$e "i$te# is "itted o the e3h!ust *i*e !d t#!*s the *!#tic$es !s the e3h!ustg!s *!sses th#ough%

The !ccumu$!tio o" *!#tic$es hi$st the egie is o*e#!tig $e!ds to the*#og#essi'e c$oggig u* o" the *!#tic$e "i$te#%

To *#e'et the *!#tic$e "i$te# "#om )ecomig )$oced/ it must )e ;#egee#!ted;%

A 4 5ARTICLE FILTER REGENERATION 5RINCI5LE

Regee#!tio cosists o" *e#iodic!$$& )u#ig o"" the *!#tic$es !ccumu$!ted ithe *!#tic$e "i$te# esseti!$$& cosistig o" c!#)o !d h&d#oc!#)os% These*!#tic$es o the *!#tic$e "i$te# )u# i the *#esece o" o3&ge !t ! tem*e#!tu#eo" ..0°C =#egee#!tio $imit?%

Regee#!tio o" the *!#tic$e "i$te# is cot#o$$ed )& the iectio s&stem%

The iectio s&stem t#igge#s ! !dditio!$ iectio to ic#e!se the iiti!$tem*e#!tu#e o" the e3h!ust g!ses "#om !**#o3im!te$& -.0°C =u#)! d#i'ig? to6.0°C !t the i$et o" the c!t!$&tic co'e#te#%

This ic#e!se i tem*e#!tu#e occu#s i 2 ste*s:

• ! *ost iectio =!"te# To* De!d Cet#e? c#e!tes ! *ost com)ustio i thec&$ide# !d $e!ds to ! ic#e!se i tem*e#!tu#e o" 200 4 2.0°C/

• ! !dditio!$ *ost com)ustio/ gee#!ted )& ! o3id!tio c!t!$&ticco'e#te# *$!ced u*st#e!m o" the *!#tic$e "i$te#/ de!$s ith the u)u#ed

h&d#oc!#)os =HC? "#om the *ost iectio% The tem*e#!tu#e ic#e!ses )&-00°C hich !$$os the com)ustio $imit o" ..0°C to )e #e!ched%

+ 4 FUEL ADDITI7E FUNCTION

To $oe# the #egee#!tio $imit/ Eo$&s/ ! ce#ie )!sed com*osite/ is !dded tothe "ue$ hich $oe#s the *!#tic$e com)ustio tem*e#!tu#e "#om ..0°C to6.0°C%

Ce#ie is used i ! o#g!ic so$utio sto#ed i ! !dditio!$ t!/ $oc!ted e!#to the "ue$ t!

I o#de# to iect ! !mout o" !dditi'e *#o*o#tio!$ to the !mout o" "ue$

iected/ ! !dditi'e s&stem h!s )ee de'e$o*ed%The s&stem cosists o" the "o$$oig com*oets:

• ! suctio de'ice ith $o $e'e$ detectio o the !dditi'e t!/

• ! !dditi'e iectio s&stem i the "ue$ t!/

• ! s*eci"ic ECU cot#o$$ig the !dditi'e "uctio%


.



C#8$-&% 1

IV SAFETY INSTRUCTIONS

Note: The safety recommendations are given in a document contained in themechanical file of the vehicle in question.

A 4 FUEL ,U55L8 CIRCUITIMPORTANT Gi'e the 'e#& high *#essu#es =-.0 )!#? i the high *#essu#e

"ue$ ci#cuit/ "o$$o these ist#uctios%

Do ot smoe e!# to the high *#essu#e ci#cuit du#ig #e*!i#s%

A'oid o#ig e!# to "$!mes o# s*!#s%

1he the egie is #uig:

• do ot o# o the high *#essu#e "ue$ ci#cuit/

• !$!&s #em!i out o" the #!ge o" ! *ossi)$e et o" "ue$ hich m!& c!usese#ious iu#&/

• e'e# *ut &ou# h!d e!# to ! $e! o the high *#essu#e "ue$ ci#cuit%

A"te# sitchig o"" the egie/ !it "o# 0 secods )e"o#e st!#tig o#%

Note: It is necessary to wait for 30 seconds to allow the high pressure fuelcircuit to return to atmospheric pressure.

Fo# !$$ #e*!i# o#/ it is #ecommeded th!t g$o'es !d *#otecti'e gogg$es !#eo#%

+ 4 FUEL ADDITI7E CIRCUIT

Do ot smoe e!# to the "ue$ !dditi'e ci#cuit du#ig #e*!i#s%


The !dditi'e is ! s$ight si i##it!t it is #ecommeded th!t g$o'es !d*#otecti'e gogg$es !#e o#%

E'i#omet!$ *#otectio: used !dditi'e !d the com*oets used "o#c$e!ig the "i$te# must )e t#e!ted%


9



C#8$-&% 1

C 4 O5ERATION, ON THE 5ARTICLE FILTER

08%*!*" Fo#ced #egee#!tio $e!ds to ! 'e#& high e3h!ust g!s tem*e#!tu#e=6.0°C !t the e3h!ust *i*e out$et?%

5#ec!utios to )e t!e:

• !$!&s ee* e$$ !!& "#om the e3h!ust *i*e/

• use suit!)$e e3h!ust g!s e3t#!ctio eui*met/

• the o# !#e! must )e c$e! !d tid&/

• the 'ehic$e ch!ssis must )e c$e!%

It is #ecommeded th!t ! m!s !d *#otecti'e gogg$es !#e o# he

#emo'ig !d #e"ittig the *!#tic$e "i$te# =#is o" ih!$ig ce#ie?%


>



C#8$-&% 1


@



C#8$-&% 2

GENERAL LAYOUTHDI SYSTEM

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C#8$-&% 2

REF. DESCRIPTIONPART NUMBER IN THE 0IRING

DIAGRAMS

- Additio!$ he!tig cot#o$ #e$!& +C5

2 Additio!$ he!tig =e$ect#ic #esisto#s =2!? o#

he!te# =2)?? =J?

@0@ 4 --0

7!#i!)$e geomet#& tu#)och!#ge# 44

6 Ai# "$omete# B !i# tem*e#!tu#e seso# --0

. Ai# "i$te# 44

9 C!t!$&tic co'e#te# 44

> 5!#tic$e "i$te# 44

@ Tu#)och!#gig *#essu#e #egu$!tioe$ect#o'!$'e

-2

Rec&c$ig #egu$!tio e$ect#o'!$'e =EGR? -2.

-0 7!#i!)$e geomet#& tu#)o cot#o$ di!*h#!gm 44

-- E3h!ust g!s #ec&c$ig '!$'e =EGR? 44

-2 E3h!ust g!s B !te# he!t e3ch!ge# 44

- Iectio ECU -20

-6 Atmos*he#ic *#essu#e seso# =ico#*o#!tedito iectio ECU?

-20

-. E$ect#oic st!)i$it& *#og#!m ECU =J? >@00

-9 Autom!tic ge!#)o3 ECU =J? -90

-> T#i* com*ute# =J? 44-@ E$ect#oic #e' coute# 62-0

- 5#ehe!tig LED 7--.0

20 Di!gostic LED 7-00

2- F! uit -.-0

22 Ai# coditioig com*#esso# @020

2 Coo$!t tem*e#!tu#e !#ig LED 76020

26 Coo$!t tem*e#!tu#e g!uge 6029

2. C#uise cot#o$ sitch >00

29 C#uise cot#o$ s!"et& cot!ct >0.

2> Redud!t )#!e sitch >0@

2@ ,itch modu$e !t stee#ig hee$ =COM2000?

C700


-0



C#8$-&% 2


DIAGRAMS

2 +ui$t4i s&stems ite#"!ce =+,I? +,I-

0 Cet#!$ di!gostic socet C00-

- +!tte#& ++002 Dou)$e iectio #e$!& =egie #e$!& uit? +,M

7ehic$e s*eed seso# -920

6 Acce$e#!to# *ed!$ *ositio seso# -29-

. C$utch *ed!$ sitch >09

9 +#!e *ed!$ sitch 2-00

> Coo$!t tem*e#!tu#e seso# -220

@ Fue$ t! 44

Lo *#essu#e *um* -2--

60 E$ect#ic "ue$ he!te# -2>96- 5#e4*ost he!tig uit --.0

62 Fue$ coo$ig 44

6 Fue$ "i$te# 44

66 High *#essu#e "ue$ *um* 44

6. High *#essu#e "ue$ #egu$!to# -22

69 Fue$ tem*e#!tu#e seso# --0

6> High *#essu#e "ue$ seso# -2-

6@ High *#essu#e "ue$ commo iectio #!i$ 44

6 5#ehe!te# *$ugs --90

.0 Egie s*eed seso# --

.- C!msh!"t *ositio seso# ---.

.2 High *#essu#e "ue$ *um* #d *istode!cti'!to#

-2>>

. Diese$ iecto#s -- 4 -2 4 - 4 -6

.6 ;,i#$; cot#o$ e$ect#o'!$'e -296

.. ;,i#$; cot#o$ di!*h#!gm 44

.9 Th#ott$e housig cot#o$ e$ect#o'!$'e =EGR? -29

.> Th#ott$e housig =EGR? 44

.@ Ai# B !i# he!t e3ch!ge# 44

. I$et m!i"o$d *#essu#e seso# --2

Note: (! depending on version.


--



C#8$-&% 2


-2



C#8$-&% 4

FUEL SUPPLY FUNCTION

I DIAGRAM

,DI0025

A

B

C

1

5

6

23

22

21

2 3

4

1

1

271

17

11

1213

14

15

16

:&; A 4 Retu# to "ue$ t! ci#cuit+ 4 Lo *#essu#e "ue$ ci#cuitC 4 High *#essu#e "ue$ ci#cuit


-



C#8$-&% 4

P8%-' )!'-


DIAGRAMS

- 4 6 Diese$ iecto#s =e$ect#oh&d#!u$ic? --- 4 --2 4 -- 4 --6

. High *#essu#e "ue$ commo iectio #!i$ 449 High *#essu#e "ue$ seso# -2-

> Fue$ tem*e#!tu#e seso# -22-

@ Fue$ coo$e# 44

Fue$ t! 44

-0 Lo *#essu#e *um* -2--

-- Fue$ *#e4"i$te# 44

-2 ,!"et& '!$'e =*#essu#e4'!cuum? 44

- Additi'e t! 44-6 Lo !dditi'e $e'e$ seso# -2@

-. Additi'e iectio *um* -2@

-9 5$ug =o'e#"$o? 44

-> Additi'e iecto# -2@6

-@ E$ect#ic "ue$ he!te# -2>9

- 1!te# )$eed sc#e 44

20 Fue$ "i$te# K !te# dec!te# K $o

*#essu#e ci#cuit *#essu#e #egu$!to#

44

2- High *#essu#e "ue$ *um* 44

22 High *#essu#e "ue$ #egu$!to# o the high*#essu#e "ue$ *um*

-22

2 High *#essu#e "ue$ *um* #d *istode!cti'!to#

-2>>


-6



C#8$-&% 4

II COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<

Commo com*oets:

• "ue$ t!/

• $o *#essu#e *um* =-2--?/

• "ue$ "i$te# =the#most!tic e$emet?/

• high *#essu#e "ue$ *um*/

• high *#essu#e "ue$ *um* #d *isto de!cti'!to# =-2>>?/

• high *#essu#e "ue$ #egu$!to# =-22?/

• high *#essu#e "ue$ commo iectio #!i$/

• diese$ iecto#s =---/ --2/ --/ --6?/

• "ue$ coo$e#%

Note: The filtration housing is fitted with a water in the fuel detector ("0#0! (ma$ore%port!.

III SPECIFIC COMPONENTS

,*eci"ic "e!tu#es o" the D1-2 TED6 egie:

• e$ect#ic "ue$ he!te# =-2>9?/

• high *#essu#e "ue$ *um* ith )$ue su**$ie#s *$!te%


-.



C#8$-&% 4

IV ELECTRIC FUEL HEATER 126/

A 4 ROLE

The "ue$ he!te# #!ises the "ue$ to its us!ge tem*e#!tu#e%

+ 4 DE,CRI5TION

,DI00:C

2 1

The "ue$ he!te# he!ts the "ue$ "#om the "ue$ t!%

The "ue$ he!te# cosists o" ! he!tig #esisto#%

The tem*e#!tu#e is #egu$!ted )& ! the#most!t:

• "ue$ tem*e#!tu#e o" 42 =KB42?°C: "ue$ he!te# !cti'!ted/

• "ue$ tem*e#!tu#e o" K =KB42?°C: "ue$ he!te# de!cti'!ted%

C 4 ELECTRIC FEATURE,

A$$oc!tio o" coecto# ch!e$s:

• ch!e$ -: -2 'o$ts =K igitio o?/

• ch!e$ 2: e!#th%

5oe#: -.0 1%

D 4 LOCATION

The "ue$ he!te# is $oc!ted o the "ue$ "i$te# i$et *i*e%

V LO0 PRESSURE PUMP SUPPLY CUTOFF

The !i#)!g ECUs ico#*o#!te the $o *#essu#e *um* cut4o"" "uctio =ie#ti!sitch discotiued?%


-9



C#8$-&% 4

AIR SUPPLY FUNCTION

I DIAGRAM

,DI0065

A

B

C1 1 16 15 14

11

17

27

1

21

26

13

12

6

4

25

24

22

23

1

2

5

923

8

2


->



C#8$-&% 4

A!% ,!%,()8-!* =))>!*" 8%%>'/

A 4 E3te#io# !i# i$et

+ 4 E3h!ust g!ses K !i#

C 4 E3h!ust g!ses

! 4 ,ho#t i$et duct =he$ic!$ sh!*e? ) 4 Log i$et duct =t!geti!$?

P8%-' )!'-

REF. DESCRIPTIONPART NUMBER IN

THE 0IRINGDIAGRAMS

COMMENTS

- Th#ott$e housig cot#o$e$ect#o'!$'e =EGR?

-29

2 ;,i#$; cot#o$ e$ect#o'!$'e -296

;,i#$; cot#o$ di!*h#!gm 44 7!cuum cot#o$$ed

6 Rec&c$ig #egu$!tioe$ect#o'!$'e =EGR?

-2.

. 7!cuum *um* 44

9 7!cuum #ese#'e 44

> E3h!ust g!s #ec&c$ig '!$'e=EGR?

44 7!cuum cot#o$$ed

@ Tu#)och!#gig *#essu#e#egu$!tio e$ect#o'!$'e

-2

E3h!ust g!s m!i"o$d 44-0 I$et !i# he!te# th#ott$e cot#o$

e$ect#o'!$'e-2@.

-- 7!#i!)$e geomet#& tu#)o cot#o$di!*h#!gm

44 7!cuum cot#o$$ed

-2 Fied di""use# *isto 44

- 5!#tic$e "i$te# K c!t!$&ticco'e#te#

44

-6 E3h!ust tu#)ie 44

-. 7!#i!)$e geomet#& tu#)och!#ge# 44

-9 I$et !i# tu#)ie 44

-> Ai# "$omete# K !i# tem*e#!tu#eseso#

--0


-@



C#8$-&% 4


THE 0IRINGDIAGRAMS

COMMENTS

-@ Ai# "i$te# 44

- Ai#B!i# he!t e3ch!ge# 44

20 Ai#B!te# he!t e3ch!ge# =i$et!i# he!te#?

44

2- I$et m!i"o$d *#essu#e seso# --2

22 I$et !i# he!te# th#ott$e 44 7!cuum cot#o$$ed

2 ;,i#$; cot#o$ th#ott$e 44

26 I$et !i# m!i"o$d 44

2. E3h!ust g!sBcoo$!t e3ch!ge# 44

29 Th#ott$e housig =EGR? 44 7!cuum cot#o$$ed

2> Iectio ECU -202@ Atmos*he#ic *#essu#e seso#

=ico#*o#!ted ito iectioECU?

-20

Note: &': e%haust gas recycling.

T(%9,#8%"!*" $%&''(%& %&"()8-!* &)&,-%?8)?& 1hiteBg#e& #e"e#eced hose o**osite hite s*ot o e$ect#o'!$'e

S>!%) ,*-%) &)&,-%?8)?&

Um!#ed hoseEGR %&"()8-!* &)&,-%?8)?& 1hiteB)$ue #e"e#eced hose o**osite hite s*ot o e$ect#o'!$'e

EGR -#%--)& #('!*" ,*-%) &)&,-%?8)?& 1hiteB)$!c #e"e#eced hose o**osite hite s*ot o e$ect#o'!$'e

I*)&- 8!% #&8-&% -#%--)& ,*-%) &)&,-%?8)?& 1hiteB)#o #e"e#eced hose o**osite hite s*ot o e$ect#o'!$'e

I*)&- 8!% #&8-&% -#%--)&

+#o c!*su$e 4 )#o #e"e#eced hose

EGR -#%--)& #('!*" +$!c c!*su$e 4 )$!c #e"e#eced hose


-



C#8$-&% 4


Com*oets commo ith the documet:

• !i# "i$te#/

• !tmos*he#ic *#essu#e seso# =-20?/

• !i#B!i# he!t e3ch!ge#/

• i$et m!i"o$d *#essu#e seso# =--2?/

• '!cuum *um*/

• tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e =-2?%



• '!cuum #ese#'e/

• '!#i!)$e geomet#& tu#)och!#ge#/

• '!#i!)$e ;si#$;/

• ;,i#$; cot#o$ e$ect#o'!$'e =-296?%


20



C#8$-&% 4

IV VACUUM RESERVE

A 4 ROLE

The '!cuum #ese#'e !$$os su""iciet )#!ig !ssist!ce to )e m!it!ied i"

the "o$$oig com*oets !#e cot#o$$ed simu$t!eous$&:• ;,i#$; cot#o$ )utte#"$& '!$'e/

• i$et !i# he!te# )utte#"$& '!$'e/

• '!#i!)$e geomet#& tu#)o cot#o$ di!*h#!gm%

+ 4 DE,CRI5TION

,DI00.

& @

,

c 4 7!cuum *um* '!cuum i$et

d 4 Out$et: ;,i#$; cot#o$ )utte#"$& '!$'e

e 4 Out$et: '!#i!)$e geomet#& tu#)o cot#o$ di!*h#!gm

C!*!cit& 0%. Lit#e

C 4 LOCATION

The '!cuum #ese#'e is $oc!ted i the egie com*!#tmet/ e!# to the )#!ese#'o =de*edig o 'ehic$e?%

Note: The vacuum circuit contains 3 no))les of 0.## mm.


2-



C#8$-&% 4

V VARIABLE GEOMETRY TURBOCHARGER

A 4 ROLE

The tu#)och!#ge# is used to tu#)och!#ge the !i# ete#ig the egie%

The '!#i!)$e geomet#& tu#)och!#ge# is used:• to ic#e!se the s*eed o" the e3h!ust g!ses hich st#ie the tu#)ie !t $o

egie s*eeds/

• to #educe the s*eed o" the e3h!ust g!ses hich st#ie the tu#)ie !t highegie s*eeds/

• to !d!*t the tu#)ie to ! '!#i!tio i e3h!ust g!s "$o%

+ 4 DE,CRI5TION

,DI009D

"

=

16

2

16

12

11

14

14

-- 4 Fied di""use# *isto cot#o$ di!*h#!gm: '!cuum cot#o$$ed

-2 4 Fied di""use# *isto-6 4 E3h!ust tu#)ie

-9 4 I$et !i# tu#)ie

2 4 The#m!$ housig

" 4 G!ses "#om the e3h!ust m!i"o$d

g 4 To i$et m!i"o$d

The tu#)och!#ge# h!s to se*!#!te ch!m)e#s%


22



C#8$-&% 4

The tu#)och!#ge# cosists o" the "o$$oig com*oets:

• ! ch!m)e# $ied to the egie e3h!ust "uctio/

• ! ch!m)e# $ied to the i$et "uctio/

• ! tu#)ie !d ! com*#esso#/ oied togethe# )& ! sh!"t%

The tu#)ie/ d#i'e )& the e3h!ust g!ses/ d#i'es the com*#esso# hichcom*#esses the i$et !i#%

The mo'emet o" the *isto =-2? !$$os the i$et c#oss sectio o" the e3h!usttu#)ie to )e '!#ied i o#de# to !$te# the s*eed o" the e3h!ust g!ses%

The #egu$!tio e$ect#o'!$'e cot#o$s the tu#)och!#gig *#essu#e #egu$!to#*isto =-2?%

The tu#)och!#gig *#essu#e is #egu$!ted *#og#essi'e$& !d is cot#o$$ed )& !c!#tog#!*hic m!* =iectio ECU?%

Note: *ubrication of the turbocharger: careful lubrication is required due tothe very high speeds of the moving parts and the high temperaturesto be dissipated.

The *#essu#ised oi$ #eui#ed "o# this "uctio is t!e "#om the egies oi$ci#cuit%

IMPORTANT +e"o#e sitchig o"" the egie/ it is esseti!$ to $et the egie#etu# to id$e s*eed% F!i$u#e to com*$& ith this coditio i$$e'etu!$$& dest#o& the tu#)och!#ge# =due to $!c o"$u)#ic!tio?%


2



C#8$-&% 4

C 4 O5ERATION AT LO1 ENGINE ,5EED

,DI00>D

12

14

The g!s "$o *!ssig th#ough the e3h!ust tu#)ie =-6? is $o%

To ic#e!se the tu#)och!#gig *#essu#e/ ! m!3imum !mout o" ee#g& must)e co'e#ted i the tu#)ie%

The e3h!ust g!ses must )e m!de to *!ss th#ough ! sm!$$ c#oss sectio: the

"ied di""use# *isto =-2? is c$osed%

N-& The "ied di""use# *isto is c$osed he it is ot cot#o$$ed*eum!tic!$$&%


26



C#8$-&% 4

D 4 O5ERATION AT HIGH ENGINE ,5EED

,DI00@D

14

12

Tu#)och!#gig *#essu#e #egu$!tio: the ee#g& o" the e3h!ust g!ses iscot#o$$ed )& !dustig the s*eed !t hich the g!ses ete# the e3h!ust tu#)ie)& !$te#ig the *ositio o" the "ied di""use# *isto%

Cot#!#& to ! "i3ed geomet#& tu#)och!#ge#/ !$$ o" the e3h!ust g!s "$o *!ssesth#ough the e3h!ust tu#)ie =o ee#g& $ost?%


2.



C#8$-&% 4

VI VARIABLE <S0IRL<

,DI00C

9

8

! 4 ,ho#t i$et duct =he$ic!$ sh!*e?

) 4 Log i$et duct =t!geti!$?

Usig the sho#t i$et duct !$$os m!3imum si#$ to )e o)t!ied =si#$ mo'emet?%

Ai# is $et ito the i$et ducts )& o*eig the ;,i#$; cot#o$ )utte#"$& '!$'e !t highegie s*eeds%

Usig 2 i$et ducts !$$os m!3imum "i$$ig =#educed si#$?%

Ad'!t!ges o" the '!#i!)$e ;,i#$;:

• o*timis!tio o" com)ustio =!i#B"ue$ mi3tu#e?/

• )ette# *e#"o#m!ceB*o$$ut!t emissios com*#omise%

The '!#i!)$e ;,i#$; gi'es ! #eductio i c!#)o *!#tic$es%


29



C#8$-&% 4

VII S0IRL CONTROL ELECTROVALVE 1264/

A 4 ROLE

The ,i#$ cot#o$ e$ect#o'!$'e cot#o$s the ,i#$ cot#o$ di!*h#!gm%

+ 4 DE,CRI5TIONThe cot#o$ e$ect#o'!$'e coects the '!cuum *um* !d the ,i#$ cot#o$di!*h#!gm%

,DI0-0C

#

)

h 4 7!cuum i$et "#om the '!cuum #ese#'e

4 Atmos*he#ic *#essu#e i$et

4 E$ect#ic!$ coecto#

$ 4 ;Us!ge; out$et

The e$ect#o'!$'e is cot#o$$ed ith ! OCR =O*e C&c$e R!tio? !d usig !c!#tog#!*hic m!* =iectio ECU?%

The e$ect#o'!$'e is su)ect to the "o$$oig:


• '!cuum su**$ied )& the '!cuum *um*%

The *#essu#e su**$ied )& the e$ect#o'!$'e is )etee !tmos*he#ic *#essu#e

!d the '!cuum "#om the '!cuum *um*%

08%*!*" The ;,i#$; cot#o$ th#ott$e is c$osed he it is ot cot#o$$ed*eum!tic!$$&%

Coditios !$$oig the th#ott$e to o*e:

• egie s*eed !)o'e 2-00 #*m =!t @0°C? =2.00 #*m !t 0°C?/

• iected "ue$ "$o g#e!te# th! 60 mgBst#oe%


2>



C#8$-&% 4

C 4 ELECTRICAL FEATURE,

Cot#o$: iectio ECU =e!#th?%

Fu$$ su**$& =m!3imum OCR? m!3imum '!cuum%

No su**$& =miimum OCR? o '!cuum =!tmos*he#ic *#essu#e?%

Resist!ce !t 2. °C 2@ ohms%

D 4 LOCATION

The ,i#$ cot#o$ e$ect#o'!$'e is $oc!ted o the coo$!t out$et housig%

VIII FEATURE INLET MANIFOLD PRESSURE SENSOR 1312/

,DI0--C

The i$et m!i"o$d *#essu#e seso# is $oc!ted o the out$et o" the !i#B!i# he!te3ch!ge#%


2@



C#8$-&% 5

EHAUST GAS RECYCLING FUNCTION

I DIAGRAM

,DI0065

A

B

C1 1 16 15 14

11

17

27

1

21

26

13

12

6

4

25

24

22

23

1

2

5

923

8

2


2



C#8$-&% 5

A!% ,!%,()8-!* =))>!*" 8%%>'/

A 4 E3te#io# !i# i$et

+ 4 E3h!ust g!ses K !i#

C 4 E3h!ust g!ses

! 4 ,ho#t i$et duct =he$ic!$ sh!*e? ) 4 Log i$et duct =t!geti!$?

P8%-' )!'-


THE 0IRINGDIAGRAMS

COMMENTS

- Th#ott$e housig cot#o$e$ect#o'!$'e =EGR?

-29

2 ;,i#$; cot#o$ e$ect#o'!$'e -296

;,i#$; cot#o$ di!*h#!gm 44 7!cuum cot#o$$ed6 Rec&c$ig #egu$!tio

e$ect#o'!$'e =EGR?-2.

. 7!cuum *um* 44

9 7!cuum #ese#'e 44

> E3h!ust g!s #ec&c$ig '!$'e=EGR?

44 7!cuum cot#o$$ed

@ Tu#)och!#gig *#essu#e#egu$!tio e$ect#o'!$'e

-2

E3h!ust g!s m!i"o$d 44-0 I$et !i# he!te# th#ott$e cot#o$

e$ect#o'!$'e-2@.

-- 7!#i!)$e geomet#& tu#)o cot#o$di!*h#!gm

44 7!cuum cot#o$$ed

-2 Fied di""use# *isto 44

- 5!#tic$e "i$te# K c!t!$&ticco'e#te#

44

-6 E3h!ust tu#)ie 44

-. 7!#i!)$e geomet#& tu#)och!#ge# 44

-9 I$et !i# tu#)ie 44

-> Ai# "$omete# K !i# tem*e#!tu#eseso#

--0


0



C#8$-&% 5


THE 0IRINGDIAGRAMS

COMMENTS

-@ Ai# "i$te# 44

- Ai#B!i# he!t e3ch!ge# 44

20 Ai#B!te# he!t e3ch!ge# =i$et!i# he!te#?

44

2- I$et m!i"o$d *#essu#e seso# --2

22 I$et !i# he!te# th#ott$e 44 7!cuum cot#o$$ed

2 ;,i#$; cot#o$ th#ott$e 44

26 I$et !i# m!i"o$d 44

2. E3h!ust g!sBcoo$!t e3ch!ge# 44

29 Th#ott$e housig =EGR? 44 7!cuum cot#o$$ed

2> Iectio ECU -202@ Atmos*he#ic *#essu#e seso#

=ico#*o#!ted ito iectioECU?

-20

Note: &': e%haust gas recycling.


-



C#8$-&% 5



• !i# "$omete# =--0?/

• e3h!ust g!s #ec&c$ig '!$'e =EGR?/

• #ec&c$ig #egu$!tio e$ect#o'!$'e =EGR? =-2.?%



• !te#Be3h!ust g!s e3ch!ge# =EGR?/

• #ec&c$ig #egu$!tio e$ect#o'!$'e =EGR? =-2.?/

• th#ott$e housig =EGR?/

• th#ott$e housig cot#o$ e$ect#o'!$'e =EGR? =-29?%

IV 0ATEREHAUST GAS ECHANGER EGR/

A 4 ROLE

The !te#Be3h!ust g!s he!t e3ch!ge# coo$s the #ec&c$ed e3h!ust g!ses $etito the c&$ide#s%

+ 4 LOCATION

Loc!tio: o the #e!# o" the c&$ide# he!d =)u$he!d side?%

V THROTTLE HOUSING EGR/

A 4 ROLE

I !dditio to the EGR '!$'e/ the th#ott$e housig/ de*edig o its *ositio/ isused to im*#o'e e3h!ust g!s #ec&c$ig% The th#ott$e housig is cot#o$$ed*#og#essi'e$& !d usig ! c!#tog#!*hic m!* =iectio ECU?%

08%*!*" The th#ott$e housig is o*e he it is ot cot#o$$ed*eum!tic!$$&%

+ 4 LOCATION

The th#ott$e housig is $oc!ted !t the i$et to the i$et m!i"o$d%


2



C#8$-&% 5

VI THROTTLE HOUSING CONTROL ELECTROVALVE EGR/ 1263/

A 4 ROLE

The e$ect#o'!$'e cot#o$s the c$osig o" the th#ott$e housig%

+ 4 DE,CRI5TION

The e$ect#o'!$'e is the s!me !s the "o$$oig e$ect#o'!$'es:

• tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e/

• #ec&c$ig #egu$!tio e$ect#o'!$'e =EGR?/

• i$et !i# he!te# th#ott$e cot#o$ e$ect#o'!$'e%

The e$ect#o'!$'e coects the '!cuum *um* to the th#ott$e housig:

• the g#e!te# the '!cuum/ the mo#e the th#ott$e housig c$oses/

• the $oe# the '!cuum/ the mo#e the th#ott$e housig o*es%

C 4 LOCATION

,DI0-2C

1

The e$ect#o'!$'e is $oc!ted i the egie com*!#tmet%




C#8$-&% 5


6



C#8$-&% 6

HDI SYSTEM

I COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<



• high *#essu#e "ue$ *um* #d *isto de!cti'!to# =-2>>?/

• high *#essu#e "ue$ #egu$!to# =-22?/


• )!tte#& =++00?/

• dou)$e iectio #e$!& =-06?/

• !cce$e#!to# *ed!$ seso# =-29-?/

• egie s*eed seso# =--?/

• c!msh!"t *ositio seso# =---.?/

• coo$!t tem*e#!tu#e seso# =-220?/

• !i# tem*e#!tu#e seso# =--0?/

• "ue$ tem*e#!tu#e seso# =-22-?/

• high *#essu#e "ue$ seso# =-2-?/

• 'ehic$e s*eed seso# =-920?/

• )#!e sitch =2-00?/

• s*eci"ic "e!tu#e o" the diese$ iecto# cot#o$%


.



C#8$-&% 6

II SPECIFIC COMPONENTS


• iectio ECU =-20?/

• diese$ iecto#s =--/ -2/ -/ -6?%

III DOUBLE INJECTION RELAY BSM/ FEATURE

The dou)$e #e$!& is ico#*o#!ted ito the egie #e$!& uit =+,M?%

,DI0-:C

1

- 4 Dou)$e #e$!&


9



C#8$-&% 6

IV COOLANT TEMPERATURE SENSOR 1227/ FEATURE

A 4 ROLE

The coo$!t tem*e#!tu#e seso# i"o#ms the ECU o" the tem*e#!tu#e o" the

egie coo$!t%

Ro$e o" the iectio ECU de*edig o the i"o#m!tio #ecei'ed:

• to !dust the *#ehe!tig time/

• to !dust the *ost4he!tig time/

• to !dustig the st!#tig "$o/

• to !dust the id$e s*eed/

• to !utho#ise e3h!ust g!s #ec&c$ig =EGR?/

• to !dust the "ue$ "$o/

• to $imit the iected "$o i" the coo$!t tem*e#!tu#e is c#itic!$ =!ti4)oi$"uctio?/

• to cot#o$ the o*e#!tio o" the #!di!to# "!s/

• to cot#o$ the coo$!t tem*e#!tu#e g!uge o the ist#umet *!e$ =J?/

• to cot#o$ the !#ig !d *#e4!#ig LEDs =J?%


+ 4 DE,CRI5TION

G#ee 24!& seso#%

The seso# cosists o" ! Neg!ti'e Tem*e#!tu#e Coe""iciet #esisto# =NTC?%

The highe# the tem*e#!tu#e/ the $oe# its #esist!ce%


>



C#8$-&% 6

C 4 LOCATION

,DI0-6C 2

2 4 coo$!t tem*e#!tu#e seso#%

The coo$!t tem*e#!tu#e seso# is $oc!ted o the coo$!t housig%

The#e !#e 2 t&*es o" !ssem)$&%

Met!$ coo$!t out$et housig%

• the coo$!t tem*e#!tu#e seso# is sc#eed i/

• it is se!$ed )& ! co**e# se!$%

5$!stic coo$!t out$et housig:

• the tem*e#!tu#e seso# is secu#ed )& ! *$!stic c$i*/

• it is se!$ed )& ! O4#ig%


@



C#8$-&% 6

V FUEL TEMPERATURE SENSOR 1221/ FEATURE

A 4 ROLE


• to !dust the "ue$ "$o/

• to c!$cu$!te the "ue$ desit&%

+ 4 DE,CRI5TION

,DI0-.C

3

4 Fue$ tem*e#!tu#e seso#


The highe# the tem*e#!tu#e/ the $oe# its #esist!ce:

• #esist!ce !t 20 °C 2 ohms/

• #esist!ce !t @0 °C 2@> ohms%

C 4 LOCATION

The "ue$ tem*e#!tu#e seso# me!su#es the tem*e#!tu#e o" the "ue$ di#ect$& othe t! #etu# ci#cuit%




C#8$-&% 6

VI BRA:E S0ITCH 2177/ FEATURE

A 4 ROLE

The sitch !$$os the iectio ECU to esu#e co##ect d#i'ig com"o#t%

The e$ect#ic!$ i"o#m!tio su**$ied )& the )#!e sitch is t#!smitted to the+,I !d set to the iectio ECU 'i! the mu$ti*$e3ed eto# =J?%

=J? de*edig o 'e#sio%

+ 4 LOCATION

The )#!e sitch is $oc!ted o the *ed!$ set%

VII CRUISE CONTROL BRA:E PEDAL S0ITCH 37/ FEATURE

A 4 ROLE

The sitch !$$os the iectio ECU to esu#e co##ect d#i'ig com"o#t%

The i"o#m!tio "#om the )#!e sitches is cost!t$& com*!#ed ith e!chothe# i o#de# to detect !& "!u$ts%

+ 4 LOCATION

The )#!e sitch is $oc!ted o the *ed!$ set%

VIII CLUTCH S0ITCH 376/ FEATURE

A 4 ROLE

The c$utch sitch !$$os the iectio ECU to *e#"o#m the d#i'e id$e "uctio%

+ 4 LOCATION

The c$utch sitch is $oc!ted o the *ed!$ set%

I VEHICLE SPEED SENSOR FEATURE

The 'ehic$e s*eed i"o#m!tio is t#!smitted )& the A+, ECU o the mu$ti*$e3edeto#s%


60



C#8$-&% 6

INJECTION ECU 1327/ FEATURE

A 4 ROLE

The ECU cot#o$s !$$ o" the iectio s&stem%

The ECU so"t!#e ico#*o#!tes:

• the "uctios "o# cot#o$$ig iectio !d de*o$$utio/

• the d#i'ig *$e!su#e st#!tegies/

• the egie immo)i$ise# "uctio/

• the eme#gec& st#!tegies/

•

cot#o$ o" the "! uits !d !#ig LEDs =J?/

• cot#o$ o" the coo$!t he!tig s&stems "o# the he!te# m!t#i3 =J?/

• di!gostics ith "!u$t memo#isig/

• the c#uise cot#o$ "uctio =J?/

• the di!$ogue ith !$$ ECUs o" the mu$ti*$e3ed eto#s%


The ECU e$ect#ic!$$& o*e#!tes the "o$$oig com*oets:

• diese$ iecto#s/


• high *#essu#e "ue$ #egu$!to#/

• #ec&c$ig #egu$!tio e$ect#o'!$'e/

• *#e !d *ost he!tig uit =*ost4he!tig cut4out?

• high *#essu#e "ue$ *um* #d *isto de!cti'!to#%

The ECU su**$ies the "o$$oig i"o#m!tio:

• egie s*eed: to the ist#umet *!e$ di!$s

• ist!t cosum*tio: to the t#i* com*ute#/

• !i# coditioig cut4o""/

• coo$!t he!te# o*e#!tio !utho#is!tio =de*edig o 'e#sio?%


6-



C#8$-&% 6

The !tmos*he#ic *#essu#e seso# c!ot )e #emo'ed "#om the iectio ECU%

The ECU h!s ! *oe# st!ge hich is c!*!)$e o" *#o'idig the 'e#& highcot#o$ cu##et #eui#ed "o# the iecto#s to o*e#!te%

The ECU is coected to the iectio h!#ess )& ! @@ t#!c coecto#%The iectio ECU so"t!#e is u*g#!ded )& do$o!dig =ECU ith ! "$!shE5ROM?%

+ 4 ALLOCATION OF ECU CHANNEL,

CHANNEL N DESCRIPTION

- K-2 7 su**$& =!"te# dou)$e #e$!&? =egie #e$!& uit?

2 Iecto# °- cot#o$

Iecto# ° cot#o$6 Iecto# °6 cot#o$

. Iecto# °2 cot#o$

9 Iecto# °2 cot#o$

> 4

@ Di!gostic $ie "o# the coi$s o" the "! uit cot#o$ #e$!&s

Di!$ogue $ie: CAN H eto#

-0 4

-- I*ut: !i# tem*e#!tu#e seso# ="$omete#?

-2 ,u**$&: c!msh!"t *ositio seso# B di""e#eti!$ *#essu#eseso#

- I*ut: !i# "$o sig!$ ="$omete#?

-6 I*ut: egie s*eed seso# sig!$

-. I*ut: !cce$e#!to# *ed!$ seso# sig!$

-9 4

-> 4

-@ I*ut: c!msh!"t seso# sig!$

- 420 4


62



C#8$-&% 6


2- I*ut: c$utch sitch

22 ,eso#s e!#th

2 44426 Out*ut: ,i#$ cot#o$ e$ect#o'!$'e

2. Out*ut: "! uit - cot#o$ =high s*eed?

29 Out*ut: tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e

2> E!#th: di""e#eti!$ *#essu#e seso#

2@ Out*ut: i$et !i# he!te# th#ott$e cot#o$ e$ect#o'!$'e

2 K-2 'o$ts su**$& =!"te# dou)$e #e$!&? =egie #e$!& uit?

0 Iecto# N° - cot#o$

- Iecto# N° cot#o$

2 Iecto# N° 6 cot#o$

E!#th

6 ,eso#s e!#th

. 444

9 Egie immo)i$ise# se#i!$ $ie =J?

> Di!$ogue $ie: CAN L eto#

@ di!gostic $ie

I*ut: "ue$ tem*e#!tu#e seso#

60 E!#th: c!msh!"t *ositio seso#

6- I*ut: egie s*eed seso# sig!$

62 I*ut: di""e#eti!$ *#essu#e seso#

6 444

66 ,eso#s su**$& =. 'o$ts?

6. E!#th: coo$!t tem*e#!tu#e seso#

69 I*ut: coo$!t tem*e#!tu#e i"o#m!tio

6> 444

6@ ,to* $!m*s cot!ct

6 E!#th


6



C#8$-&% 6


.0 444

.- E!#th

.2 Out*ut: #ec&c$ig e$ect#o'!$'e cot#o$ =EGR?

. E!#th

.6 444

.. Out*ut: th#ott$e housig e$ect#o'!$'e cot#o$ =EGR?

.9 444

.> Out*ut: "! uit cot#o$: mid s*eed =J?

.@ Out*ut: !dditio!$ he!tig cot#o$ -

. 444

90 Out*ut: high *#essu#e "ue$ #egu$!to# 9- 444

92 444

9 444

96 444

9. 444

99 444

9> I*ut: *#ehe!te# uit di!gostic

9@ I*ut: !cce$e#!to# *ed!$ seso#

9 K igitio o: egie #e$!& uit =+,M?

>0 I*ut: e3h!ust g!s tem*e#!tu#e seso# =u*st#e!m o" thec!t!$&tic co'e#te#?

>- I*ut: i$et m!i"o$d !i# *#essu#e

>2 444

> I*ut: #edud!t )#!e sitch

>6 I*ut: "ue$ *#essu#e

>. Ai# coditioig *#essu#est!t =29 )!# cot#o$ st!ge?>9 444

>> 444


66



C#8$-&% 6


>@ 444

> 444

@0 Out*ut: high *#essu#e "ue$ *um* #d *isto de!cti'!to# @- 444

@2 444

@ Out*ut: "! uit cot#o$ 2 =$o s*eed?

@6 444

@. Out*ut: !dditio!$ he!tig cot#o$ 2

@9 Out*ut: dou)$e #e$!& cot#o$ =egie #e$!& uit?

@> I*ut: ie#ti! sitch =e!#thig?

@@ Out*ut: *#ehe!tig uit cot#o$



6.



C#8$-&% 6


69



C#8$-&%

PREPOST HEATING FUNCTION



• *#ehe!te# *$ugs =--90?/

• *#e4*ost he!tig uit =--.0?%

II PREHEATER PLUGS 1167/ FEATURE

The *#ehe!te# *$ugs !#e $oc!ted o the c&$ide# he!d/ o the #e!# o" the egie=)u$he!d side?%

The *#ehe!te# *$ugs c! )e !cti'!ted du#ig *!#tic$e "i$te# #egee#!tio!ssist!ce%


6>



C#8$-&%


6@



C#8$-&%

ENGINE COOLING FUNCTION FRIC/INCORPORATED INTO THE INJECTION ECU/

The iectio ECU *e#"o#ms the "o$$oig "uctios:

• it sitches the "! uits o !d o"" =egie coo$ig?/

• it cot#o$s *ost 'eti$!tio ="o# 9 miutes m!3imum?/

• it i$$umi!tes the coo$!t tem*e#!tu#e !#ig LED o the ist#umet *!e$/

• it cot#o$s the coo$!t tem*e#!tu#e g!uge o the ist#umet *!e$/

• it *e#"o#ms di!gostics "o# "! uit o*e#!tio/

• it !cui#es the egie coo$!t tem*e#!tu#e/

• it m!!ges dog#!ded modes%


6



C#8$-&%

I DIAGRAM

,DI02.D

1

5

3

4

6

A

B

C77 4726

7774

727

1517

1367

V1377

V4727

77

1227

C771

1327

BSI1

:&;

A 4 7AN eto#

+ 4 CAN eto#

C 4 1i#e coectio

DESCRIPTIONPART NUMBER IN THE 0IRING

DIAGRAMS

Autom!tic ge!#)o3 ECU =J? -90

Di!gostic LED 7-00

F! uit -.-0

Ai# coditioig com*#esso# @020

Cot#o$ *!e$ =$ogomete# K !#ig LED othe cot#o$ *!e$

0006

Coo$!t tem*e#!tu#e !#ig LED 76020

Coo$!t tem*e#!tu#e $ogomete# 6029+ui$t4i s&stems ite#"!ce +,I-

Cet#!$ di!gostic socet C00-

Iectio ECU -20

Ai# coditioig ECU @0@0

Ai# coditioig *#essu#est!t @00>

Coo$!t tem*e#!tu#e seso# -220



.0



C#8$-&%

CONNECTIONS

CONNECTION N SIGNAL SIGNAL NATURE

- Coo$!t tem*e#!tu#e seso# F#euec&

2 Reuest "o# !utom!tic ge!#)o3 oi$

tem*e#!tu#e coo$ig =J?

CAN

F! uit #e$!& cot#o$: $o s*eed =-.0@? A$$ o# othig

F! uit #e$!& cot#o$: high s*eed =-.0? A$$ o# othig

6 Ai# coditioig com*#esso# cot#o$ A$$ o# othig

. Reuest to i$$umi!te di!gostic LED CAN

Reuest to i$$umi!te coo$!t tem*e#!tu#e$ogomete#

CAN

Reuest to i$$umi!te coo$!t tem*e#!tu#e!#ig LED

CAN

Autho#is!tio to eg!ge the !i#

coditioig com*#esso# =ACBOUT?

CAN

9 Reuest to i$$umi!te di!gostic LED 7AN

Reuest to i$$umi!te coo$!t tem*e#!tu#e$ogomete#

7AN

Reuest to "$!sh coo$!t tem*e#!tu#e!#ig LED

7AN

> Reuest to !utho#ise eg!gig o" the !i#coditioig com*#esso# =ACBTH?

CAN

Note: (! depending on vehicle equipment.


.-



C#8$-&%

II FAN UNIT 1517/

SDI026C

BSI1

D!" * DBATDBAT

157

1514

157

1517

1327

BSM

K+AT K )!tte#&

Kig o K igitio o

+,M 4 Dou)$e iectio #e$!&

-.-6 4 F! uit #e$!& !t mid s*eed

The#e is o$& oe t&*e o" !ssem)$&: th#ee s*eed "! uit%

08%*!*" The $imits "o# eg!gig the "! uit de*ed o the 'ehic$e: #e"e# to theco##es*odig documet!tio%

The#e !#e th#ee o*e#!tig s*eeds:

• $o s*eed >°C/

• mid s*eed/

• high s*eed -0.°C%


.2



C#8$-&%

A 4 DE,CRI5TION

Lo s*eed is o)t!ied )& su**$&ig the "! uit th#ough ! #esisto# !##!ged ise#ies o the su**$& ci#cuit%

Mid s*eed is o)t!ied )& su**$&ig the "! uit th#ough 2 #esisto#s !##!gedi *!#!$$e$ i the su**$& ci#cuit:

4 the $o s*eed #e$!& is cot#o$$ed )& the iectio ECU/

4 the mid s*eed #e$!& is cot#o$$ed )& the )ui$t4i s&stems ite#"!ce/

4 high s*eed is o)t!ied )& su**$&ig the "! uit di#ect$&%

+e"o#e sitchig to high s*eed/ the "! uit is o*e#!ted !t $o s*eed "o# secods%

+e"o#e sitchig to mid s*eed/ the "! uit is o*e#!ted !t $o s*eed "o# secods =J?%

=J? #e"e# to the *#ocedu#e: coo$ig #eui#emets "o# the !i# coditioig=+RAC?%

+ 4 ELECTRICAL RE,I,TOR,

,DI02>C

The 2 #esisto#s !#e $oc!ted o the "#ot *!e$/ e!# to the !i#B!i# e3ch!ge#!d the "! uit%


.



C#8$-&%

III COOLANT TEMPERATURE SENSOR 1227/

The coo$!t tem*e#!tu#e seso# i"o#ms the ECU o" the tem*e#!tu#e o" the egiecoo$!t%

The coo$!t tem*e#!tu#e seso# is $oc!ted o the coo$!t housig%

IV POST VENTILATION

1he the egie is sitched o""/ the ECU cot#o$s *ost 'eti$!tio i" the coo$!ttem*e#!tu#e e3ceeds ! ce#t!i $imit =J? =-0.°C?%

=J? de*edig o 'ehic$e

5ost 'eti$!tio occu#s !t $o s*eed !d $!sts "o# ! m!3imum o" 9 miutes !"te#the egie is sitched o""%

V DO0NGRADED MODE

Ro$e o" the iectio ECU he the coo$!t tem*e#!tu#e seso# is "!u$t&:

• to cot#o$ o*e#!tio o" the "! uit !t high s*eed/

• to cot#o$ the "$!shig o" the coo$!t tem*e#!tu#e !#ig LED o the cot#o$*!e$ =de*edig o 'e#sio?/

• to *#e'et the !i# coditioig com*#esso# "#om )eig eg!ged =ACBOUT?%


.6



C#8$-&%

COOLING REQUIREMENTS FOR THE AIRCONDITIONING BRAC/

INCORPORATED INTO THE INJECTION ECU/

Fuctios o" the iectio ECU:

• to o*e#!te the "! uits =!i# coditioig codese# coo$ig?/

• to !cui#e the *#essu#e o" the !i# coditioig ci#cuit/

• to m!!ge dog#!ded modes%


..



C#8$-&%

I DIAGRAM

SDI028D

1

7

5

2

3

4

6

A

B

C8080 4026

0004

8020

1510

1360

V1300

V4020

8007

1220

C001

1320

BSI1

:&;

A 4 7AN eto#

+ 4 CAN eto#

C 4 1i#e coectio

DESCRIPTION PART NUMBER IN THE 0IRINGDIAGRAMS

Autom!tic ge!#)o3 ECU =J? -90

Di!gostic LED 7-00

F! uit -.-0

Ai# coditioig com*#esso# @020

Ist#umet *!e$ 0006

Coo$!t tem*e#!tu#e !#ig LED 76020

Coo$!t tem*e#!tu#e g!uge 6029

+ui$t4i s&stems ite#"!ce +,I-

Cet#!$ di!gostic socet C00-

Iectio ECU -20

Ai# coditioig ECU @0@0

Ai# coditioig *#essu#est!t @00>

Coo$!t tem*e#!tu#e seso# -220



.9



C#8$-&%

CONNECTIONS

CONNECTION N SIGNAL SIGNAL NATURE

- Ai# coditioig *#essu#est!t A!$ogue

2 F! uit #e$!& cot#o$: $o s*eed =-.0@? A$$ o# othig

F! uit #e$!& cot#o$: high s*eed =-.0? A$$ o# othig

F! uit #e$!& cot#o$: mid s*eed =-.-6? A$$ o# othig

6 Ai# coditioig com*#esso# cot#o$ A$$ o# othig

. Reuest to i$$umi!te di!gostic LED 7AN

9 Reuest to i$$umi!te di!gostic LED CAN

Autho#is!tio to eg!ge !i# coditioigcom*#esso# =ACBOUT?

CAN

Ai# coditioig *#essu#est!t CAN

> Reuest !utho#is!tio to eg!ge !i#coditioig com*#esso# =ACBTH?

CAN


.>



C#8$-&%

II AIR CONDITIONING PRESSURESTAT 77/

A 4 ROLE

The seso# me!su#es the '!$ue o" the *#essu#e i the !i# coditioig ci#cuit%


• to !utho#ise o*e#!tio o" the "! uit =!i# coditioig codese# coo$ig?/

• to !utho#ise eg!gig o" the !i# coditioig com*#esso#%

+ 4 DE,CRI5TION

,DI02C

The seso# is o" *ieo4e$ect#ic t&*e%

The seso# cosists o" st#!i g!uges%

The $ie!# seso# su**$ies ! 'o$t!ge *#o*o#tio!$ to the *#essu#e i the !i#coditioig ci#cuit%

Ideti"ic!tio: )$!c coecto#%

Note: The electrical information provided by the sensor is transmitted bywire to the in$ection &+,- and sent to the builtin systems interface viathe multiple%ed networ/.


.@



C#8$-&%



• ch!e$ -: . 'o$ts su**$&/

• ch!e$ 2: *#essu#e i"o#m!tio =0 4 . 'o$ts?/

• ch!e$ : e!#th%

7o$t!ge su**$ied "o# ! *#essu#e o" - )!#: K 0%. 'o$t%

7o$t!ge su**$ied "o# ! *#essu#e o" - )!#s: K 6%. 'o$ts%

D 4 LOCATION

The seso# is $oc!ted o the !i# coditioig codese#%


.



C#8$-&%

III FAN UNIT 1517/

The ECU cot#o$s o*e#!tio o" the "! uit !t $o s*eed i" the *#essu#e is g#e!te#th! -0 )!#s =o"" i" the *#essu#e is $ess th! > )!#s?%

The ECU cot#o$s o*e#!tio o" the "! uit !t high s*eed i" the *#essu#e is g#e!te#th! 22 )!#s =o"" i" the *#essu#e is $ess th! - )!#s?%

Note: The 1I controls operation of the fan unit at mid speed if the pressure isgreater than 2 bars (off if the pressure is less than 2" bars!.

IV DO0NGRADED MODE

Ro$e o" the iectio ECU i" the *#essu#est!t de'e$o*s ! "!u$t:

• to cot#o$ the i$$umi!tio o" the di!gostic LED o the cot#o$ *!e$/

• to *#e'et o*e#!tio o" the !i# coditioig com*#esso# =ACBOUT?%


90



C#8$-&% 17

PARTICLE FILTER FUNCTION

I DIAGRAM

,DI0-95

1

A

B

1 1

28

29

3

4 5

6

71

5

3

4

6 14

16

61

67 53

13

12 11

21

22

15

217

6

6

66

64

63 62

5

5

5

54

55

56

52 33

23

2624

2

44

46

51

3

32

31

2

37

3435

36

4342

4 4 4

33

47

41

57

1 1

27

6

65

45

25

2

:&; A 4 7AN eto#+ 4 CAN eto#


9-



C#8$-&% 17


DIAGRAMS

- Additio!$ he!tig cot#o$ #e$!& +C5

2 Additio!$ he!tig =e$ect#ic!$ #esisto#s =2!? o#he!te# =2)?? =J?

@0@ 4 --0

7!#i!)$e geomet#& tu#)och!#ge# 44

6 Ai# "$omete# B !i# tem*e#!tu#e seso# --0

. Ai# "i$te# 44

9 C!t!$&tic co'e#te# 44

> 5!#tic$e "i$te# 44

@ E3h!ust g!s tem*e#!tu#e seso#=dost#e!m o" the c!t!$&tic co'e#te#?

-6

Di""e#eti!$ *#essu#e seso# -6-

-0 E3h!ust g!s tem*e#!tu#e seso#=u*st#e!m o" the c!t!$&tic co'e#te#?

-66

-- Tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e -2

-2 Rec&c$ig #egu$!tio e$ect#o'!$'e =EGR? -2.

- 7!#i!)$e geomet#& tu#)o cot#o$ di!*h#!gm 44

-6 E3h!ust g!s #ec&c$ig '!$'e =EGR? 44

-. Ai#B!te# he!t e3ch!ge# =i$et !i# he!te#? 44

-9 Coo$!tBe3h!ust g!s e3ch!ge# =EGR? 44

-> I$et !i# he!te# th#ott$e cot#o$ e$ect#o'!$'e -2@.

-@ Atmos*he#ic *#essu#e seso# =ico#*o#!ted itothe iectio ECU?

-20

- Iectio ECU -2020 He!ted #e!# sc#ee @-20

2- E$ect#oic st!)i$it& *#og#!m ECU =J? >@00

22 Autom!tic ge!#)o3 ECU =J? -90

2 T#i* com*ute# =J? 44

26 E$ect#oic #e' coute# 62-0

2. ,e#'ice LED =J? 44

29 5#ehe!te# LED 7--.0

2> Di!gostic LED 7-00

2@ Fue$ g!uge =J? 442 F! uit -.-0


92



C#8$-&% 17


DIAGRAMS

0 Ai# coditioig com*#esso# @020

- Coo$!t tem*e#!tu#e !#ig LED 76020

2 Coo$!t tem*e#!tu#e g!uge 6029 +ui$t4i s&stems ite#"!ce +,I-

6 C#uise cot#o$ sitch >00

. C#uise cot#o$ s!"et& cot!ct >0.

9 Redud!t )#!e sitch >0@

> ,itch modu$e !t the stee#ig hee$ =COM2000? C700

@ Fue$ !dditi'e ECU -2@2

Additi'e t! 444

60 Lo !dditi'e $e'e$ seso# -2@

6- Additi'e iectio *um* -2@

62 Fue$ t! 44

6 Additi'e iecto# -2@6

66 Lo *#essu#e *um* -2--

6. E$ect#ic "ue$ he!te# -2>9

69 Coo$!t tem*e#!tu#e seso# -220

6> 5$ug =o'e#"$o? 44

6@ ,!"et& '!$'e 444

6 Fue$ "i$$e# c!* *#esece seso# =J? 620

.0 Cet#!$ di!gostic socet C00-

.- +!tte#& ++00

.2 Dou)$e iectio #e$!& =egie #e$!& uit? +,M

. 7ehic$e s*eed seso# -920

.6 Acce$e#!to# *ed!$ *ositio seso# -29-

.. C$utch *ed!$ sitch >09

.9 +#!e *ed!$ sitch 2-00

.> 5#e4*ost he!tig uit --.0

.@ Fue$ coo$e# 44

. Fue$ "i$te# 44

90 Egie s*eed seso# --9- C!msh!"t *ositio seso# ---.

92 5#ehe!te# *$ugs --90


9



C#8$-&% 17


DIAGRAMS

9 High *#essu#e "ue$ commo iectio #!i$ 44

96 High *#essu#e "ue$ seso# -2-

9. Fue$ tem*e#!tu#e seso# --099 High *#essu#e "ue$ #egu$!to# -22

9> High *#essu#e "ue$ *um* 44

9@ High *#essu#e "ue$ *um* #d *isto de!cti'!to# -2>>

9 Diese$ iecto#s -- 4 -2 4 - 4 -6

>0 ,i#$ cot#o$ e$ect#o'!$'e -296

>- ,i#$ cot#o$ di!*h#!gm 44

>2 I$et !i# he!te# th#ott$e 44

> Th#ott$e housig =EGR? 44

>6 Ai#B!i# he!t e3ch!ge# 44

>. Th#ott$e housig cot#o$ e$ect#o'!$'e =EGR? -29

>9 I$et m!i"o$d *#essu#e seso# --2



96



C#8$-&% 17

II PARTICLE FILTER

A 4 ROLE

The *!#tic$e "i$te# t#!*s c!#)o *!#tic$es !s e3h!ust g!ses *!ss th#ough%

+ 4 DE,CRI5TION

,DI0->D

@

& =

,

8

9

8

9

! 4 C!#)o *!#tic$es

) 4 Ce#ie

c 4 Fi$te#ed e3h!ust g!ses

d 4 5o#ous ce#!mic !$$s

e 4 ,t!i$ess stee$ c!sig

" 4 The#m!$ isu$!to#

The *!#tic$e "i$te# is ! *o#ous si$ico c!#)ide st#uctu#e cot!iig ch!e$s!##!ged so !s to "o#ce the e3h!ust g!ses to *!ss th#ough the !$$s%

Com*oets #et!ied i the *!#tic$e "i$te#:

• c!#)o *!#tic$es/

• ce#ie/

• de*osits "#om the egie oi$ !d egie e!#%


9.



C#8$-&% 17

Esseti!$$& cosistig o" c!#)o !d h&d#oc!#)os/ these *!#tic$es !tt!ched tothe *!#tic$e "i$te# )u# i the *#esece o" o3&ge !t ! tem*e#!tu#e o" ..0°C=!tu#!$ #egee#!tio o# !ssisted ith *ost4iectio?%

Ce#ie is ! io#g!ic m!te#i!$ hich does ot )u# !d is #et!ied i the

*!#tic$e "i$te# i the "o#m o" ! so$id de*osit%The !ccumu$!tio o" *!#tic$es du#ig egie o*e#!tio $e!ds to the*#og#essi'e c$oggig u* o" the *!#tic$e "i$te#%

08%*!*" The *!#tic$e "i$te# must )e #e*$!ced o# c$e!ed e'e#& @0 000 m=i o#de# to #emo'e the *!#tic$es #et!ied i the "i$te#?% Re"e# to them!ite!ce sectio%

C 4 LOCATION

The *!#tic$e "i$te# is ico#*o#!ted ito the e3h!ust *i*e =dost#e!m o" thec!t!$&tic co'e#te#?%


99



C#8$-&% 17

III CATALYTIC CONVERTER

A 4 ROLE

The c!t!$&tic co'e#te# is used to ic#e!se the tem*e#!tu#e o" the e3h!ust

g!ses/ th#ough *ost4com)ustio o" the u)u#ed h&d#oc!#)os =HC? #esu$tig"#om *ost4iectio%

+ 4 DE,CRI5TION

Com*ositio o" ! o3id!tio c!t!$&tic co'e#te#:

• ! st!i$ess stee$ e'e$o*e/

• ! the#m!$ isu$!to#/

• ! ce#!mic hoe&com)ed moo$ith im*#eg!ted ith *#ecious met!$s%

C 4 LOCATION

The c!t!$&tic co'e#te# is $oc!ted immedi!te$& !"te# the *!#tic$e "i$te#%


9>



C#8$-&% 17

IV EHAUST GAS TEMPERATURE SENSOR UPSTREAM OF THE CATALYTICCONVERTER/ 1344/

A 4 ROLE

The tem*e#!tu#e seso# i"o#ms the iectio ECU o" the tem*e#!tu#e o" the

e3h!ust g!ses =u*st#e!m o" the c!t!$&tic co'e#te#?%

+ 4 DE,CRI5TION

,DI0-@C


The highe# the tem*e#!tu#e/ the $oe# its #esist!ce%



• ch!e$ -: . 'o$ts/

• ch!e$ 2: e!#th%

Resist!ce !t -00°C 9 000 ohms%

Resist!ce !t 6.0°C >92 ohms%

08%*!*" The e$ect#ic!$ i"o#m!tio *#o'ided )& the u*st#e!m tem*e#!tu#eseso# is t#!smitted di#ect$& to the iectio ECU%

D 4 LOCATION

The tem*e#!tu#e seso# is $oc!ted u*st#e!m o" the c!t!$&tic co'e#te#%

The tem*e#!tu#e seso# is sc#eed oto ! )!se%

IMPORTANT Use the co##ect tighteig to#ue%


9@



C#8$-&% 17

V EHAUST GAS TEMPERATURE SENSOR DO0NSTREAM OF THECATALYTIC CONVERTER/ 1343/

A 4 ROLE

The tem*e#!tu#e seso# i"o#ms the iectio ECU o" the tem*e#!tu#e o" thee3h!ust g!ses =dost#e!m o" the c!t!$&tic co'e#te#?%

+ 4 DE,CRI5TION

The dost#e!m tem*e#!tu#e seso# is idetic!$ to the u*st#e!m tem*e#!tu#eseso#%


08%*!*" The e$ect#ic!$ i"o#m!tio *#o'ided )& the dost#e!m

tem*e#!tu#e seso# is t#!smitted )& i#e to the !dditi'e ECU !dset to the iectio ECU 'i! the mu$ti*$e3ed eto#s%

D 4 LOCATION

The tem*e#!tu#e seso# is $oc!ted )etee the c!t!$&tic co'e#te# !d the*!#tic$e "i$te#%


9



C#8$-&% 17

VI DIFFERENTIAL PRESSURE SENSOR 1341/

A 4 ROLE

The seso# *e#m!et$& me!su#es the *#essu#e di""e#ece o" the e3h!ustg!ses/ )etee the i$et !d the out$et o" the *!#tic$e "i$te#/ to dete#mie the

st!tus o" the "i$te# =c$oggig *#o)$ems o# d!m!ge to "i$te#?%+ 4 DE,CRI5TION

,DI0-D#

"

HI

REF

)

g 4 HI: 5!#tic$e "i$te# u*st#e!m i"o#m!tio i*ut =di!mete# 6%2 mm?h 4 REF: 5!#tic$e "i$te# dost#e!m i"o#m!tio i*ut =di!mete# 6%2 mm? 4 1hite m!#ig 4 E$ect#ic!$ coecto# $ 4 Mem)#!e

The seso# com*#ises the "o$$oig com*oets:

• e$ect#oics "o# !m*$i"&ig the sig!$/

• ! se!$ed mem)#!e%

The mem)#!e is su)ect to the "o$$oig *#essu#es:

• the i$et *#essu#e o" the *!#tic$e "i$te# =u*st#e!m?/

• the out$et *#essu#e o" the *!#tic$e "i$te# =dost#e!m?%

The seso# *#o'ides ! 'o$t!ge *#o*o#tio!$ to the *#essu#e di""e#eti!$me!su#ed )& the mem)#!e =*#essu#e di""e#eti!$ u*st#e!m *#essu#e 4dost#e!m *#essu#e?%

IMPORTANT Do ot i'e#t the u*st#e!m !d dost#e!m i"o#m!tio *i*es=m!$"uctio o" the "i$t#!tio s&stem?% M!!gemet o" the*!#tic$e "i$te# de*eds o this i"o#m!tio%


>0



C#8$-&% 17



• ch!e$ -: *#essu#e i"o#m!tio =0%. 4 . 'o$ts?/

• ch!e$ 2: e!#th/

• ch!e$ : . 'o$ts su**$&

7o$t!ge su**$ied "o# ! *#essu#e di""e#eti!$ o" 0 )!#: K 0%. 'o$t =egie o""?%

7o$t!ge su**$ied "o# ! *#essu#e di""e#eti!$ o" 0% )!#: K 6%- 'o$ts =*!#tic$e "i$te#c$ogged?%

D 4 LOCATION

,DI020C

4 hite m!#ig

The seso# =? is $oc!ted i the cet#e o" the )u$he!d !t the to* =de*edigo 'ehic$e?%


>-



C#8$-&% 17

VII AIR TEMPERATURE SENSOR 1317/

The !i# tem*e#!tu#e seso# i"o#ms the ECU o" the tem*e#!tu#e o" the i$et !i#%

08%*!*" The !i# tem*e#!tu#e seso# is ico#*o#!ted ito the !i# "$omete#%


• to #egu$!te the tem*e#!tu#e o" the i$et !i# )& o*e#!tig the i$et !i# he!te#th#ott$e cot#o$ e$ect#o'!$'e%

Note: 4hen the air temperature sensor (2320! is faulty- the &+, uses a

replacement value of #0 ° +.

Note: The information from the e%terior air temperature sensor (5"2#! located inthe door mirror is used by the &+, to perform comparison tests. Thee%terior air sensor is controlled by the front 6 door station (70#0!.


>2



C#8$-&% 17

VIII AIR0ATER HEAT ECHANGER HEATING OF THE INLET AIR/

A 4 ROLE

The !i#B!te# he!t e3ch!ge# he!ts the i$et !i# i the c&$ide#s =du#ig the*!#tic$e "i$te# #egee#!tio !ssist!ce *h!se?%

The i$et !i# he!te# is used to ic#e!se the com)ustio tem*e#!tu#e #eui#edto #egee#!te the *!#tic$e "i$te#%

+ 4 DE,CRI5TION

The !i#B!i# he!t e3ch!ge#/ hich coo$s the i$et !i# i the c&$ide#s/ issu##ouded )& ! !i#B!te# e3ch!ge# hich he!ts the i$et !i#%

C 4 LOCATION

,DI02-C

15

4

-. 4 !i#B!te# he!t e3ch!ge# =i$et !i# he!te#?>6 4 !i#B!i# he!t e3ch!ge#

The !te#B!i# he!t e3ch!ge# =-.? is $oc!ted e!# to the "#ot !i#B!i# he!te3ch!ge# =>6?%

I INLET AIR HEATER THROTTLE

A 4 DE,CRI5TION

08%*!*" The i$et !i# he!te# th#ott$e is c$osed he it is ot cot#o$$ed*eum!tic!$$&%

+ 4 LOCATION

The th#ott$e housig is $oc!ted !t the i$et to the i$et m!i"o$d%


>



C#8$-&% 17

THROTTLE HOUSING CONTROL ELECTROVALVE HEATING OF THE INLETAIR/ 125/

A 4 ROLE

The e$ect#o'!$'e cot#o$s the o*eig o" the i$et !i# he!te# th#ott$e%

+ 4 DE,CRI5TION

The e$ect#o'!$'e is the s!me !s the "o$$oig e$ect#o'!$'es:


• e3h!ust g!s #ec&c$ig e$ect#o'!$'e =EGR?/

• th#ott$e housig cot#o$ e$ect#o'!$'e =EGR?%

*

$

*

,DI022C

m 4 ;use#; out*ut

4 '!cuum *um* '!cuum i$et

* 4 hite m!#ig

4 !tmos*he#ic *#essu#e i$et

The e$ect#o'!$'e is cot#o$$ed ith ! OCR =o*e c&c$e #!tio?%


>6



C#8$-&% 17

The *#o*o#tio!$ e$ect#o'!$'e cot#o$$ed ith ! OCR 'o$t!ge is coected tothe "o$$oig:


• '!cuum su**$ied )& the '!cuum *um*%

The *#essu#e su**$ied )& the e$ect#o'!$'e is )etee !tmos*he#ic *#essu#e!d the '!cuum "#om the '!cuum *um*%

The e$ect#o'!$'e coects the '!cuum *um* !d the he!te# th#ott$e%

O*e#!tig *h!ses ith *!#tic$e "i$te# #egee#!tio !ssist!ce:

• egie !t $o $o!d !d mid $o!d: the i$et !i# he!te# th#ott$e is o*e=cot#o$$ed?/

• egie !t "u$$ $o!d: the i$et !i# he!te# th#ott$e is c$osed =ot cot#o$$ed? =imode#!te !m)iet tem*e#!tu#e?%

Note: The inlet air heater throttle can be controlled outside the regenerationassistance operating phase (engine cold- moderate ambienttemperature!.


Cot#o$: iectio ECU =e!#th?%

7!#i!)$e 'o$t!ge cot#o$ =OCR?:

• "u$$ su**$& =m!3imum OCR? m!3imum '!cuum/

• o su**$& =miimum OCR? o '!cuum =!tmos*he#ic *#essu#e?%


>.



C#8$-&% 17

D 4 LOCATION

,DI02:C

1

-> 4 i$et !i# he!te# th#ott$e cot#o$ e$ect#o'!$'e

The e$ect#o'!$'e is $oc!ted )etee the !i# "i$te# housig !d the i$etm!i"o$d% It h!s ! 2 !& o#!ge coecto#%


>9



C#8$-&% 17

I THROTTLE HOUSING CONTROL ELECTROVALVE EGR/ 1263/

A 4 ROLE

The e$ect#o'!$'e cot#o$s the c$osig o" the th#ott$e housig =EGR?%

+ 4 DE,CRI5TION

08%*!*" The th#ott$e housig is o*e he it is ot cot#o$$ed*eum!tic!$$&%

O*e#!tig *h!ses ith *!#tic$e "i$te# #egee#!tio !ssist!ce:

• egie !t $o $o!d: the th#ott$e housig is c$osed =cot#o$$ed? =JJ?=de*edig o e3te#io# tem*e#!tu#e?/

•

egie !t mid $o!d !d "u$$ $o!d: the th#ott$e housig is o*e =otcot#o$$ed?%

=JJ? the egie o$& $ets i he!ted !i#%

The e$ect#o'!$'e h!s ! 2 !& )$!c coecto#%

II BUILTIN SYSTEMS INTERFACE BSI1/

A 4 ROLE

The +,I *e#"o#ms the "o$$oig o*e#!tios:

• it t#!smits i"o#m!tio "#om the "ue$ !dditi'e ECU to the iectio ECU/

• it t#!smits i"o#m!tio "#om the iectio ECU to the "ue$ !dditi'e ECU/

• it i"o#ms the d#i'e# o" the st!tus o" the *o$$ut!t *!#tic$e "i$t#!tio s&stem/

• it #eiiti!$ises the s&stem !"te# ! m!ite!ce o*e#!tio%


>>



C#8$-&% 17

+ 4 DIAGRAM

SDI024P

79

77

80

8182

83

78

89

88

BSI1

87

86

1282

A

B

C

1320

84

85

:&;

A 4 7AN eto#

+ 4 CAN eto#

C 4 1i#e coectio

+,I- 4 +ui$t4i s&stems ite#"!ce

-2@2 4 Fue$ !dditi'e ECU

-20 4 Iectio ECU


>@



C#8$-&% 17

CONNECTIONS

CONNECTIONN

SIGNALSIGNAL NATURE

>> O*e#!tig st!tus o" the !dditi'e ECU CAN

Lo !dditi'e $e'e$ #e!ched !#ig CANTot!$ u!tit& o" !dditi'e iected sice st!#t o"*!#tic$e "i$te#s $i"e

CAN

E3h!ust g!s tem*e#!tu#e =dost#e!m o" thec!t!$&tic co'e#te#?

CAN

Reuest to "o#ce "! uit =!t $o s*eed? CAN

Reuest to "o#ce *#e4*ost he!te# *$ugs CAN

>@ Reuest to i$$umi!te di!gostic LED 7AN

5!#tic$e "i$te# "!u$t CAN

Reuest to !cti'!te cosume#s =!$te#!to#s!tu#!tio?

CAN

Reuest to "o#ce "! uit =!t mid s*eed? CAN

Egie s*eed seso# sig!$ =egie #uigi"o#m!tio?

CAN

> 5#e4*ost he!tig uit B *#ehe!te# *$ugs cot#o$ A$$ o# othig

@0 F! uit #e$!& cot#o$ =!t $o s*eed? A$$ o# othig

@- F! uit #e$!& cot#o$ =!t mid s*eed? A$$ o# othig

@2 He!ted #e!# sc#ee #e$!& cot#o$ A$$ o# othig

@ Reuest to i$$umi!te di!gostic LED 7AN

Reuest to "$!sh se#'ice LED o the cot#o$*!e$ =J? 7AN

Reuest to dis*$!& ! mess!ge o themu$ti"uctio sc#ee =J?

7AN

@6 O*e#!tig st!tus o" the !dditi'e ECU 7AN

Lo !dditi'e $e'e$ #e!ched !#ig 7AN

Tot!$ u!tit& o" !dditi'e iected sice st!#t o"*!#tic$e "i$te#s $i"e

7AN

,t!tus o" the "ue$ "i$$e# c!* *#esece seso# 7AN

E3h!ust g!s tem*e#!tu#e =dost#e!m o" the

c!t!$&tic co'e#te#?

7AN


>



C#8$-&% 17

CONNECTIONS

CONNECTIONN

SIGNALSIGNAL NATURE

@. Egie s*eed seso# sig!$ =egie #uigi"o#m!tio?

7AN

Fue$ sede# i"o#m!tio 7AN

Igitio e& *ositio 7AN

7ehic$e s*eed i"o#m!tio 7AN

@9 Fue$ "i$$e# c!* *#esece seso# A$$ o# othig

@> E3h!ust g!s tem*e#!tu#e =dost#e!m o" thec!t!$&tic co'e#te#?

A!$ogue

@@ Fue$ sede# A!$ogue

@ Igitio e& A$$ o# othig

=J? de*edig o eui*met%


@0



C#8$-&% 17

III INJECTION ECU 1327/

A 4 ROLE

The ECU so"t!#e *e#"o#ms:

• the "uctios "o# cot#o$$ig iectio !d de*o$$utio/

• the cot#o$ o" *!#tic$e "i$te# #egee#!tio/

• the d#i'ig *$e!su#e st#!tegies/


• the cot#o$ o" the "! uits !d !#ig LEDs =J?/

• the di!gostic "uctio ith memo#isig o" "!u$ts/

• the di!$ogue ith the "ue$ !dditi'e ECU/

• the di!$ogue ith the !utom!tic ge!#)o3 ECU =J?/

• the di!$ogue ith the e$ect#oic st!)i$it& *#og#!m ECU =J?%

=J? de*edig o eui*met%

+ 4 DE,CRI5TION

The ECU is #es*osi)$e "o# e$ect#ic!$$& cot#o$$ig the "o$$oig com*oets:

• di""e#eti!$ *#essu#e seso#/

• e3h!ust g!s tem*e#!tu#e seso# =u*st#e!m o" the c!t!$&tic co'e#te#?/

• i$et !i# he!te# th#ott$e cot#o$ e$ect#o'!$'e%


@-



C#8$-&% 17


@2



C#8$-&% 11

FUEL ADDITIVE FUNCTION

I ADDITIVE

A 4 ROLE

Ro$e o" the !dditi'e:

• to $oe# the *!#tic$e com)ustio tem*e#!tu#e to 6.0°C =iste!d o" ..0°C?/

• to im*#eg!te the *!#tic$es "o#mig i the com)ustio ch!m)e#/

• to *#o*!g!te com)ustio o" the *!#tic$es%

+ 4 DE,CRI5TION

EOL8, !dditi'e =su**$ied )& RHODIA?%

Com*ositio:

• ce#ie: 6%2 )& eight =D5 62?/

• c!t!$&tic co'e#te#: )#o i co$ou#/

• so$'et *#oduct =com)usti)$e h&d#oc!#)o?%


@



C#8$-&% 11

II ADDITIVE TAN:

A 4 DE,CRI5TION

,*eci"ic!tios:

• c!*!cit&: . $it#es/

• #!ge: @0 000 m/

• iteg#!ted !dditi'e iectio *um*/

• iteg#!ted $o !dditi'e $e'e$ seso#/

• 6 o#i"ices%

O#i"ices:

• !dditi'e iectio *um* out$et =-0 mm di!mete# c$ic4"it coecto#?/

• !dditi'e iectio *um* #etu# =@ mm di!mete# c$ic4"it coecto#?/

• )#e!the# =*#essu#e 4 '!cuum s!"et& '!$'e?/

• deg!ssig =o'e#"$o?%

Fi$$ig: #e"e# to the *#ocedu#e gi'e i the mech!ic!$ "i$e o" the 'ehic$e i

uestio%

+ 4 LOCATION

Loc!tio: ude# the "ue$ t!%


@6



C#8$-&% 11

III ADDITIVE INJECTION PUMP 123/

A 4 ROLE

The !dditi'e iectio *um* su**$ies the *#essu#e !d the "$o #eui#ed i the!dditi'e ci#cuit%

+ 4 DE,CRI5TION

,DI0:0D

4

3

2

51

A

B

A 4 Additi'e #etu# ci#cuit+ 4 Additi'e $o *#essu#e ci#cuit

,u**$ie#: MAR1ALThe !dditi'e iectio *um* com*#ises the "o$$oig com*oets:

- 4 No #etu# '!$'e =!dditi'e $o *#essu#e ci#cuit?2 4 Lo !dditi'e $e'e$ seso# 4 Fi$te# 6 4 No #etu# '!$'e =!dditi'e t! #etu# ci#cuit?. 4 Ro$$e# dis*$!cemet *um*

The o #etu# '!$'es *#e'et !dditi'e "#om "$oig out he the !dditi'eiectio *um* out$et !d #etu# c$ic4"it coecto#s !#e o*eed%

Note: 1afety valve rating: 0.8 bar.5um* "$o: @0 $Bh%

No#m!$ o*e#!tig *#essu#e: )!#s%

The !dditi'e *um* is su**$ied ith -2 'o$ts )& the "ue$ !dditi'e ECU i the"o$$oig c!ses:

4 "o# . secods he the igitio is sitched o

4 du#ig the !dditi'e *h!se


@.



C#8$-&% 11


Cot#o$$ed )& the "ue$ !dditi'e ECU%


•

ch!e$ -: =4? $o !dditi'e $e'e$ seso#/• ch!e$ 2: =K? $o !dditi'e $e'e$ seso#/

• ch!e$ : !dditi'e iectio *um* -2 'o$t su**$&/

• ch!e$ 6: !dditi'e iectio *um* e!#th/

• ch!e$ .: s*!#e/

• ch!e$ 9: s*!#e%

D 4 LOCATION

The *um* is su)me#ged i the !dditi'e t!%

Note: The pump cannot be separated from the additive tan/.

III LO0 ADDITIVE LEVEL SENSOR 123/

A 4 ROLE

The seso# i"o#ms the !dditi'e ECU th!t the $o !dditi'e $e'e$ h!s )ee#e!ched he the#e is 0% $it#es #em!iig i the !dditi'e t!%

De*edig o the i"o#m!tio #ecei'ed/ the !dditi'e ECU i"o#ms the "ue$iectio ECU%

The iectio ECU i"o#ms the +,I hich #euests !cti'!tio o" the "o$$oig:

• #euest to "$!sh the se#'ice LED o the cot#o$ *!e$ =J?/

• #euest to dis*$!& ! mess!ge o the mu$ti"uctio sc#ee =J?%

Note: 0.3 litres of additive is sufficient to fill up the tan/ 5 times with 90 litresof fuel (!.

=J? de*edig o 'ehic$e eui*met%

+ 4 DE,CRI5TION

The seso# cosists o" ! the#misto#%

The i"o#m!tio *#o'ided '!#ies/ de*edig o hethe# the the#misto# is ithe !dditi'e o# i !i# =miimum $e'e$ #e!ched?%

C 4 LOCATION

The seso# is ico#*o#!ted ito the !dditi'e iectio *um*%


@9



C#8$-&% 11

IV SAFETY VALVE

A 4 ROLE

Ro$e o" the s!"et& '!$'e:

• se!$ig "uctio =*#e'ets the so$'et "#om e'!*o#!tig !d the ig#ess o"dust/ mud !d !te#?/

• o'e#tu# s!"et& "uctio/

• )#e!the# "o# the !dditi'e t! de*edig o the !dditi'e $e'e$%

+ 4 DE,CRI5TION

,DI0:-D

6

6

9 4 7!cuum '!$'e =0%09 )!#?

> 4 5#essu#e #e$ie" '!$'e =0%0. KB4 0%0- )!#?

@ 4 7!cuum '!$'e #etu# s*#ig

4 5#essu#e #e$ie" '!$'e #etu# s*#ig

O*e#!tio:

• the '!$'e =9? !cts !s ! )#e!the# "o# the !dditi'e t! de*edig o the!dditi'e $e'e$/

• the '!$'e =@? *e#"o#ms the se!$ig !d o'e#tu# s!"et& "uctio%


@>



C#8$-&% 11

C 4 LOCATION

,DI0:2C

The s!"et& '!$'e is $oc!ted i the #e!# $e"t h!d hee$ !#ch =)ehid the mud"$!*?%


@@



C#8$-&% 11

V ADDITIVE INJECTOR 124/

A 4 ROLE

The iecto# is used to iect ! set !mout o" !dditi'e ito the "ue$ t!%

+ 4 DE,CRI5TION

SDI033D A 4 Additi'e #etu# ci#cuit

B 4 Additi'e $o *#essu#e ci#cuit

T&*e: 1E+ER I15 06

Note: 1afety valve rating: 3 bars.


Cot#o$$ed )& the "ue$ !dditi'e ECU%


• ch!e$ -: K-2 'o$ts su**$&/

• ch!e$ 2: cot#o$%

E$ect#ic!$ s*eci"ic!tios: #esist!ce !t 2. °C -6%> ohms%

C 4 LOCATION

The !dditi'e iecto# is $oc!ted o the "ue$ t!%


@



C#8$-&% 11

VI FUEL FILLER CAP PRESENCE SENSOR 4327/

A 4 ROLE

The "ue$ "i$$e# c!* *#esece seso# i"o#ms the !dditi'e ECU hethe# the "ue$

"i$$e# c!* is o*e o# c$osed%Ro$e o" the !dditi'e ECU de*edig o the i"o#m!tio #ecei'ed: to detecthethe# "ue$ m!& h!'e )ee !dded%

+ 4 DE,CRI5TION

,DI0:6C

11

17

-0 4 5e#m!et m!get

-- 4 Cot!ct

The "i$$e# c!* is "itted ith ! m!get% 1he the c!* is c$osed/ the m!get iso**osite the cot!ct%


,u**$&: "ue$ !dditi'e ECU%


• ch!e$ -: . 'o$t su**$&/• ch!e$ 2: sig!$/

• *#esece o" the m!get o**osite the cot!ct: #esist!ce -.0 000 ohms/

• !)sece o" the m!get o**osite the cot!ct: #esist!ce -. ohms%


0



C#8$-&% 11

VII FUEL SENDER 1211/

A 4 ROLE

The "ue$ sede# i"o#ms the !dditi'e ECU o" ! '!#i!tio i "ue$ $e'e$/ th#ough

the )ui$t4i s&stems ite#"!ce%Ro$e o" the !dditi'e ECU de*edig o the i"o#m!tio #ecei'ed:

• to dete#mie the !mout o" !dditi'e to )e iected/

• to cot#o$ the !dditi'e iectio *um*/

• to cot#o$ the !dditi'e iecto#%

+ 4 DE,CRI5TION

,DI0:.C

H

Cot#o$$ed )& the "ue$ sede#%

,u**$ie# 7DO:

HEIGHT OF THE FLOAT AIS INRELATION TO THE BASE LEVEL

RESISTANCE

-6 mm .0 ± . ohms

66 mm 00 ± . ohms

>. mm 2.0 ± . ohms

--0 mm 200 ± . ohms

- mm -.0 ± . ohms

->- mm -00 ± . ohms

202 mm .0 ± . ohms


-



C#8$-&% 11

,u**$ie# MAR1AL:

HEIGHT OF THE FLOAT AIS INRELATION TO THE BASE LEVEL

RESISTANCE

-6 mm .0 ± -- ohms

6- mm 00 ± -0 ohms

>2 mm 2.0 ± -0 ohms

-06 mm 200 ± ohms

-@ mm -.0 ± ohms

->- mm -00 ± @ ohms

206 mm .0 ± 2 ohms

Note: The fuel sender cannot detect a variation in fuel level of less than

litres precisely.


2



C#8$-&% 11

VIII BUILTIN SYSTEMS INTERFACE BSI1/

The +,I seds the !dditi'e ECU the "o$$oig i"o#m!tio:

• egie s*eed seso# sig!$ =egie #uig i"o#m!tio?/

• 'ehic$e s*eed i"o#m!tio/

• "ue$ sede# i"o#m!tio/

• igitio e& *ositio%

I FUEL ADDITIVE ECU 122/

A 4 ROLE

The ECU cot#o$s !dditi'e iectio%

The ECU so"t!#e is #es*osi)$e "o#:

• cot#o$$ig the st!#t o" !dditi'e iectio !d !dditi'e iectio time ito the"ue$ t!/

• m!!gig the tot!$ !mout o" !dditi'e iected sice the )egiig o" the"i$te#s $i"e/


• di!gostic ith memo#isig o" "!u$ts/

• di!$ogue ith the iectio ECU%

+ 4 DE,CRI5TION

The ECU e$ect#ic!$$& cot#o$s the "o$$oig com*oets:

• $o !dditi'e $e'e$ seso#/

• !dditi'e iectio *um*/

• !dditi'e iecto#/

• "ue$ "i$$e# c!* *#esece cot!ct/

• c!t!$&tic co'e#te# dost#e!m e3h!ust g!s tem*e#!tu#e seso#%

,u**$ie#: MAGNETTI MARELLI%




C#8$-&% 11




- K -2 'o$t su**$& =*e#m!et K+AT?

2 K+AT +,I B K igitio o su**$&

K+OD8 7AN su**$& =K-2 'o$ts?

6 I*ut: "ue$ "i$$e# c!* *#esece seso# i"o#m!tio

. I*ut: $o !dditi'e $e'e$ seso# i"o#m!tio

9 4

> 4

@ Out*ut: !dditi'e iecto# -27 cot#o$

Out*ut: !dditi'e iectio *um* -27 cot#o$

-0 I*ut: c!t!$&tic co'e#te# dost#e!m e3h!ust g!stem*e#!tu#e seso# i"o#m!tio

-- I*ut: c!t!$&tic co'e#te# dost#e!m e3h!ust g!stem*e#!tu#e seso# i"o#m!tio

-2 I*ut: "ue$ "i$$e# c!* *#esece seso# i"o#m!tio

- I*ut: $o !dditi'e $e'e$ seso# i"o#m!tio

-6 7AN D!t! eto#

-. 7AN D!t! )!# eto#-9 E!#th

D 4 LOCATION

Loc!tio: o the ch!ssis mem)e# e!# to the )ottom o" the RH cet#e *ost=de*edig o 'ehic$e?%


6



C#8$-&% 12

OPERATING PHASESHDI DIRECT INJECTION SYSTEM



• "o#eo#d/

• iectio di!g#!m/

• #o$e o" the m!i c!#tog#!*hic m!*s/

• gee#!$ o*e#!tio/

• o#ig out the !mout o" "ue$ to iect/

• high *#essu#e "ue$ #egu$!tio/

• di#ect iectio/

• o#ig out the iectio t&*e/

• tu#)och!#gig *#essu#e #egu$!tio/

• st!#tig the egie/

• sto**ig the egie/

• egie o*e#!tig s!"et&/

• d#i'e#s i"o#m!tio "uctio%


.



C#8$-&% 12

II SPECIFIC COMPONENTS

,*eci"ic "e!tu#es o" the D1-2TED6 egie:

• tu#)och!#gig *#essu#e #egu$!tio/

• e3h!ust g!s #ec&c$ig #egu$!tio/

• *#e4*ost he!tig/

• !dditio!$ he!tig/

• !i# coditioig com*#esso# cut4o""/

• dis*$!&ig "!u$ts/

• dog#!ded o*e#!tig modes%

III TURBOCHARGING PRESSURE REGULATION FEATURE

The tu#)och!#gig *#essu#e is #educed to *#e'et the tu#)och!#ge# "#om )eigd!m!ged i the "o$$oig c!ses:

• he the !$titude is !)o'e .00 m/

• he the e3te#io# !i# tem*e#!tu#e is !)o'e 2@°C =!t the i$et m!i"o$d i$et?%

Du#ig *!#t o" the EGR *h!se =$o egie s*eed B $o $o!d?/ the tu#)och!#gig*#essu#e is cot#o$$ed i ! o*e $oo* to *#e'et !& ite#"e#ece o the !i# $oo*%


9



C#8$-&% 12

IV EHAUST GAS RECYCLING REGULATION

,DI0:9C

2

13 4

6

5

- 4 Ai# "$omete#

2 4 Egie s*eed seso#

4 Iectio ECU

6 4 E3h!ust g!s #ec&c$ig '!$'e =EGR?

. 4 Th#ott$e housig =EGR?

9 4 Th#ott$e housig cot#o$ e$ect#o'!$'e =EGR?

> 4 Rec&c$ig #egu$!tio e$ect#o'!$'e =EGR?

E3h!ust g!s #ec&c$ig is o" *#og#essi'e t&*e !d is cot#o$$ed )& ! c!#tog#!*hicm!*%

Ro$e o" the iectio ECU de*edig o the i"o#m!tio #ecei'ed =e3h!ust g!s#ec&c$ig #!te dete#mied i the c!#tog#!*hic m!*?:

• to cot#o$ the e3h!ust g!s #ec&c$ig e$ect#o'!$'e ith ! OCR 'o$t!ge/

• to dete#mie the e3h!ust g!s #ec&c$ig #!te/

• to co##ect the OCR !**$ied to the e3h!ust g!s #ec&c$ig e$ect#o'!$'e so !s too)t!i the theo#etic!$ #ec&c$ig #!te eu!$ to the me!su#ed #!te%

Note: &%haust gas recycling rate difference between the measurement from theair flowmeter and the calculation of the amount of air entering the engine(depending on engine speed and air temperature!.


>



C#8$-&% 12

Coditios !$$oig e3h!ust g!s #ec&c$ig:

• egie s*eed g#e!te# th! >2. #*m/

• $o egie $o!d/

• coo$!t tem*e#!tu#e =ECU c!#tog#!*hic m!*? B !i# tem*e#!tu#e =ECUc!#tog#!*hic m!*?/

• #egee#!tio !ssist!ce ot !cti'e%

Coditios *#ohi)itig e3h!ust g!s #ec&c$ig:

• "u$$ egie $o!d/

• egie s*eed g#e!te# th! 29.0 #*m/

• !$titude !)o'e -.00 m/

• coo$!t tem*e#!tu#e !)o'e -0.°C/

• #egee#!tio !ssist!ce !cti'e%

Th#ott$e housig =EGR?:

• i !dditio to the #ec&c$ig '!$'e/ the th#ott$e housig/ de*edig o its*ositio/ is used to im*#o'e e3h!ust g!s #ec&c$ig/

• the th#ott$e housig is cot#o$$ed *#og#essi'e$& !d usig ! c!#tog#!*hic m!*=iectio ECU?%


@



C#8$-&% 12

V PREPOST HEATING

The *#ehe!tig !d *osthe!tig times !#e dete#mied )& the ECU de*edig othe coo$!t tem*e#!tu#e%

VI PREHEATING OPERATION

The *#ehe!tig time '!#ies !s ! "uctio o" coo$!t tem*e#!tu#e%

COOLANT TEMPERATURE PREHEATING TIME

4 2.°C -. secods

4 -@°C -0 secods

4 -0°C 0%. secods

4 -°C 0%. secods

VII HEATING OF THE PLUGS 0HILST CRAN:INGDu#ig the c#!ig *h!se/ the *$ugs !#e ee#gised i the "o$$oig c!ses:

• coo$!t tem*e#!tu#e )e$o 2.°C

• egie s*eed $ess th! >0 #*m "o# 0%2 secods%

Note: ;fter the *&< e%tinguishes- if the starter motor is not operated- the preheater plugs remain energised for a ma%imum of 20 seconds.

VIII POSTHEATING OPERATION5osthe!tig c! e3ted the o*e#!tio o" the *$ugs !"te# the c#!ig *h!se%

COOLANT TEMPERATURE POSTHEATING TIME

4 2.°C -@0 secods

->°C -@0 secods

-°C 600 secods

2.°C 600 secods

.0°C 0 secods

5!#!mete#s hich c! ite##u*t *osthe!tig:

• coo$!t tem*e#!tu#e !)o'e .0°C/

• egie s*eed !)o'e -.00 #*m%




C#8$-&% 12

I ADDITIONAL HEATING

As the egie is high$& e""iciet/ ! s&stem is #eui#ed to !ssist the #ise item*e#!tu#e i the *!ssege# com*!#tmet i co$d c$im!tes%

The *!ssege# com*!#tmet tem*e#!tu#e #ise !ssist!ce s&stem is cot#o$$ed )&the )ui$t4i s&stems ite#"!ce !d o*e#!ted )& the iectio ECU%

2 de'ices !#e used de*edig o the m!#etig cout#&:• se'e#!$ the#mo*$uge#s =e$ect#ic!$ #esisto#s? $oc!ted i the coo$!t ci#cuit o" the

he!te# m!t#i3/

• ! !dditio!$ "ue$ *oe#ed he!te# $oc!ted i the "#ot $e"t h!d hee$ !#ch ="o#'ehic$es i 'e#& co$d cout#ies?%

A 4 DIAGRAM

,DI0:>D

A

B

C

6415 1227

757

BSI11327

117

7

:&;

A 4 7AN eto#+ 4 CAN eto#C 4 1i#e coectio=-220? Coo$!t tem*e#!tu#e seso#%=-20? Iectio ECU%

=96-.? E3te#io# !i# tem*e#!tu#e seso#%=@0@? E$ect#ic!$ #esisto#s%=--0? Additio!$ he!te#%=0.0? F#ot RH doo# st!tio%=+,I-? +ui$t4i s&stems ite#"!ce%

The )ui$t4i s&stems ite#"!ce !utho#ises o*e#!tio o" these !dditio!$ he!tigs&stems de*edig o the "o$$oig *!#!mete#s:

• coo$!t tem*e#!tu#e/

• e3te#io# !i# tem*e#!tu#e%


-00



C#8$-&% 12

+ 4 5RE,ENTATION OF THE ADDITIONAL HEATING ,8,TEM,

1 E)&,-%!,8) %&'!'-%'

SDI038C

BSI1

1327

D!". * DBAT

7 7 7

Assem)$& ith #e$!&s !d #esisto#s

-20 4 Iectio ECU

@0@ 4 E$ect#ic!$ #esisto#s


The #esisto#s c! e!ch su**$& ! *oe# o" 0 !tts%This !ssem)$& !$$os he!tig *oe#s o" 0/ 990 o# 0 !tts%

2 A@@!-!*8) #&8-&%

The i#ig o$& !$$os oe he!tig *oe# to )e o)t!ied%

The !dditio!$ he!te# is cot#o$$ed )& ! iteg#!ted ECU%

C 4 CONTROL OF THE 5A,,ENGER COM5ARTMENT HEATING ,8,TEM,

The !dditio!$ he!te# is sitched o i the "o$$oig c!ses:

• $o *!ssege# com*!#tmet tem*e#!tu#e =s*eci"ic cu#'e?/

• he the egie o*e#!tig coditios so !$$o%


-0-



C#8$-&% 12

D 4 1ORING OUT THE ADDITIONAL HEATING REUIREMENT,

,DI0:D

7

27 17 17

T&

T8

7

65

47

8

9

t! 4 E3te#io# !i# tem*e#!tu#e

te 4 Coo$!t tem*e#!tu#e

! 4 E3!m*$e -

) 4 E3!m*$e 2

=outside sh!ded !#e!? he!tig !utho#is!tio oe%

The +,I dete#mies the *!ssege# com*!#tmet he!tig #eui#emet hethe egie is st!#ted de*edig o the e3te#io# !i# tem*e#!tu#e !d thecoo$!t tem*e#!tu#e%

E3!m*$e -:

• coo$!t tem*e#!tu#e 60°C/

• e3te#io# tem*e#!tu#e -0°C/

• the tem*e#!tu#e coditios !#e ithi the !dditio!$ he!tig o*e#!tigoe%

E3!m*$e 2:

• coo$!t tem*e#!tu#e >0°C/

• e3te#io# tem*e#!tu#e -0°C%

• the tem*e#!tu#e coditios !#e outside the !dditio!$ he!tig o*e#!tigoe%


-02



C#8$-&% 12

E 4 O5ERATION

The +,I dete#mies the *!ssege# com*!#tmet he!tig #eui#emet hethe egie is st!#ted de*edig o the e3te#io# !i# tem*e#!tu#e !d thecoo$!t tem*e#!tu#e%

The )ui$t4i s&stems ite#"!ce o*e#!tes the !dditio!$ he!te# i the "o$$oigcoditios:

• egie o*e#!tig "o# mo#e th! 90 secods/

• egie s*eed !)o'e >00 #*m/

• )!tte#& 'o$t!ge g#e!te# th! -2 'o$ts =*ositi'e e$ect#ic!$ )!$!ce?/

• coo$!t tem*e#!tu#e !)o'e 60°C%

The )ui$t4i s&stems ite#"!ce cot#o$s the he!te# st!ges *#og#essi'e$&:

• "i#st st!ge/

• secod st!ge/

• secod st!ge !d "i#st st!ge%

The !dditio!$ he!tig is sitched o"" he the tem*e#!tu#e coditios so!$$o =cu#'e?%


-0



C#8$-&% 12

AIR CONDITIONING COMPRESSOR CUTOFF

The iectio ECU is coected to the "o$$oig com*oets:

• ! *#essu#est!t $oc!ted o the !i# coditioig ci#cuit/

• the coo$!t tem*e#!tu#e seso#%The ECU c! cut o"" the su**$& to the e$ect#om!getic c$utch o" the !i#coditioig com*#esso# i the "o$$oig c!ses:

• egie s*eed $ess th! >00 #*m/

• coo$!t tem*e#!tu#e g#e!te# th! --.°C/

• *#essu#e i the !i# coditioig ci#cuit $ess th! 2%. )!#s =#e4!utho#is!tio !t )!#s?/

• *#essu#e i the !i# coditioig ci#cuit g#e!te# th! 0 )!#s =#e4!utho#is!tio !t2@ )!#s?%

I ENGINE IMMOBILISER FUNCTION

The iectio ECU *#e'ets the egie "#om )eig st!#ted )& *#ohi)itig iectio%

De'ice o*e#!tig *#ici*$e: #e"e# to the co##es*odig documet!tio%

U*),!*" -#& ';'-&

1he the igitio is sitched o/ the !utheticit& o" the e&s is checed )& the

+,I%

L,!*" !"*!-!* ==

The iectio ECU is !utom!tic!$$& $oced 20 secods m!3imum !"te# the igitiois sitched o""%

P8%-' %&$)8,&&*- $%,&@(%&

Re"e# to the #e*!i# sectio%


-06



C#8$-&% 12

II DISPLAYING FAULTS DO0NGRADED MODES OPERATION

A 4 DI,5LA8ING FAULT,

The !**e!#!ce o" ce#t!i "!u$ts i the iectio s&stem $e!ds to the

i$$umi!tio o" the egie di!gostic LED%The egie di!gostic LED i$$umi!tes i" ! "!u$t occu#s o the "o$$oigcom*oets o# i"o#m!tio:

• c!*!cito# N°- 'o$t!ge/

• c!*!cito# N°2 'o$t!ge/

• high *#essu#e "ue$ seso#/

• high *#essu#e "ue$ moito#ig/

• "ue$ *#essu#e #egu$!to#Bseso# cohe#ece/

• !cce$e#!to# *ed!$ seso# N°-/

• !cce$e#!to# *ed!$ seso# N°2/

• i$et m!i"o$d *#essu#e seso#/

• !i# "$omete#/

• st!)i$it& o" the ECU . 'o$t su**$&/

• e3h!ust g!s #ec&c$ig "uctio =#egu$!tio?/

• high *#essu#e "ue$ #egu$!to#/• diese$ iecto# "!u$t =- 4 6?/

• i$et *#essu#e/

• ;,i#$; cot#o$ e$ect#o'!$'e/

• te$ecodig/

• tu#)och!#gig "uctio%

+ 4 DO1NGRADED O5ERATING MODE,

The iectio s&stem m!!ges the "o$$oig dog#!ded modes:

• ! o*e#!tig mode ith ! #educed "ue$ "$o/

• the othe# mode $e!ds to the egie )eig sto**ed immedi!te$&%


-0.



C#8$-&% 12

C 4 REDUCED FUEL FLO1

This dog#!ded o*e#!tig mode $imits the "ue$ "$o !d the egie s*eedc!ot e3ceed 2200 #*m =ith the iected "ue$ "$o )eig $ess th! 0 mm?%

The iectio s&stem sitches to ;#educed "$o; mode he ! "!u$t is *#eset

o oe o" the "o$$oig com*oets:• high *#essu#e "ue$ seso#/

• "ue$ *#essu#e #egu$!to#Bseso# cohe#ece/

• !cce$e#!to# *ed!$ seso# N°-/

• !cce$e#!to# *ed!$ seso# N°2/

• i$et m!i"o$d *#essu#e seso#/

• !i# "$omete#/

• e3h!ust g!s #ec&c$ig "uctio =#egu$!tio?/• high *#essu#e "ue$ #egu$!to#/

• st!)i$it& o" the ECU . 'o$t su**$&/

• diese$ iecto# "!u$t =- 4 6?/

• i$et *#essu#e/

• tu#)och!#gig "uctio%

D 4 AIR CONDITIONING COM5RE,,OR CUT4OFF

The iectio ECU cuts o"" the su**$& to the !i# coditioig com*#esso# c$utchi" ! "!u$t is detected o the "! uit cot#o$ #e$!& coi$s%

E 4 HIGH 5RE,,URE FUEL 5UM5 RD 5I,TON DEACTI7ATOR

1he the "ue$ tem*e#!tu#e is !)o'e -09°C/ the iectio ECU de!cti'!tes the#d *isto o" the high *#essu#e *um* =so$eoid ee#gised?%

F 4 ,TO55ING THE ENGINE

The s&stem sto*s the egie immedi!te$& he ! "!u$t is *#eset o oe o"the "o$$oig com*oets:

• E*#om i the iectio ECU

• egie s*eed seso#

• c!*!cito# N°- 'o$t!ge

• c!*!cito# N°2 'o$t!ge

• high *#essu#e "ue$ moito#ig


-09



C#8$-&% 12

III COOLANT TEMPERATURE 0ARNING LED V4727/ FEATURE

The coo$!t tem*e#!tu#e !#ig LED c! )e cot#o$$ed )& oe o" the "o$$oigcom*oets:

• iectio ECU/

• coo$!t tem*e#!tu#e seso# =2 ch!e$s?%

No#m!$ LED o*e#!tio:

• the LED i$$umi!tes i" the tem*e#!tu#e e3ceeds --@°C/

• the LED e3tiguishes i" the tem*e#!tu#e "!$$s )e$o -->°C%


-0>



C#8$-&% 12

IV CRUISE CONTROL

The c#uise cot#o$ de'ice is used to m!it!i the 'ehic$e s*eed !t ! '!$ue*#og#!mmed )& the d#i'e# i the "o$$oig c!ses:

• he the !cce$e#!to# *ed!$ is ot *#essed/

• #eg!#d$ess o" the #o!d *#o"i$e/

• ithout *#essig the )#!e *ed!$%

5ossi)i$ities o""e#ed )& the c#uise cot#o$ de'ice:

• the d#i'e# c! e3ceed the *#og#!mmed s*eed )& *#essig the !cce$e#!to#*ed!$/

• the d#i'e# c! c!ce$ c#uise cot#o$ )& *#essig the )#!e *ed!$/ the c#uisecot#o$ sitch o# the oBo"" )utto%

Note: The cruise control device can only be used above "0 /m=h.

O$&%8-!*.

1he c#uise cot#o$ is o/ the iectio ECU *e#m!et$& com*!#es the*#og#!mmed s*eed ith the 'ehic$es ist!t!eous s*eed%

The s*eed i"o#m!tio is su**$ied )& the s*eed seso#%

1he the *#og#!mmed s*eed is g#e!te# th! the 'ehic$es cu##et s*eed/ theiectio ECU ic#e!ses the "ue$ "$o: the 'ehic$e !cce$e#!tes u* to the*#og#!mmed s*eed%

1he the 'ehic$es cu##et s*eed is g#e!te# th! the *#og#!mmed s*eed/ theiectio ECU #educes the "ue$ "$o: the 'ehic$e dece$e#!tes do to the*#og#!mmed s*eed%

C#uise cot#o$ is c!ce$$ed )& *#essig:

• the !cce$e#!to# *ed!$/

• the c$utch *ed!$/

• the oBo"" )utto/

• the )#!e *ed!$%

Note: In the above " cases- the vehicle decelerates very quic/ly (acceleratorreleased without declutching!.

1he c#uise cot#o$ is c!ce$$ed )& *#essig the c#uise cot#o$ )utto/ the 'ehic$edece$e#!tes s$o$&%


-0@



C#8$-&% 13

OPERATING PHASESPARTICLE FILTRATION

I GENERAL PRINCIPLE

The !im o" "i$t#!tio is to #emo'e the *!#tic$es #et!ied o the "i$te# !$$s%

Regee#!tio cosists o" *e#iodic!$$& )u#ig o"" the *!#tic$es !ccumu$!ted i the*!#tic$e "i$te#%

Regee#!tio c! )e !tu#!$ i" the tem*e#!tu#e o" the e3h!ust g!ses is su""iciet%

Regee#!tio c! )e c!used )& the iectio ECU i" the tem*e#!tu#e o" thee3h!ust g!ses is isu""iciet !d i" the *!#tic$e "i$te# is c$ogged%

The iectio ECU !#ti"ici!$$& ic#e!ses the tem*e#!tu#e o" the e3h!ust g!sesusig *ost4iectio: this is the ;#egee#!tio !ssist!ce; *h!se%

Note: The driving conditions directly affect the temperature of the e%haust gasesand consequently the temperature inside the particle filter.

The iectio ECU *e#m!et$& cot#o$s the "o$$oig com*oets:

• the st!tus o" the "i$te# usig ! "uctio hich moito#s the $o!d $e'e$ o" the*!#tic$e "i$te#/

• #egee#!tio !ssist!ce usig ! #egee#!tio !ssist!ce "uctio%


-0



C#8$-&% 13

II DIAGRAM

SDI040P

1 2 3

4

5 6

17

11

15

16

1

1

1

27

12

13

14

A 4 7AN eto#G

B 4 CAN eto#G

C 4 1i#e coectio


--0



C#8$-&% 13

REF. DESCRIPTION

- +ui$t4i s&stems ite#"!ce

2 Mi$e!ge

Cet#!$ di!gostic socet6 Di!gostic LED

. ,e#'ice LED

9 He!ted #e!# sc#ee

> F! uit=s?

@ 5#e4*ost he!tig uit

Diese$ iecto#s

-0 High *#essu#e "ue$ *um* #d *isto de!cti'!to#

-- Rec&c$ig #egu$!tio e$ect#o'!$'e =EGR?-2 Th#ott$e housig cot#o$ e$ect#o'!$'e =EGR?

- Th#ott$e housig cot#o$ e$ect#o'!$'e =i$et !i# he!te#?

-6 Tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e

-. Ai# "$omete#

-9 Di""e#eti!$ *#essu#e seso#

-> E3h!ust g!s tem*e#!tu#e seso# =u*st#e!m o" the c!t!$&ticco'e#te#?

-@ Iectio ECU- E3h!ust g!s tem*e#!tu#e seso# =dost#e!m o" the c!t!$&tic

co'e#te#?

20 Fue$ !dditi'e ECU


---



C#8$-&% 13

III PARTICLE FILTER LOAD LEVEL MONITORING FUNCTION

A 4 ROLE

4 To dete#mie the coditio o" the *!#tic$e "i$te# =c$oggig $e'e$?

4 To #euest !cti'!tio o" the #egee#!tio !ssist!ce "uctio/ heecess!#&

4 To esu#e the e""ecti'eess o" the #egee#!tio !ssist!ce "uctio%

M!i i"o#m!tio used "o# moito#ig the *!#tic$e "i$te#:

• *#essu#e di""e#eti!$/

• e3h!ust g!s tem*e#!tu#e =dost#e!m o" the c!t!$&tic co'e#te#?/

• e3h!ust g!s tem*e#!tu#e =u*st#e!m o" the c!t!$&tic co'e#te#?/

• um)e# o" mi$es t#!'e$$ed/

• i$et !i# "$o%

Note: This information depends on the load level of the particle filter.

+ 4 1ORING OUT THE 5ARTICLE FILTER LOAD LE7EL

The !mout o" *!#tic$es *#eset i the "i$te# '!#ies its $o!d $oss =i$et B out$et*#essu#e di""e#eti!$?%

This *e#m!et$& me!su#ed '!$ue #e*#esets the $o!d $e'e$ o" the *!#tic$e"i$te#%

The c!#tog#!*hic m!*s o" the iectio ECU h!'e 9 o*e#!tig $e'e$sdete#mied )& cu#'es/ "#om the 'o$ume "$o o" e3h!ust g!ses%

The 'o$ume "$o o" e3h!ust g!ses is esseti!$$& c!$cu$!ted "#om the "o$$oig*!#!mete#s:


• i$et !i# "$o/


• e3h!ust g!s tem*e#!tu#e =dost#e!m o" the c!t!$&tic co'e#te#?%


--2



C#8$-&% 13

C 4 5ARTICLE FILTER LOAD LE7EL,

,DI06-D

8

9

,

@

&=

77

D

E

D 4 E3h!ust g!s 'o$ume "$o =$Bh?

E 4 5#essu#e di""e#eti!$ =m)!#?

! 4 Fi$te# *uctu#ed

) 4 Fi$te# #egee#!ted

c 4 Ite#medi!te oed 4 Fi$te# $o!ded

e 4 Fi$te# o'e#$o!ded

" 4 Fi$te# c$ogged

Note: These statuses can be read using the diagnostic tool- in parametermeasurements.

Poes ;!; 4 ;"; #e*#eset the *ossi)$e c$oggig $e'e$s o" the *!#tic$e "i$te#% The!im o" the iectio ECU is to )e *e#m!et$& i oe ;); o# ;c; =#eg!#d$ess o"

'ehic$e mi$e!ge?%1he $e!'ig oe ;c; to go to oe ;d; =!t ! '!#i!)$e s*eed de*edig od#i'ig coditios?/ the iectio ECU #euests #egee#!tio !ssist!ce to#etu# to oe ;); o# *ossi)$& ;c; =de*edig o d#i'ig coditios?%

Note: >ones ?a? and ?f? are )ones where the pressure differential isabnormal.


--



C#8$-&% 13

The iectio ECU #euests !cti'!tio o" the #egee#!tio "uctio i the"o$$oig c!ses:

• $o!d $e'e$ o" the "i$te# *!ssig "#om oe ;c; 4 ;d;/

• $o!d $e'e$ o" the "i$te# i oe ;e; o# ;";/

• $o!d $e'e$ o" the "i$te# i oe ;c; !d d#i'ig coditios "!'ou#!)$e "o##egee#!tio =!'e#!ge s*eed g#e!te# th! >0 mBh? =JJ?/

=JJ? ude# these coditios #egee#!tio i$$ )e uice# =#egee#!tio st#!teg&i ecoomic coditios?%

F!)-&% ?&%)8@&@ *& <&<

The iectio ECU sitches to the o'e#$o!ded "i$te# st!te he #egee#!tioh!s "!i$ed ude# ce#t!i d#i'ig coditios%

This is ! !#ig st!te%

F!)-&% ,)""&@ *& <=<

The *#essu#e di""e#eti!$ is *e#m!et$& g#e!te# th! 00 m)!# =m!3imum)!c *#essu#e !$$o!)$e )& the egie? o# g#e!te# th! ! $imit de*edig othe 'o$ume "$o #!te%

5ossi)$e c!uses o" the "!u$t:

• #egee#!tio !ssist!ce ie""ecti'e/

• "i$te# c$ogged ith ce#ie/

• ico##ect i"o#m!tio "#om the di""e#eti!$ *#essu#e seso#%

The iectio ECU sus*eds !$$ #euests "o# #egee#!tio !ssist!ce !dsig!$s ! "!u$t%

IMPORTANT I" the ;"i$te# c$ogged; "!u$t occu#s/ it is esseti!$ to $oc!te theo#igi o" the c$oggig o# e$se the "i$te# i$$ )e d!m!ged%

F!)-&% $(*,-(%&@ *& <8<

The *#essu#e di""e#eti!$ is $ess th! ! $imit/ de*edig o the 'o$ume "$o#!te%

5ossi)$e c!uses o" the "!u$t:• ico##ect i"o#m!tio "#om the di""e#eti!$ *#essu#e seso#

• se!$ig "!u$t o" the e3h!ust *i*e/ u*st#e!mBdost#e!m i"o#m!tio *i*es

• "i$te# !ctu!$$& *uctu#ed

The iectio ECU sus*eds !$$ #euests "o# #egee#!tio !ssist!ce !dsig!$s ! "!u$t%

Note: The ?filter punctured? fault may be due to an e%cess temperatureduring a regeneration as the amount of burnt particles may be too

great.


--6



C#8$-&% 13

D 4 CORRECTION OF THE LOAD LE7EL, DE5ENDING ON THE AMOUNT OFCERINE

The ce#ie i the "ue$:

• is ot )u#t ith the soot/

• )ui$ds u* o the !$$s o" the *!#tic$e "i$te#%The iectio ECU the#e"o#e *e#m!et$& !d!*ts its c!#tog#!*hic m!*sde*edig o the !mout o" ce#ie !ccumu$!ted i the *!#tic$e "i$te#%

E 4 EFFECT OF DRI7ING CONDITION, ON THE 5RE,,URE DIFFERENTIAL

The ch!ge i *#essu#e di""e#eti!$ !$so de*eds o the "o$$oig *!#!mete#s:

• "ue$ cosum*tio ="ue$ K !dditi'e?/• 'ehic$e d#i'ig coditios =!cti'!tio o" *ost4iectio?/• e3h!ust g!s tem*e#!tu#e/• e3h!ust g!s s*eed i the *!#tic$e "i$te#%

,DI062D

F G

E E

D D

"

# #

"

D 4 7o$ume "$o o" e3h!ust g!ses =$Bh?E 4 5#essu#e di""e#eti!$ =m)!#?F 4 Ro!d o# moto#!& t&*e d#i'ig =)e"o#e #egee#!tio?G 4 U#)! t&*e d#i'ig =)e"o#e #egee#!tio? h 4 Fi$te#ed e3h!ust g!ses g 4 De*osits =ce#ie/ soot/ u)u#ed h&d#oc!#)os/ oi$ de*osits/ etc?

E3!m*$e F:

• the de*osits co$$ect !t the )ottom o" the *!#tic$e "i$te#/• the g!ses *!ss e!si$& th#ough the ch!e$s !d the *#essu#e di""e#eti!$ is

$o%

E3!m*$e G:

• the de*osits co$$ect i ! st#!ti"ied $!&e# o the ch!e$s/• the g!ses h!'e *#o)$ems *!ssig th#ough the ch!e$s !d the *#essu#e

di""e#eti!$ is high%

08%*!*" Fo# the s!me !mout o" ce#ie !d "o# the s!me 'ehic$e mi$e!ge/the di""e#eti!$ *#essu#e m!& '!#&%


--.



C#8$-&% 13

IV REGENERATION ASSISTANCE MANAGEMENT FUNCTION

A 4 ROLE

• To cot#o$ #euests "#om the moito#ig "uctio%

• To !cti'!te the "uctios #eui#ed "o# #egee#!tio/ de*edig o themoito#ig st!tes%

• To dete#mie the #eui#ed #egee#!tio !ssist!ce $e'e$%

• To cot#o$ the e""ects o" *ost4iectio o egie o*e#!tio%

Regee#!tio cosists o" *e#iodic!$$& )u#ig o"" the *!#tic$es !ccumu$!ted othe "i$te# e!)$ig it to #em!i i oe ;); o# ;c;%

Fi$te# #egee#!tio de*eds o the tem*e#!tu#e o" the e3h!ust g!ses hichmust )e !)o'e the soot com)ustio $imit%

The#e !#e 2 techiues "o# !chie'ig this:

• !tu#!$ #egee#!tio/

• !#ti"ici!$ #egee#!tio =#egee#!tio !ssist!ce?%

N!tu#!$ #egee#!tio%

1he the e3h!ust tem*e#!tu#e #e!ches the #egee#!tio $imit itse$" =highegie $o!d?/ the *!#tic$es )u# o"" !tu#!$$& i the *!#tic$e "i$te#% No e3te#!$!ctios !#e #eui#ed to !ssist #egee#!tio%

A#ti"ici!$ #egee#!tio =#egee#!tio !ssist!ce?%

Regee#!tio !ssist!ce is ! set o" *#o'isios cot#o$$ed )& the iectioECU/ the !im o" hich is to ic#e!se the tem*e#!tu#e o" the e3h!ust g!ses tothe #egee#!tio $imit%

+ 4 1ORING OUT THE REUIRED REGENERATION A,,I,TANCE LE7EL

The#e !#e 2 t&*es o" #egee#!tio !ssist!ce/ de*edig o the the#m!$ st!teo" the e3h!ust *i*e:

• $e'e$ - #egee#!tio !ssist!ce =c!#tog#!*hic m!*s "o# co$d e3h!ust *i*e!d c!t!$&tic co'e#te#? =c!t!$&tic co'e#te# *#e4he!tig?/

• $e'e$ 2 #egee#!tio !ssist!ce =c!#tog#!*hic m!*s "o# !#m e3h!ust *i*e?%


--9



C#8$-&% 13

C 4 LE7EL - REGENERATION A,,I,TANCE

1he the moito#ig "uctio detects ! ch!ge i o*e#!tig oe/ it #euests!cti'!tio o" $e'e$ - #egee#!tio !ssist!ce =e%g% ch!gig "#om oe ;c; to;d;?%

E'e#& time !cti'!tio is #euested/ the iectio ECU *e#"o#ms the "o$$oigo*e#!tios:

• it *#e'ets e3h!ust g!s #ec&c$ig =EGR?/

• it #euests !cti'!tio o" e$ect#ic!$ cosume#s =he!ted #e!# sc#ee/ "! uit/*#ehe!te# *$ugs? =J?/

• it cot#o$s the o*eig !d c$osig o" the i$et !i# he!te# th#ott$e =i"ecess!#&?/

• it !cti'!tes *ost4iectio =he!tig o" the e3h!ust g!ses?%

=J? this #euest is su)ect to the e$ect#ic!$ $o!d sheddig st#!teg& o" the +,I=de*edig o eui*met?%

D 4 LE7EL 2 REGENERATION A,,I,TANCE

The *#ici*$e is the s!me !s $e'e$ - #egee#!tio !ssist!ce )ut st#icte#c!#tog#!*hic m!*s $e!d to ! highe# e3h!ust g!s tem*e#!tu#e%

The sitch "#om $e'e$ - to $e'e$ 2 #egee#!tio !ssist!ce de*eds o the"o$$oig coditios:

• u*st#e!m !d dost#e!m e3h!ust tem*e#!tu#e/

• "o# !s $og !s the tem*e#!tu#e h!s ot #e!ched ! $imit%

It is im*ossi)$e to sitch "#om $e'e$ - to $e'e$ 2 #egee#!tio !ssist!ce i" $e'e$- h!s ot )ee !cti'e "o# ! gi'e time%

E 4 CA,E OF REUE,TING REGENERATION A,,I,TANCE IN ECONOMICCONDITION, =+8 THE MONITORING FUNCTION?

The !im o" this #euest is to !cti'!te #egee#!tio !ssist!ce ude# o*timumd#i'ig coditios/ i o#de# to #educe "ue$ cosum*tio%

The *#ici*$e is the s!me !s $e'e$s - !d 2 #egee#!tio !ssist!ce )ut ith !sho#te# *ost4iectio time%

5!#!mete#s #eui#ed:

• *!#tic$e "i$te# i oe ;c;/ ;e; o# ;";/

• su""iciet 'ehic$e s*eed o# egie s*eedB$o!d "o# ! gi'e time


-->



C#8$-&% 13

F 4 CONDITION, FOR ACTI7ATING REGENERATION A,,I,TANCE =+8 THEMONITORING FUNCTION?

5!#!mete#s hich c! !cti'!te #egee#!tio !ssist!ce:


• dist!ce t#!'e$$ed )etee e!ch #egee#!tio%

PARAMETERS REGENERATION ASSISTANCE

5#essu#e di""e#eti!$ Acti'!tio 5#essu#e di""e#eti!$=!)o'e ! $imit ;E;?

De!cti'!tio E""ecti'e *ost4iectio time=!)o'e ! $imit ;;?

Dist!ce Acti'!tio Dist!ce t#!'e$$ed sice $!st#egee#!tio =!)o'e ! $imit ;<;?

De!cti'!tio E""ecti'e *ost4iectio time=!)o'e ! $imit ;;?

G 4 5RE,,URE DIFFERENTIAL

The *#essu#e di""e#eti!$ *!#!mete# is used to !cti'!te #egee#!tio!ssist!ce ide*edet$& to the dist!ce i"o#m!tio%

1he this coditio is #es*osi)$e "o# dete#miig !cti'!tio o" #egee#!tio!ssist!ce/ ! e""ecti'e *ost4iectio time must h!'e e$!*sed )e"o#e#egee#!tio !ssist!ce c! )e sto**ed =this !$$os com*$ete sootcom)ustio/ i o#m!$ o*e#!tio?%

Moito#ig the *ost4iectio time:

• *#e'ets the *ost4iectio time )eig too $og =d!m!ge to the egie/e3*!sio o" the egie oi$?/

• $imits "ue$ cosum*tio%


--@



C#8$-&% 13

H 4 DI,TANCE

The dist!ce *!#!mete#:

• !cti'!tes #egee#!tio !ssist!ce ide*edet$& to the *#essu#e di""e#eti!$i"o#m!tio/

• $imits the !mout o" soot to )e )u#t o"" i the "i$te#/ shou$d the *#essu#edi""e#eti!$ i"o#m!tio "!i$%

Note: Too many particles to be burned would lead to e%cessivetemperatures which would damage the particle filter.

I" the !'e#!ge dist!ce o" the $!st . #egee#!tios is $ess th! ! $imit =.0m?/ the iectio ECU sitches to the ;dist!ce; st#!teg&%

The dist!ce t#!'e$$ed sice the $!st #egee#!tio is couted )& the m!iiectio ECU hich !cti'!tes #egee#!tio !ssist!ce he this coute#

#e!ches ! $imit ;<;%This $imit/ o# #egee#!tio "#euec&/ de*edig o the tot!$ dist!ce t#!'e$$ed)& the *!#tic$e "i$te#%

The #egee#!tio "#euec& must )e ic#e!sed to t!e ito !ccout the#eductio i c!*!cit& o" the *!#tic$e "i$te# =cosum*tioBu!tit& o"!ccumu$!ted ce#ie?%

,DI06:C

J

H7

7 777

1477

57

H 4 Dist!ce t#!'e$$ed )& the *!#tic$e "i$te# =m?

< 4 Regee#!tio "#euec& =m?

I 4 OTHER CONDITION,

Othe# coditios !utho#isig !cti'!tio o" #egee#!tio !ssist!ce:

• coo$!t tem*e#!tu#e !)o'e 90°C/

• su""iciet egie s*eed B $o!d%


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C#8$-&% 13

V EFFECTS OF ACTIVATING REGENERATION ASSISTANCE

A 4 5ROHI+ITION OF EHAU,T GA, REC8CLING REGULATION =EGR?

E'e#& time #egee#!tio !ssist!ce is !cti'!ted/ the iectio ECU *#ohi)its

e3h!ust g!s #ec&c$ig #egu$!tio:• e3h!ust g!s #ec&c$ig '!$'e c$osed =*#e'ets !& hutig *heome!?/

• th#ott$e housig o*e =e3ce*t i" c$osig is #euested to "o#ce !i# to "$o itothe he!te#?%

+ 4 ACTI7ATION OF ELECTRICAL CON,UMER,

1 R)&

Re!so "o# !cti'!tig e$ect#ic!$ cosume#s:

• to ic#e!se the #esist!t to#ue o" the !$te#!to#/ thus $e!dig to !ic#e!se i egie $o!d/

• to "!ci$it!te the #ise i tem*e#!tu#e o" the e3h!ust g!ses/

• to uic$& *$!ce the egie o*e#!tig *oit ithi coditios !$$oige""ecti'e *ost4iectio%

2 O$&%8-!*

The iectio ECU !ss the +,I to !cti'!te cosume#s hich !)so#) !high *oe# =!$te#!to# s!tu#!tio #euest? =J?%


O#de# i hich cosume#s !#e !cti'!ted )& the +,I =JJ?:

• he!ted #e!# sc#ee cot#o$/

• #euest to "o#ce the "! uit !t $o s*eed/

• cot#o$ o" the "! uit !t mid s*eed/

• #euest to "o#ce the *#e4*ost he!tig *$ugs%

=JJ? !$$oed )& the $o!d sheddig $e'e$ o" the 'ehic$e =*#o'ided th!t the)!tte#& 'o$t!ge is !)o'e -2%@ 'o$ts?%


-20



C#8$-&% 13

C 4 INLET AIR HEATER

The i$et !i# he!te# is used:

• to "!ci$it!te the #ise i tem*e#!tu#e o" the e3h!ust g!ses/

• to uic$& *$!ce the egie o*e#!tig *oit ithi coditios !$$oige""ecti'e *ost4iectio%

Note: The temperature of the air entering the engine must be between "0 ° +

and 0 ° + to allow efficient postcombustion.

D 4 5O,T4IN<ECTION

The c!t!$&tic co'e#te#/ $oc!ted u*st#e!m o" the *!#tic$e "i$te#/ is ! o3id!tio

c!t!$&tic co'e#te#%I the *#esece o" u)u#ed h&d#oc!#)os =HC?/ the he!t e""iciec& o" thec!t!$&tic co'e#te# ic#e!ses%

The tem*e#!tu#e o" the e3h!ust g!ses ic#e!ses%

Du#ig *ost4iectio:

• the "ue$ is iected !"te# To* De!d Cet#e =20 4 -20 ° c#!sh!"t?/

• the tem*e#!tu#e o" the e3h!ust *i*e ic#e!ses *#og#essi'e$& u* to the#egee#!tio $imit%

Oce the #egee#!tio $imit h!s )ee #e!ched/ *ost4iectio is m!it!ieduti$ !$$ o" the *o$$ut!t *!#tic$es h!'e )ee e$imi!ted%

The *ost4iectio "$o !d time !#e dete#mied )& c!#tog#!*hic m!*s/ t!igito !ccout the egie o*e#!tig coditios%


-2-



C#8$-&% 13

O*e#!tig cu#'e:

SDI044P

E

L1

L2

E1

M :

L

E 4 5#essu#e di""e#eti!$ =m)!#?

E- 4 5#essu#e di""e#eti!$ cu#'e =m)!#? 4 Time =s?

L 4 Tem*e#!tu#e =°C?

L- 4 E3h!ust g!s tem*e#!tu#e =dost#e!m o" the c!t!$&tic co'e#te#? =°C?

L2 4 E3h!ust g!s tem*e#!tu#e =u*st#e!m o" the c!t!$&tic co'e#te#? =°C?

M 4 5ost4iectio cot#o$

O*e#!tio ith *ost4iectio: the tem*e#!tu#e u*st#e!m o" the c!t!$&ticco'e#te# is $ess th! the tem*e#!tu#e dost#e!m o" the c!t!$&tic co'e#te#%

O*e#!tio ithout *ost4iectio: the tem*e#!tu#e u*st#e!m o" the c!t!$&ticco'e#te# is g#e!te# th! the tem*e#!tu#e dost#e!m o" the c!t!$&ticco'e#te# =!t ste!d& s*eed?%


-22



C#8$-&% 13

E 4 EFFECT, ON ENGINE O5ERATION

At cost!t egie $o!d !d s*eed/ *ost4iectio $e!ds to ! ic#e!se iegie to#ue%

To m!it!i the s!me d#i'ig *$e!su#e !d !'oid egie hesit!tio du#ig*ost4iectio/ the iectio ECU *#og#!m ico#*o#!tes the "o$$oigst#!tegies:

• #eductio o" the m!i iectio "$o/

• tu#)och!#gig *#essu#e #egu$!tio%

1 R&@(,-!* = -#& 8!* !*+&,-!* =)>

,DI06.D

N

:

)

*

4 Time =s?

N 4 C&$ide# *#essu#e =)!#?

4 5#e4iectio

4 M!i iectio

$ 4 5ost4iectiom 4 Reductio i m!i iectio time

4 Reductio i c&$ide# *#essu#e

Reducig the m!i iectio "$o c!ce$s out the ic#e!se i to#ue due to*ost4iectio%


-2



C#8$-&% 13

2 T(%9,#8%"!*" $%&''(%& %&"()8-!*

To m!it!i the s!me egie to#ue du#ig #egee#!tio !ssist!ce/ thetu#)och!#gig *#essu#e is #egu$!ted%

3 O$&%8-!* = -#& #!"# $%&''(%& =(&) $($ 3%@ $!'-* @&8,-!?8-%

The high *#essu#e "ue$ *um* o*e#!tes o *istos du#ig #egee#!tio!ssist!ce%

Aim o" the s&stem: to *#o'ide the "$o #eui#ed )& *ost4iectio%


-26



C#8$-&% 13

VI FUEL ADDITIVE FUNCTION

A 4 O5ERATION

To $oe# the #egee#!tio $imit/ ! ce#ie )!sed !dditi'e =Eo$&s? is !dded to

the "ue$/ hich $oe#s the *!#tic$e com)ustio tem*e#!tu#e "#om ..0°

C to6.0°C%

Ce#ie is used i ! o#g!ic so$utio sto#ed i ! !dditio!$ t!/ $oc!ted e!#to the "ue$ t!%

A !dditi'e s&stem h!s )ee de'e$o*ed i o#de# to iect ! !mout o"!dditi'e *#o*o#tio!$ to the !mout o" "ue$ iected%

The s&stem com*#ises the "o$$oig com*oets:

• ! suctio de'ice ith ! miimum $e'e$ detecto# o the !dditi'e t!/

• ! s&stem "o# iectig the !dditi'e ito the "ue$ t!/

• ! s*eci"ic ECU "o# cot#o$$ig the !dditi'e "uctio%

,ede# "i$te#ig #eui#es ! *um*ig $imit eu!$ to > $it#es o" "ue$%


-2.



C#8$-&% 13

O*e#!tio:

FUEL ADDITIVE FUNCTIONENGINE STATIONARY

FUEL ADDITIVE FUNCTIONENGINE RUNNING

Egie o"" No e#o 'ehic$e s*eed

Memo#isig o" the "ue$ $e'e$ ;-; Pe#o 'ehic$e s*eedO*eig o" the "ue$ "i$$e# c!* O*eig o" the "ue$ "i$$e# c!*

Memo#isig o" the "ue$ "i$$e# c!* o*e Memo#isig o" the "ue$ $e'e$ ;-;

C$osig o" the "ue$ "i$$e# c!* C$osig o" the "ue$ "i$$e# c!* o# o e#o'ehic$e s*eed

,t!#tig o" the egie Acuisitio o" the "ue$ $e'e$ ;2; 4checig o" the *ositio o" the "ue$ "i$$e#c!*

Acuisitio o" the "ue$ $e'e$ ;2; 4checig o" the *ositio o" the "ue$ "i$$e#

c!*

C!se -: 2 Q - !d "ue$ "i$$e# c!* c&c$e =J? 4Q "ue$ !dditi'e "uctio 4 o#m!$o*e#!tio

C!se 2: 2 Q - !d "ue$ "i$$e# c!* c&c$e "!u$t& o# o c&c$e 4Q "ue$ !dditi'e "uctio 4"ue$ "i$$e# c!* "!u$t&

C!se : 2 - !d "ue$ "i$$e# c!* c&c$e 4Q "ue$ !dditi'e eu!$ to *um*ig $imit =>$it#es?

C!se 6: 2 - !d "ue$ "i$$e# c!* c&c$e "!u$t& o# o c&c$e 4Q othig 4 o#m!$o*e#!tio

=J? "ue$ "i$$e# c!* c&c$e:• o*eig o" the "ue$ "i$$e# c!*/

• c$osig o" the "ue$ "i$$e# c!*%

The "ue$ "i$$e# c!* c&c$e is e""ecti'e i" the time ite#'!$ )etee o*eig !dc$osig is g#e!te# th! . secods%

+ 4 TOTAL AMOUNT OF ADDITI7E IN<ECTED

E'e#& time !dditi'e is !dded/ the !dditi'e ECU memo#ises the !mout o"

!dditi'e iected%

This '!$ue is !dded to the *#e'ious$& iected '!$ues to gi'e ! '!$ue#e*#esetig the tot!$ !mout o" !dditi'e iected sice the )egiig o" the*!#tic$e "i$te#s $i"e%

This '!$ue is set to the iectio ECU hich uses it !s the )!sis "o#cot#o$$ig the c$oggig $e'e$ o" the *!#tic$e "i$te# ith ce#ie%


-29



C#8$-&% 13

VII DISPLAYING FAULTS DO0NGRADED OPERATING MODES

A 4 DI,5LA8ING FAULT,

The !**e!#!ce o" ce#t!i "!u$ts i the *!#tic$e "i$t#!tio s&stem $e!ds to the

i$$umi!tio o" the egie di!gostic LED%The egie di!gostic LED i$$umi!tes he ! "!u$t is *#eset o oe o" the"o$$oig com*oets o# items o" i"o#m!tio:

• di""e#eti!$ *#essu#e seso#/

• e3h!ust g!s tem*e#!tu#e seso#s =u*st#e!m !d dost#e!m o" thec!t!$&tic co'e#te#?/

• *!#tic$e "i$te# c$ogged/

• *!#tic$e "i$te# *uctu#ed%

+ 4 DO1NGRADED O5ERATING MODE

The iectio s&stem cot#o$s the "o$$oig dog#!ded mode: ! o*e#!tigmode ith #educed "ue$ "$o%

C 4 REDUCED FUEL FLO1

This dog#!ded o*e#!tig mode $imits the "ue$ "$o such th!t the egie

s*eed c!ot e3ceed 2200 #*m ude# !& ci#cumst!ces =!d the iected"ue$ "$o #em!is $ess th! 0 mm?%

The iectio sitches to ;#educed "$o; mode he oe o" the "o$$oigcom*oets is "!u$t&:

• *!#tic$e "i$te# c$ogged/

• *!#tic$e "i$te# *uctu#ed/

• e3h!ust g!s tem*e#!tu#e seso#s =u*st#e!m !d dost#e!m o" the

c!t!$&tic co'e#te#? =J?/

• di""e#eti!$ *#essu#e seso# =J?%

=J? 200 m !"te# the "!u$t !**e!#s%


-2>



C#8$-&% 13

D 4 FUEL ADDITI7E FUNCTION 4 O5ERATION IN DO1NGRADED MODE,

m!i st#!tegies !#e used i" the !dditi'e s&stem de'e$o*s ! "!u$t%

F(&) =!))&% ,8$ =8()-

The !dditi'e ECU uses the 'ehic$e s*eed i"o#m!tio i couctio ith the"ue$ sede# i"o#m!tio to iect the !dditi'e%

F(&) '&*@&% =8()-

The !dditi'e ECU !dds ! !mout o" !dditi'e eu!$ to th!t !dded "o# ! "u$$t! he the "ue$ "i$$e# c!* is o*eedBc$osed%

C(*!,8-!*' =8()- * -#& VAN ()-!$)&&@ *&->%

The !dditi'e ECU !dds ! !mout o" !dditi'e eu!$ to th!t !dded "o# ! "u$$t! he commuic!tios !#e ite##u*ted "o# mo#e th! -0 secods%


-2@



C#8$-&% 13

VIII DRIVERS INFORMATION FUNCTION

A 4 DIAGNO,TIC LED =7-00?

No#m!$ LED o*e#!tio:

• the LED i$$umi!tes he the igitio is sitched o%

• !"te# the igitio is sitched o/ the LED e3tiguishes !"te# ! 6 secodtime#%

A)o#m!$ LED o*e#!tio:

• the LED i$$umi!tes he the igitio is sitched o/

• the LED #em!is i$$umi!ted%

+ 4 RI, OF THE 5ARTICLE FILTER CLOGGING

I the e'et o" *#o$oged id$ig/ #egee#!tio !ssist!ce is ie""ecti'e=e3h!ust g!s tem*e#!tu#e ot su""iciet?%

The "i$te# c$ogs u* ith *!#tic$es%

The iectio ECU i"o#ms the +,I%

The +,I #euests th!t ! mess!ge is dis*$!&ed o the mu$ti"uctio sc#ee=#is o" *!#tic$e "i$te# c$oggig? i the "o$$oig c!ses: *!#tic$e "i$te# "!u$t

=*!#tic$e "i$te# o'e#$o!ded?%The !im is to ecou#!ge the d#i'e# to !d!*t his d#i'ig to "!ci$it!te *!#tic$e"i$te# #egee#!tio%

1ithi -00 i$omet#es !"te# the mess!ge !**e!#s/ the custome# must d#i'e "o#!t $e!st miutes !t ! s*eed g#e!te# th! .0 mBh hich shou$d c!use themess!ge to dis!**e!#%

F!i$u#e to com*$& ith this #ecommed!tio i$$ $e!d to the "o$$oig "!u$t:*!#tic$e "i$te# c$ogged%

The iectio ECU i"o#ms the +,I hich:

• #euests th!t the di!gostic LED is i$$umi!ted/

• #euests th!t ! mess!ge is dis*$!&ed o the mu$ti"uctio sc#ee=!ti*o$$utio *#o)$em?%


-2



C#8$-&% 13

C 4 MINIMUM LE7EL OF ADDITI7E REACHED

The iectio ECU i"o#ms the +,I hich:

• #euests th!t the se#'ice LED is "$!shed o the cot#o$ *!e$ ="o# 20

secods !"te# the igitio is sitched o? =J?/

• #euests th!t ! mess!ge is dis*$!&ed o the mu$ti"uctio sc#ee =$odiese$ !dditi'e $e'e$? =!"te# the igitio is sitched o? =J?%



-0



C#8$-&% 14

MAINTENANCEHDI INJECTION SYSTEM

I RECOMMENDED FUEL

The iectio s&stem #eui#es the use o" diese$ ith ! $o su$*hu# cotet =$essth! .0 **m/ EURO st!d!#d?%

08%*!*" It is "o#)idde to !dd *#oducts such !s "ue$ ci#cuit c$e!e# !d#eg!$'!isig *#oducts%


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C#8$-&% 14

II SAFETY INSTRUCTIONS

A 4 FORE1ORD

A$$ o*e#!tios c!##ied out o the iectio s&stem must )e *e#"o#med i

!cco#d!ce ith the "o$$oig *#o'isios !d #egu$!tios:• *#o"essio!$ he!$thc!#e !utho#ities/

• *#e'etio o" !ccidets/

• *#otectio o" the e'i#omet%

08%*!*" O*e#!tios must )e *e#"o#med )& s*eci!$ist techici!s ho h!'e)ee t#!ied i the s!"et& ist#uctios !d *#ec!utios to )et!e%

+ 4 ,AFET8 IN,TRUCTION,

1 H!"# $%&''(%& =(&) ,!%,(!-

IMPORTANT Gi'e the 'e#& high *#essu#es i the high *#essu#e "ue$ci#cuit =-.0 )!#s?/ com*$& ith the "o$$oig ist#uctios%

Do ot smoe e!# to the high *#essu#e ci#cuit du#ig #e*!i#s%


1he the egie is #uig:

• do ot o# o the high *#essu#e "ue$ ci#cuit/

• !$!&s #em!i out o" the #!ge o" ! *ossi)$e "ue$ et hich m!& c!usese#ious iu#&/

• e'e# *ut &ou# h!d e!# to ! $e! o the high *#essu#e "ue$ ci#cuit%

A"te# sitchig o"" the egie/ !it "o# 0 secods )e"o#e st!#tig o#%

Note: It is necessary to wait for 30 seconds to allow the high pressurefuel circuit to return to atmospheric pressure.

A$$ o*e#!tios o the "ue$ ci#cuit !#e *e#"o#med i the *#esece o" "ue$ ith!dditi'e% It is #ecommeded th!t g$o'es !d *#otecti'e gogg$es !#e o#!s the !dditi'e is ! s$ight si i##it!t%


-2



C#8$-&% 14

2 F(&) 8@@!-!?& ,!%,(!-

Do ot smoe e!# to the "ue$ !dditi'e ci#cuit du#ig #e*!i#s%


The !dditi'e is ! s$ight si i##it!t it is #ecommeded th!t g$o'es !d*#otecti'e gogg$es !#e o#%

5#otectio o" the e'i#omet: used !dditi'e !d items used "o# c$e!igthe "i$te# must )e #ec&c$ed%

The !dditi'e must )e sto#ed ude# the "o$$oig coditios:

• !!& "#om moistu#e/

• !!& "#om $ight/

• !!& "#om he!t/

• i its o#igi!$ se!$ed/ o*!ue *!c!gig/ to *#e'et the so$'et "#ome'!*o#!tig%

The cotets o" !& o*eed cot!ie#s must ot )e used !d must )e#ec&c$ed%

3 O$&%8-!*' * -#& $8%-!,)& =!)-&%

Fo#ced #egee#!tio $e!ds to 'e#& high e3h!ust g!s tem*e#!tu#es =6.0°C!t the e3h!ust *i*e out$et?:

• !$!&s ee* e$$ !!& "#om the e3h!ust *i*e/

• use suit!)$e e3h!ust g!s e3t#!ctio eui*met/

• the o#ig !#e! must )e c$e! !d tid&/

• the 'ehic$e ch!ssis must )e c$e!/

• the "ue$ t! must cot!i !t $e!st 20 $it#es o" "ue$ to *#e'et the "ue$"#om o'e#he!tig/

• the coo$!t tem*e#!tu#e must )e !)o'e 9.°C/ )e"o#e *e#"o#mig !"o#ced #egee#!tio%

It is #ecommeded th!t ! m!s !d *#otecti'e gogg$es !#e o# he#emo'ig !d #e"ittig the *!#tic$e "i$te# =#is o" ih!$ig ce#ie?%


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C#8$-&% 14

4 0%!*" 8%&8

The o#ig !#e! must )e c$e! !d tid&%

5!#ts )eig #e*!i#ed must )e sto#ed !!& "#om dust%

5 P%&)!!*8%; $&%8-!*'

IMPORTANT The o*e#!to# must e!# c$e! o'e#!$$s%

+e"o#e st!#tig o# o the iectio ci#cuit/ the coecto#s o" the"o$$oig sesiti'e com*oets m!& h!'e to )e c$e!ed =seeco##es*odig o*e#!tios?:

• "ue$ "i$te#/



• high *#essu#e "ue$ $ies/

• diese$ iecto# c!##ie#s%

IMPORTANT A"te# #emo'!$/ )$! the coecto#s o" the sesiti'ecom*oets immedi!te$& ith *$ugs/ to *#e'et theig#ess o" di#t%

Use the co##ect tighteig to#ues "o# the !)o'e com*oets o" the high*#essu#e "ue$ ci#cuit/ usig ! #egu$!#$& is*ected to#ue #ech:

• diese$ iecto#s/


• high *#essu#e "ue$ $ies%

The D1-2TED6 egie #eui#es *!#ticu$!# c!#e to )e t!e he o#igo the "ue$ !dditi'e ci#cuit%

C$e!$iess o" the "ue$ !dditi'e ci#cuit:

• !dditi'e t!/

• !dditi'e iecto# su**$& !d #etu# *i*es/

• !dditi'e iecto#%


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C#8$-&% 14

III MAINTENANCE

A 4 IN<ECTION ,8,TEM

+$eed !te# "#om the "ue$ "i$te# e'e#& 20 000 m%

Re*$!ce the "ue$ "i$te# e'e#& 90 000 m%

08%*!*" The "ue$ "i$te# is desiged to )e used o ! so*histic!ted iectios&stem: #e"e# to the *#ocedu#e gi'e i the mech!ic!$ "o$de# o"the 'ehic$e i uestio% It is #ecommeded th!t g$o'es !d*#otecti'e gogg$es !#e o# he h!d$ig "ue$%

Note: It is recommended that the cleanliness of the ?1wirl? controlelectrovalve filter is chec/ed periodically.

+ 4 5ARTICLE FILTRATION ,8,TEM

Re*$!ce o# c$e! the *!#tic$e "i$te# e'e#& @0 000 m%

To* u* the !dditi'e t! e'e#& @0 000 m%

Note: ;dditive is sold by the eplacement @arts <epartment in 2 litrecontainers (part number @ 735.5#!.

IMPORTANT Use the #ecommeded !dditi'e% A$$ othe# !dditi'es =o#*#oducts? used i$$ $e!d to ico##ect o*e#!tio o" the *!#tic$e"i$t#!tio s&stem%

De!$ig ith !ste:

• !dditi'e !d com*oets used "o# c$e!ig the "i$te# must )e #ec&c$ed/

• the cotets o" !& cot!ie# hich h!s )ee o*eed !d ot usedimmedi!te$& must )e #ec&c$ed%

C 4 DIAGNO,TIC TOOL,

Di!gostic too$s !#e used to c!##& out se#'icig !d di!gostic o*e#!tios othe *!#tic$e "i$t#!tio s&stem:

• #e!dig o" "!u$t codes/

• *!#!mete# me!su#emets/

• "o#ced #egee#!tio/

• #eiiti!$is!tio o" the tot!$ !dditi'e u!tit&%


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C#8$-&% 14

D 4 5ARAMETER MEA,UREMENT,

P8%-!,)& =!)-&% '-8-&

This shos the st!tus o" the *!#tic$e "i$te# =#egee#!ted/ ite#medi!te oe/

$o!ded/ o'e#$o!ded/ c$ogged o# *uctu#ed?%

P8%-!,)& =!)-&% @!==&%&*-!8) $%&''(%& =di""e#ece )etee i$etBout$et*#essu#e?%

This *!#!mete# co##es*ods to the *#essu#e di""e#ece )etee the i$et !dthe out$et o" the *!#tic$e "i$te#%

This '!$ue is simi$!# to the ;"i$te# st!te; *!#!mete#%

The *#essu#e di""e#eti!$ '!#ies de*edig o the 'ehic$e mi$e!ge !d d#i'igcoditios%

R&"&*&%8-!* 8''!'-8*,& '-8-&

This *!#!mete# st!tes hethe# #egee#!tio !ssist!ce is i *#og#ess =!cti'eo# ot !cti'e?%

T-8) 8(*- = 8@@!-!?& !*+&,-&@

The tot!$ !mout o" !dditi'e iected sice the !dditi'e t! !s $!st #e"i$$ed%

A?&%8"& @!'-8*,& = )8'- 5 %&"&*&%8-!*' @!'-8*,& -%8?&))&@ '!*,&

%&"&*&%8-!*

Re"e# to the o*e#!tig *h!ses 4 *!#tic$e "i$te# sectio%

E 4 FORCED REGENERATION

+e"o#e ! *!#tic$e "i$te# is c$e!ed/ "o#ced #egee#!tio !$$os !& #em!iigsoot to )e #emo'ed !d "!ci$it!tes c$e!ig o" ce#ie de*osits%

F 4 REINITIALI,ING THE TOTAL ADDITI7E UANTIT8

A"te# #e*$!cig o# c$e!ig ! *!#tic$e "i$te#/ the tot!$ !mout o" !dditi'e must)e #eset i the !dditi'e ECU =c!$cu$!tio o" the iectio ECU c!#tog#!*hicm!*s?%


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C#8$-&% 14

IV REPLACING PARTS OPERATIONS TO BE PERFORMED

A 4 DIAGNO,TIC +EFORE RE5AIR

08%*!*" +e"o#e o#ig o the s&stem/ #e!d the memo#ies o" !$$ ECUs%

Re"e# to the "!u$t "idig ch!#ts:

• "!u$t ch!#ts usig "!u$t codes/

• "!u$t ch!#ts usig custome# com*$!its =ithout "!u$t codes?%

+ 4 RE5LACING 5ART,

08%*!*" +e"o#e !ddig o# #e*$!cig *!#ts/ esu#e th!t the custome# h!sthei# co"ideti!$ c!#d%

COMPONENTSREPLACED

OPERATIONS TO BEPERFORMED

COMMENTS REQUIRED

INFORMATION

Iectio ECU 5#og#!mmig o" the iectioECU

Access code

Checig o" te$ecoded*!#!mete#s =i" ecess!#&/te$ecodig o" the iectio ECU?

Desc#i*tio o" the 'ehic$eeui*met

Fo#ced #egee#!tio 7IN

Fue$ !dditi'e ECU 5#og#!mmig o" the tot!$ !dditi'eu!tit& *!#!mete#

Tot!$ !dditi'e u!tit&*!#!mete# "#om the o$d!dditi'e ECU

5!#tic$e "i$te# Reiiti!$is!tio o" the tot!$

!dditi'e u!tit& =#eset?T#e!tmet o" the o$d *!#tic$e "i$te#

Additi'e t! Fi$$ig o" the !dditi'e t!

5#imig o" the !dditi'e ci#cuit

T#e!tmet o" the o$d !dditi'e

Additi'e Fi$$ig o" the !dditi'e t!

5#imig o" the !dditi'e ci#cuit

T#e!tmet o" the o$d !dditi'e

The "o$$oig *#ocedu#es #eui#e the use o" the di!gostic too$s:

• *#og#!mmig o" the iectio ECU/• te$ecodig o" the iectio ECU/• *#og#!mmig o" the tot!$ !dditi'e u!tit& *!#!mete#%


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C#8$-&% 14

C 4 5ROGRAMMING THE IN<ECTION ECU

08%*!*" ,!**ig ! iectio ECU )etee to 'ehic$es m!es itim*ossi)$e to st!#t the 'ehic$es%

1he "ittig ! e iectio ECU/ the egie immo)i$ise# s&stem h!s to )e*#og#!mmed%

I o#de# to *#og#!m the egie immo)i$ise# s&stem/ &ou must:

• )e i *ossessio o" the !ccess code to the )ui$t4i s&stems ite#"!ce=#itte o the custome#s co"ideti!$ c!#d?/

• )e i *ossessio o" ! e iectio ECU/

• use the di!gostic too$/

• c!##& out ! egie ECU *#og#!mmig *#ocedu#e: ;5ROGRAMMING THEENGINE ECU;/

• do$o!d the iectio ECU =i" ecess!#&?%

D 4 TELECODING THE IN<ECTION ECU

This *#ocedu#e is used to #educe di'e#sit&%

5!#!mete#s hich c! )e te$ecoded:

• egie coo$ig ="! uit?/

• !i# coditioig *#essu#e seso#/

• ge!#)o3/

• diese$ iectio t&*e/

• !dditio!$ he!tig/

• ECUs%


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C#8$-&% 14

E 4 RE5LACING THE IN<ECTOR,

O#igi!$ "it%

Diese$ iecto# c!##ie#s m!#ed !s ! "uctio o" thei# iectio *i*e di!mete#

=diese$ "$o? =c$!ss #e"e#ece -/ 2 o# ?%

The c!#tog#!*hic m!*s o" the iectio ECU ic$ude the c$!ss o" iecto#s "ittedo the egie%

Re*!i#%

I" ! iecto# is #e*$!ced/ ! iecto# o" the s!me c$!ss must )e "itted%

08%*!*" Fittig ! iecto# o" ! di""e#et c$!ss $e!ds to ico##ect o*e#!tioo" the *!#tic$e "i$t#!tio s&stem%

Note: Aitting " in$ectors of a different class is possible- provided that theirnew class is telecoded into the in$ection &+,.

F 4 DO1NLOADING THE IN<ECTION ECU

The so"t!#e o" the iectio ECU is u*d!ted )& do$o!dig =ECU ith !"$!sh E5ROM?%

Note: This operation is performed using the diagnostic tools.

G 4 5ROGRAMMING THE TOTAL ADDITI7E UANTIT8 5ARAMETER

I" the !dditi'e ECU is #e*$!ced/ the tot!$ !dditi'e u!tit& must )e*#og#!mmed ito the e !dditi'e ECU%

08%*!*" ,!**ig ! !dditi'e ECU )etee to 'ehic$es is "o#)idde%

H 4 5RIMING THE ADDITI7E CIRCUIT

A"te# o*eig the !dditi'e ci#cuit/ it must )e #e*#imed: sitch the igitio othe o"" !g!i times%


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C#8$-&% 14

V 0ARRANTY RETURN PROCEDURE

A 4 COM5ONENT, OF THE IN<ECTION ,8,TEM

+e"o#e #etu#ig *!#ts to the !ssessmet cet#e/ the "o$$oig com*oets

must )e )$!ed/ *$!ced i ! *$!stic )!g !d *!c!ged i thei# o#igi!$*!c!gig:

• diese$ iecto#s/




• "ue$ "i$te#%

+ 4 IN<ECTION ECU

The iectio ECU i$$ !utom!tic!$$& $oc i" it is discoected%

IMPORTANT 1he #etu#ig *!#ts ude# !##!t&/ #etu# the iectio ECUith its !ccess code%


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C#8$-&% 15

0IRING DIAGRAM

I LAYOUT DIAGRAM

,DI0695


-6-



C#8$-&% 15

II PARTS LIST

++00 4 +!tte#&

+M6 4 Egie #e$!& uit ith 6 "uses


C00- 4 Di!gostic coecto#CA00 4 Igitio sitch

MC-- 4

MC0 4

MC6 4 E!#ths

MC. 4

MM0- 4

0006 4 Cot#o$ *!e$

---. 4 C&$ide# #e"e#ece seso#

--.0 4 5#e4*ost he!tig uit

--90 4 5#ehe!te# *$ugs

-20@ 4 High *#essu#e *um* #d *isto de!cti'!to#

-2-- 4 Fue$ sede# *um*

-220 4 Coo$!t tem*e#!tu#e seso#

-22- 4 Diese$ the#misto#

-2 4 Tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e-2. 4 A$$ o# othig EGR e$ect#o'!$'e

-29- 4 Acce$e#!to# *ed!$ *ositio seso#

-29 4 EGR K th#ott$e e$ect#o'!$'e

-296 4 ,i#$ e$ect#o'!$'e

-2>9 4 Diese$ he!te#

-2@. 4 I$et !i# he!te# e$ect#o'!$'e

--0 4 Ai# "$omete#

--2 4 I$et !i# *#essu#e seso#-- 4 Egie s*eed seso#

-20 4 Egie m!!gemet ECU

-2- 4 High *#essu#e "ue$ seso#

-22 4 High *#essu#e "ue$ #egu$!to#

-- 4 Iecto# 4 c&$ide# ° -


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C#8$-&% 15

PARTS LIST ,*-!*(&@/

-2 4 Iecto# 4 c&$ide# ° 2

- 4 Iecto# 4 c&$ide# °

-6 4 Iecto# 4 c&$ide# ° 6

-6- 4 5!#tic$e "i$te# *#essu#e di""e#eti!$ seso# -66 4 U*st#e!m e3h!ust g!s tem*e#!tu#e seso#

2-00 4 ,to* sitch

2-0- 4 Redud!t sto* sitch

>09 4 C#uise cot#o$ s!"et& sitch =c$utch sitch?

-- 44 4 5#ehe!te# igitio "uctio

-. 44 4 Egie coo$ig "uctio

>0 44 4 A+, "uctio

>2 44 4 T#i* com*ute#/ c$oc "uctio

@0 44 4 Ai# coditioig/ c$im!te cot#o$ "uctio


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C#8$-&% 15-66

Bosch Hdi Edc15c2 Injection System

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