B Intake metering valve. C Gear pump. D Injector. E Electronic engine control unit. F Pressure relief valve. G Pressure sensor.
High-performance engine management for diesel, gas and dual-fuel engines. Technical specifications. Please contact us. Contact form Bosch Mobility Solutions. Start enquiry. In the event of overheating, it is up to the driver whether to stop the vehicle or continue driving.
Red STOP warning light level 2 : This warning light comes on and is accompanied by the injection malfunction message. Excess pollution orange OBD warning light: This warning light, in the form of an engine symbol, comes on for about 3 seconds when the ignition is switched on then goes out.
It never comes on when the engine is running. NOTE: The individual injector correction value for each injector must be entered manually after the ECM has been replaced or re programmed by reading the individual injector correction value on each injector Refer to replacing injectors. These correction values are written on a label affixed to each injector then entered into the computer which then controls each injector taking into account its individual manufacturing variations.
When replacing one or more injectors, the parameters of the injector output concerned must be modified. DEF : At minimum limit 2. DEF : At maximum limit P 3. Conditions for applying the diagnostic procedure to the stored DTCs: The fault is declared present with the engine running. DEF 6. DEF Check the fuel flow actuator connection. Repair if necessary. Measure the resistance between terminal 1 and 2 of the fuel flow actuator, if it is not approximately 5.
Check the condition of the ECM F harness connector and replace it if necessary. Check: — that fuel is present in the tank, — that there is no air in the fuel circuit, — the condition of the fuel filter.
Follow the instructions to confirm repair. Erase the stored DTCs after repair. DEF 2. DEF 3. DEF 7. DEF Check for fuel in the tank. Carry out Test 7 "High pressure system check".
Measure the resistance across terminals 1 and 2 of the fuel flow actuator. Replace the flow actuator if the resistance is not approximately 5. Check the condition of the ECM F harness connector. Repair if necessary Check: - that fuel is present in the tank, - that there is no air in the fuel circuit, - the condition of the fuel filter. Check the condition of the ECM harness connector F and repair if necessary. Deal with any other possible DTCs. NOTES If cooling fan 1 is suspected, then cooling fan motor 2 is switched on for vehicles with air conditioning.
Check the condition of the engine coolant temperature sensor harness connector. Repair it if necessary. Check the condition of the fuel temperature sensor harness connector and repair it if necessary. At the terminal, measure the resistance of the fuel temperature sensor, if it is not approximately 2.
If P is present, the engine stops and is impossible to restart. Malfunction indicator lights up level 1. Check the condition of the common rail fuel pressure sensor harness connector and repair if necessary.
Special notes: The engine stalls when the DTC appears. Level 1 warning light comes on. Turn off the ignition switch and check the injector connections. Disconnect the injectors and turn on the ignition switch on.
Check to see if the DTC is still present. Is P present or stored? P Injector s malfunctioning. If none of the faults identifying the malfunctioning injector circuit are present: — Switch off the engine. Carry out the same procedure for the remaining injectors. NOTES Special notes: When this DTC appears, the idle speed is stuck at rpm, with engine noise, unstable engine speed, reduced engine performance and malfunction indicator lights up level 1.
CC With the ignition switched off, wait 15 seconds. Check the connection and condition of the injector 1 harness connector. Check the condition of the ECM harness connector F and replace it if necessary. Does this injector actuation cycle work? YES Injector 1 is not malfunctioning, malfunction with injector 1 control circuit. Also check for insulation between these 2 connections. NO Injector 1 malfunctioning, replace the cylinder 1 injector. Check that the injector correction value is correctly programmed into the ECM.
Check that the knock sensor is secure on the engine. If the DTC persists, replace the cylinder 1 injector. NOTES Special notes: When this DTC appears, the idle speed is stuck at rpm, with engine noise, unstable engine speed, reduced engine performance and malfunction indicator light comes on level 1. YES Injector 2 is not malfunctioning, malfunction with injector 2 control circuit.
NO Injector 2 malfunctioning, replace the cylinder 2 injector. Check that the injector correction value is correctly entered on the ECM. If the DTC persists, replace the cylinder 2 injector.
CC Switch off the ignition and wait 15 seconds. Check the connection and condition of the injector connector. Check the condition of the ECM harness connector F YES Injector 3 is not malfunctioning, malfunction with injector 3 control circuit.
NO Injector 3 malfunctioning, replace the cylinder 3 injector. If the DTC persists, replace the cylinder 3 injector. NO Injector 4 is not malfunctioning, malfunction with injector 4 control circuit. YES Injector 4 malfunctioning, replace the cylinder 4 injector.
If the DTC persists, replace the cylinder 4 injector. DEF : No signal 3. Check the condition of the ECM harness connector E61 and replace it if necessary. Check the connection and condition of the fuel flow actuator connector. Measure the resistance between the terminals 1 and 2 of the fuel flow actuator. DEF : Permanent low signal P 2. DEF : Above maximum threshold 5. DEF : Inconsistency 6. DEF : At maximum stop 7. DEF repair if necessary. DEF 4. DEF Visually check that the turbocharger circuit is leak tight.
DEF Repair if necessary. DEF Remove the air supply ducts and check that they are not blocked. With the engine stopped, the pressure should be approximately the same between the two sensors.
Replace the TC boost pressure sensor if necessary. Check the turbocharger. DEF, 2. DEF, 7. Check the tightness of the cylinder and repair if necessary. Check the valve clearances and adjust them if necessary. Check the air inlet conduits and the EGR valve and clean them if necessary. Replace the injector. Check the conformity of the injectors fitted to the vehicle in relation to the type of vehicle and engine number low injector, high or very high pressure.
Check the knock sensor connection. DEF : Additional teeth 6. DEF, 3. DEF, 6. DEF present: engine stops and malfunction indicator lights up level 1. DEF, 5. Check the condition of the crankshaft position sensor harness connector and repair if necessary. Check that the flywheel ring gear is not suspected missing teeth. Check the condition of the camshaft position sensor harness connector and repair if necessary. If necessary, replace the sensor. Check the timing gear setting.
Refer to "EM section". Check the condition and connection of the glow relay harness connector. Change it if necessary. Check the condition and connection of the glow plug harness connectors.
Change them, if necessary. Measure the resistance of each glow plug. If not, replace the suspected plugs. Check the condition and connection of the glow relay unit connector. DEF : Inconsistency 4. DEF : Valve jammed 5. Starting problems, or even impossible when cold, with malfunction indicator lights up level 1 ". Check the condition and connection of the EGR volume control solenoid valve harness connector and repair it if necessary.
Difficult to start engine or even impossible when cold. Check the condition and connection of EGR volume control solenoid valve harness connector and repair it if necessary. Measure the resistance at the EGR volume control solenoid valve harness connector terminal.
DEF : Above minimum threshold 2. Check the condition of the EGR volume control solenoid valve harness connector and repair if necessary. Also check there are no malfanctions in the ABS part or in the system which supplies the vehicle speed. Carry out a trouble diagnosis on the multiplex network. LAN section Refer to the trouble diagnosis for the keyless vehicle function. Check the pressure sensor connection.
Check the battery voltage when the ignition is switched on. Check the condition of the battery terminals. Check the vehicle's charge circuit. Check the condition of the ECM E61 harness connector. Deal with the DTC even if it is stored. Check the switch connection and repair if necessary. Check the condition of the ECM harness connector E61 and repair if necessary. Check that the switch is working. DEF : Memory self-test 6. DEF : Non refreshed watchdog 7. DEF : Interference on the injector control line 8.
Check that the individual injection correction value matches the injectors. If NG, write the individual correction value codes see "Trouble diagnosis - Introduction". If the value corresponds correctly to the injectors, replace ECM. DEF 5. DEF 8. DEF Follow the instructions to confirm repair. Malfunction indicator lights up Level 1. Check the condition and connection of all the sensor connectors as follows: — engine coolant temperature sensor — turbocharger boost pressure sensor — common rail fuel pressure sensor — APP sensor — EGR valve position sensor — camshaft position sensor Repair if necessary.
If the DTC persists, apply the trouble diagnosis strategy to each sensor supplied by an external terminal. Check the condition of the APP sensor harness connector.
Check the insulation to ground of the connection on terminal 18 of ECM harness connector E Check the insulation between terminal 18 and terminal 12 on ECM harness connector E Check the condition of the APP harness connector and repair it if necessary. Check the condition of the APP sensor harness connector and repair it if necessary.
Replace the ECM. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation not independent.
Diagnostic Procedure 1. Turn ignition switch "ON". YECA Check that the print out data is matched with above. Application condition: engine off, ignition on. PR Engine speed Gives the engine's In the event of a rotational speed in rpm. This malfunction, apply parameter is controlled the trouble diagnostic External air by the BCM and procedure for this 5 temperature transmitted to the malfunction injection on the described in the BCM multiplex network.
This malfunction, apply Warm: 50C value is given by the the diagnostic Fuel 7 fuel temperature procedure for temperature sensor. Fuel temperature sensor circuit. PR Atmospheric Gives the atmospheric If not consistent, pressure pressure in mbar. PR Rail pressure Gives the pressure of In the event of a Warm or cold the diesel in the malfunction, apply - 90 bar injection rail in Bar.
Rail pressure sensor Default value: Bar. PR Vehicle speed Gives the vehicle speed Test the multiplex in kph. This parameter is network. This trouble diagnosis. The coolant pressure sensor should not be suspected. Satisfactory engine operating conditions coolant temperature, engine load etc. The vehicle is not in a specific movement phase hill start or stop etc. PR Refrigerant Gives the value in BAR If there is a problem: pressure for the refrigerant fluid apply the diagnostic in the system.
If the DTC persists, replace the refrigerant sensor. PR Engine speed Gives the engine's In the event of a rotational speed in malfunction, apply rpm. The fans are prevented from operating under certain coolant temperature conditions when driving.
Gives the engine's In the event of a rotational speed in malfunction, apply rpm. This malfunction, apply parameter is controlled the diagnostic by the Inteligent Key procedure for this External air 2 unit or BCM and malfunction temperature transmitted to the ECM described in the on the multiplex Inteligent Key unit or network.
BCM document. Inlet sensor voltage delivered by the 4 temperature computer to supply the sensor voltage inlet temperature sensor PR Engine speed Gives the engine's In the event of a rotational speed in rpm. Test conditions: Engine at idle speed. PR Engine speed. Gives the engine's In the event of a Cold: rpm V rotational speed in malfunction, apply Warm: rpm rpm.
The UCH should request the injection to Compressor be engaged. The 2 engagement refrigerant pressure request sensor should not be faulty.
The vehicle 3 authorisation is not in a specific movement phase hill start or stop etc. This parameter network. This diagnosis. PR Fuel flow Shows the fuel flow None.
Default value: Bar. PR Rail pressure Gives a theoretical None. Engine optimum engine Rail pressure 4 starting pressure operation. Gives the engine's In the event of a Cold: rpm V rotational speed in malfunction, apply the 6 Engine speed Warm: rpm rpm. This malfunction, apply parameter is controlled the diagnostic External air by the BCM and procedure for this 2 temperature transmitted to the malfunction injection on the described in the BCM multiplex network. PR Atmospheric Gives the If not consistent, pressure atmospheric check pressure in mbar.
PR Inlet pressure Shows the pressure in the inlet circuit in mbar. PR Air flow Air flow estimated by None. Inlet sensor voltage delivered by the 4 temperature computer to supply sensor voltage the inlet temperature sensor PR Engine speed. Check the condition of the turbocharger air temperature pressure sensor connections. If necessary replace the sensor. Check the condition of the engine coolant temperature sensor connections.
Measure the resistance between terminals 1 and 4 of the coolant temperature sensor. If the value is incorrect, replace the engine coolant temperature sensor. NO Carry out the required repairs. Is the low pressure circuit connection correct? YES Look for leaks on the unions. YES Carry out the required repairs. Digital engine controls provided a step-change in engine control performance, and functionality as advances in microcomputers and digital circuit design expanded capabilities, increased reliability, and enabled control of larger, more powerful, efficient, and complex engines.
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