bosch hdi edc15c2 injection system
DESCRIPTION
description of EDC15 C2 bosch common rail injection system operationTRANSCRIPT
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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
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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%
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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%
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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
+
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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
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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
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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
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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$o*ed%
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A 4 DE5OLLUTION
Fue$ 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$$ $o!d o#du#ig t#!sito#& o*e#!tio/ thus he$*ig to *#otect the e'i#omet%
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+ 4 MAIN DE,IGN OF THE D1-2 TED6 ENGINE
U* uti$ o/ diese$ egies "itted to tou#ig c!#s h!'e used idi#ect iectio%
I idi#ect iectio/ the "ue$ is iected ude# ! m!3imum *#essu#e o" 00 )!#
ito ! com)ustio *#ech!m)e#%
I di#ect iectio/ the "ue$ is iected di#ect$& oto the to* o" the *isto%
Egie e""iciec& is im*#o'ed due to:
• )ette# u!$it& o" the !i#B"ue$ mi3tu#e/
• #eductio i he!t $osses/
• di#ect com)ustio i the c&$ide#s%
Fe!tu#es o" the e c&$ide# he!d desig o" the D1-2 TED6 egie:
• c&$ide# he!d ith -9 '!$'es/
• s*eci"ic $oc!tio o" the diese$ iecto#s =cet#!$ !d 'e#tic!$/ o*timis!tio o"!i#B"ue$ mi3tu#e?/
• dou)$e com*$e3 sh!*e !i# i$et m!i"o$ds i the c&$ide# he!d ='!#i!)$esi#$?/
• o *#ecom)ustio ch!m)e#/
• s*eci"ic $oc!tio o" the he!te# *$ugs =o the #e!# o" the c&$ide# he!d?%
Modi"ic!tios used to im*#o'e the e""iciec& o" the D1-2 TED6 egies:
• '!#i!)$e geomet#& tu#)och!#ge# =highe# tu#)och!#gig *#essu#e !t $oegie s*eeds?/
• o*timis!tio o" the i$et !d e3h!ust m!i"o$ds/
• #o$$e# '!$'e #oce#s $imitig $osses c!used )& "#ictio/
• eight #eductio%
Note: The above modifications also help to reduce pollutant emissionsdirectly.
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C#8$-&% 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$es?%
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III PARTICLE FILTRATION PRINCIPLE
The !im o" the "i$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$$ig the !dditi'e "uctio%
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IV SAFETY INSTRUCTIONS
Note: The safety recommendations are given in a document contained in themechanical file of the vehicle in question.
A 4 FUEL ,U55L8 CIRCUITIMPORTANT Gi'e the 'e#& high *#essu#es =-.0 )!#? i the high *#essu#e
"ue$ ci#cuit/ "o$$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# !$$ #e*!i# o#/ it is #ecommeded th!t g$o'es !d *#otecti'e gogg$es !#eo#%
+ 4 FUEL ADDITI7E CIRCUIT
Do ot smoe e!# to the "ue$ !dditi'e ci#cuit du#ig #e*!i#s%
A'oid o#ig e!# to "$!mes o# s*!#s%
The !dditi'e is ! s$ight si i##it!t it is #ecommeded th!t g$o'es !d*#otecti'e gogg$es !#e o#%
E'i#omet!$ *#otectio: used !dditi'e !d the com*oets used "o#c$e!ig the "i$te# must )e t#e!ted%
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C 4 O5ERATION, ON THE 5ARTICLE FILTER
08%*!*" Fo#ced #egee#!tio $e!ds to ! 'e#& high e3h!ust g!s tem*e#!tu#e=6.0°C !t the e3h!ust *i*e out$et?%
5#ec!utios to )e t!e:
• !$!&s ee* e$$ !!& "#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?%
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GENERAL LAYOUTHDI SYSTEM
,DI00-5
31
32
37
2
26252324
21
22
27
1 1
1
16
2
34
1413
3357
3
3
41
42
43
45
51
44
A
B
52
53
56 5
2928
11
5 3
17
12
6
4 5
11
5 15
2
44
446
35
36
7
1
47
3
:&; A 4 7AN eto#+ 4 CAN eto#
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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
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REF. DESCRIPTIONPART NUMBER IN THE 0IRING
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$d *#essu#e seso# --2
Note: (! depending on version.
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FUEL SUPPLY FUNCTION
I DIAGRAM
,DI0025
A
B
C
1
5
6
23
22
21
2 3
4
1
1
271
17
11
1213
14
15
16
:&; A 4 Retu# to "ue$ t! ci#cuit+ 4 Lo *#essu#e "ue$ ci#cuitC 4 High *#essu#e "ue$ ci#cuit
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P8%-' )!'-
REF. DESCRIPTIONPART NUMBER IN THE 0IRING
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>>
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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 *$!te%
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IV ELECTRIC FUEL HEATER 126/
A 4 ROLE
The "ue$ 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$$oc!tio o" coecto# ch!e$s:
• ch!e$ -: -2 'o$ts =K igitio o?/
• ch!e$ 2: e!#th%
5oe#: -.0 1%
D 4 LOCATION
The "ue$ he!te# is $oc!ted o the "ue$ "i$te# i$et *i*e%
V LO0 PRESSURE PUMP SUPPLY CUTOFF
The !i#)!g ECUs ico#*o#!te the $o *#essu#e *um* cut4o"" "uctio =ie#ti!sitch discotiued?%
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AIR SUPPLY FUNCTION
I DIAGRAM
,DI0065
A
B
C1 1 16 15 14
11
17
27
1
21
26
13
12
6
4
25
24
22
23
1
2
5
923
8
2
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A!% ,!%,()8-!* =))>!*" 8%%>'/
A 4 E3te#io# !i# i$et
+ 4 E3h!ust g!ses K !i#
C 4 E3h!ust g!ses
! 4 ,ho#t i$et duct =he$ic!$ sh!*e? ) 4 Log i$et duct =t!geti!$?
P8%-' )!'-
REF. DESCRIPTIONPART NUMBER IN
THE 0IRINGDIAGRAMS
COMMENTS
- Th#ott$e housig cot#o$e$ect#o'!$'e =EGR?
-29
2 ;,i#$; cot#o$ e$ect#o'!$'e -296
;,i#$; cot#o$ di!*h#!gm 44 7!cuum cot#o$$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
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REF. DESCRIPTIONPART NUMBER IN
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 )$!c #e"e#eced hose
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II COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<
Com*oets commo ith the documet:
• !i# "i$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'!$'e =-2?%
III SPECIFIC COMPONENTS
,*eci"ic "e!tu#es o" the D1-2 TED6 egie:
• '!cuum #ese#'e/
• '!#i!)$e geomet#& tu#)och!#ge#/
• '!#i!)$e ;si#$;/
• ;,i#$; cot#o$ e$ect#o'!$'e =-296?%
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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$$ed simu$t!eous$&:• ;,i#$; cot#o$ )utte#"$& '!$'e/
• i$et !i# he!te# )utte#"$& '!$'e/
• '!#i!)$e geomet#& tu#)o cot#o$ di!*h#!gm%
+ 4 DE,CRI5TION
,DI00.
& @
,
c 4 7!cuum *um* '!cuum i$et
d 4 Out$et: ;,i#$; cot#o$ )utte#"$& '!$'e
e 4 Out$et: '!#i!)$e geomet#& tu#)o cot#o$ di!*h#!gm
C!*!cit& 0%. Lit#e
C 4 LOCATION
The '!cuum #ese#'e is $oc!ted i the egie com*!#tmet/ e!# to the )#!ese#'o =de*edig o 'ehic$e?%
Note: The vacuum circuit contains 3 no))les of 0.## mm.
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V VARIABLE GEOMETRY TURBOCHARGER
A 4 ROLE
The tu#)och!#ge# is used to tu#)och!#ge the !i# ete#ig the egie%
The '!#i!)$e geomet#& tu#)och!#ge# is used:• to ic#e!se the s*eed o" the e3h!ust g!ses hich st#ie the tu#)ie !t $o
egie s*eeds/
• to #educe the s*eed o" the e3h!ust g!ses hich st#ie the tu#)ie !t highegie s*eeds/
• to !d!*t the tu#)ie to ! '!#i!tio i e3h!ust g!s "$o%
+ 4 DE,CRI5TION
,DI009D
"
=
16
2
16
12
11
14
14
-- 4 Fied di""use# *isto cot#o$ di!*h#!gm: '!cuum cot#o$$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%
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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!$$& dest#o& the tu#)och!#ge# =due to $!c o"$u)#ic!tio?%
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C 4 O5ERATION AT LO1 ENGINE ,5EED
,DI00>D
12
14
The g!s "$o *!ssig th#ough the e3h!ust tu#)ie =-6? is $o%
To ic#e!se the tu#)och!#gig *#essu#e/ ! m!3imum !mout o" ee#g& must)e co'e#ted i the tu#)ie%
The e3h!ust g!ses must )e m!de to *!ss th#ough ! sm!$$ 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$$ed*eum!tic!$$&%
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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& $ost?%
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VI VARIABLE <S0IRL<
,DI00C
9
8
! 4 ,ho#t i$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$es%
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VII S0IRL CONTROL ELECTROVALVE 1264/
A 4 ROLE
The ,i#$ 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:
• !tmos*he#ic *#essu#e/
• '!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 !$$oig the th#ott$e to o*e:
• egie s*eed !)o'e 2-00 #*m =!t @0°C? =2.00 #*m !t 0°C?/
• iected "ue$ "$o g#e!te# th! 60 mgBst#oe%
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C 4 ELECTRICAL FEATURE,
Cot#o$: iectio ECU =e!#th?%
Fu$$ 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#%
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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
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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$$ed6 Rec&c$ig #egu$!tio
e$ect#o'!$'e =EGR?-2.
. 7!cuum *um* 44
9 7!cuum #ese#'e 44
> E3h!ust g!s #ec&c$ig '!$'e=EGR?
44 7!cuum cot#o$$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$$ed
-2 Fied di""use# *isto 44
- 5!#tic$e "i$te# K c!t!$&ticco'e#te#
44
-6 E3h!ust tu#)ie 44
-. 7!#i!)$e geomet#& tu#)och!#ge# 44
-9 I$et !i# tu#)ie 44
-> Ai# "$omete# K !i# tem*e#!tu#eseso#
--0
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REF. DESCRIPTIONPART NUMBER IN
THE 0IRINGDIAGRAMS
COMMENTS
-@ Ai# "i$te# 44
- Ai#B!i# he!t e3ch!ge# 44
20 Ai#B!te# he!t e3ch!ge# =i$et!i# he!te#?
44
2- I$et m!i"o$d *#essu#e seso# --2
22 I$et !i# he!te# th#ott$e 44 7!cuum cot#o$$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$$ed
2> Iectio ECU -202@ Atmos*he#ic *#essu#e seso#
=ico#*o#!ted ito iectioECU?
-20
Note: &': e%haust gas recycling.
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II COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<
Com*oets commo ith the documet:
• !i# "$omete# =--0?/
• e3h!ust g!s #ec&c$ig '!$'e =EGR?/
• #ec&c$ig #egu$!tio e$ect#o'!$'e =EGR? =-2.?%
III SPECIFIC COMPONENTS
,*eci"ic "e!tu#es o" the D1-2 TED6 egie:
• !te#Be3h!ust g!s e3ch!ge# =EGR?/
• #ec&c$ig #egu$!tio e$ect#o'!$'e =EGR? =-2.?/
• th#ott$e housig =EGR?/
• th#ott$e housig cot#o$ e$ect#o'!$'e =EGR? =-29?%
IV 0ATEREHAUST GAS ECHANGER EGR/
A 4 ROLE
The !te#Be3h!ust g!s he!t e3ch!ge# coo$s the #ec&c$ed e3h!ust g!ses $etito the c&$ide#s%
+ 4 LOCATION
Loc!tio: o the #e!# o" the c&$ide# he!d =)u$he!d side?%
V THROTTLE HOUSING EGR/
A 4 ROLE
I !dditio to the EGR '!$'e/ the th#ott$e housig/ de*edig o its *ositio/ isused to im*#o'e e3h!ust g!s #ec&c$ig% The th#ott$e housig is cot#o$$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%
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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%
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HDI SYSTEM
I COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<
Com*oets commo ith the documet:
• 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$/
• )!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$%
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II SPECIFIC COMPONENTS
,*eci"ic "e!tu#es o" the D1-2 TED6 egie:
• 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$!&
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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?%
Note: (! depending on version.
+ 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%
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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%
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V FUEL TEMPERATURE SENSOR 1221/ FEATURE
A 4 ROLE
Ro$e o" the iectio ECU de*edig o the i"o#m!tio #ecei'ed:
• 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 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:
• #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%
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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*$e3edeto#s%
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INJECTION ECU 1327/ FEATURE
A 4 ROLE
The ECU cot#o$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%
Note: (! depending on version.
The ECU e$ect#ic!$$& o*e#!tes the "o$$oig com*oets:
• diese$ iecto#s/
• tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e/
• high *#essu#e "ue$ #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?%
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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
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CHANNEL N DESCRIPTION
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
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CHANNEL N DESCRIPTION
.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
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CHANNEL N DESCRIPTION
>@ 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$
Note: (! depending on version.
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PREPOST HEATING FUNCTION
I COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<
Com*oets commo ith the documet:
• *#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%
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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$$umi!tes the coo$!t tem*e#!tu#e !#ig LED o the ist#umet *!e$/
• it cot#o$s the coo$!t tem*e#!tu#e g!uge o the ist#umet *!e$/
• it *e#"o#ms di!gostics "o# "! uit o*e#!tio/
• it !cui#es the egie coo$!t tem*e#!tu#e/
• it m!!ges dog#!ded modes%
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I DIAGRAM
,DI02.D
1
5
3
4
6
A
B
C77 4726
7774
727
1517
1367
V1377
V4727
77
1227
C771
1327
BSI1
:&;
A 4 7AN eto#
+ 4 CAN eto#
C 4 1i#e coectio
DESCRIPTIONPART NUMBER IN THE 0IRING
DIAGRAMS
Autom!tic ge!#)o3 ECU =J? -90
Di!gostic LED 7-00
F! uit -.-0
Ai# coditioig com*#esso# @020
Cot#o$ *!e$ =$ogomete# K !#ig LED othe cot#o$ *!e$
0006
Coo$!t tem*e#!tu#e !#ig LED 76020
Coo$!t tem*e#!tu#e $ogomete# 6029+ui$t4i s&stems ite#"!ce +,I-
Cet#!$ di!gostic socet C00-
Iectio ECU -20
Ai# coditioig ECU @0@0
Ai# coditioig *#essu#est!t @00>
Coo$!t tem*e#!tu#e seso# -220
Note: (! depending on version.
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CONNECTIONS
CONNECTION N SIGNAL SIGNAL NATURE
- Coo$!t tem*e#!tu#e seso# F#euec&
2 Reuest "o# !utom!tic ge!#)o3 oi$
tem*e#!tu#e coo$ig =J?
CAN
F! uit #e$!& cot#o$: $o s*eed =-.0@? A$$ 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$$umi!te coo$!t tem*e#!tu#e$ogomete#
7AN
Reuest to "$!sh coo$!t tem*e#!tu#e!#ig LED
7AN
> Reuest to !utho#ise eg!gig o" the !i#coditioig com*#esso# =ACBTH?
CAN
Note: (! depending on vehicle equipment.
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II FAN UNIT 1517/
SDI026C
BSI1
D!" * DBATDBAT
157
1514
157
1517
1327
BSM
K+AT K )!tte#&
Kig o K igitio o
+,M 4 Dou)$e iectio #e$!&
-.-6 4 F! uit #e$!& !t mid s*eed
The#e is o$& oe t&*e o" !ssem)$&: th#ee s*eed "! uit%
08%*!*" The $imits "o# eg!gig the "! uit de*ed o the 'ehic$e: #e"e# to theco##es*odig documet!tio%
The#e !#e th#ee o*e#!tig s*eeds:
• $o s*eed >°C/
• mid s*eed/
• high s*eed -0.°C%
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A 4 DE,CRI5TION
Lo s*eed is o)t!ied )& su**$&ig the "! uit th#ough ! #esisto# !##!ged ise#ies o the su**$& ci#cuit%
Mid s*eed is o)t!ied )& su**$&ig the "! uit th#ough 2 #esisto#s !##!gedi *!#!$$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%
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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?%
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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$ig?/
• to !cui#e the *#essu#e o" the !i# coditioig ci#cuit/
• to m!!ge dog#!ded modes%
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I DIAGRAM
SDI028D
1
7
5
2
3
4
6
A
B
C8080 4026
0004
8020
1510
1360
V1300
V4020
8007
1220
C001
1320
BSI1
:&;
A 4 7AN eto#
+ 4 CAN eto#
C 4 1i#e coectio
DESCRIPTION PART NUMBER IN THE 0IRINGDIAGRAMS
Autom!tic ge!#)o3 ECU =J? -90
Di!gostic LED 7-00
F! uit -.-0
Ai# coditioig com*#esso# @020
Ist#umet *!e$ 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$!t tem*e#!tu#e seso# -220
Note: (! depending on version.
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CONNECTIONS
CONNECTION N SIGNAL SIGNAL NATURE
- Ai# coditioig *#essu#est!t A!$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
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II AIR CONDITIONING PRESSURESTAT 77/
A 4 ROLE
The seso# me!su#es the '!$ue o" the *#essu#e i the !i# coditioig ci#cuit%
Ro$e o" the iectio ECU de*edig o the i"o#m!tio #ecei'ed:
• 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/.
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C 4 ELECTRICAL FEATURE,
A$$oc!tio o" coecto# ch!e$s:
• ch!e$ -: . 'o$ts su**$&/
• ch!e$ 2: *#essu#e i"o#m!tio =0 4 . 'o$ts?/
• ch!e$ : e!#th%
7o$t!ge su**$ied "o# ! *#essu#e o" - )!#: K 0%. 'o$t%
7o$t!ge su**$ied "o# ! *#essu#e o" - )!#s: K 6%. 'o$ts%
D 4 LOCATION
The seso# is $oc!ted o the !i# coditioig codese#%
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III FAN UNIT 1517/
The ECU cot#o$s o*e#!tio o" the "! uit !t $o s*eed i" the *#essu#e is g#e!te#th! -0 )!#s =o"" i" the *#essu#e is $ess th! > )!#s?%
The ECU cot#o$s o*e#!tio o" the "! uit !t high s*eed i" the *#essu#e is g#e!te#th! 22 )!#s =o"" i" the *#essu#e is $ess th! - )!#s?%
Note: The 1I controls operation of the fan unit at mid speed if the pressure isgreater than 2 bars (off if the pressure is less than 2" bars!.
IV DO0NGRADED MODE
Ro$e o" the iectio ECU i" the *#essu#est!t de'e$o*s ! "!u$t:
• to cot#o$ the i$$umi!tio o" the di!gostic LED o the cot#o$ *!e$/
• to *#e'et o*e#!tio o" the !i# coditioig com*#esso# =ACBOUT?%
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C#8$-&% 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#
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C#8$-&% 17
REF. DESCRIPTIONPART NUMBER IN THE 0IRING
DIAGRAMS
- Additio!$ 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
@ 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
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C#8$-&% 17
REF. DESCRIPTIONPART NUMBER IN THE 0IRING
DIAGRAMS
0 Ai# coditioig com*#esso# @020
- Coo$!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$$e# c!* *#esece seso# =J? 620
.0 Cet#!$ di!gostic socet C00-
.- +!tte#& ++00
.2 Dou)$e iectio #e$!& =egie #e$!& uit? +,M
. 7ehic$e s*eed seso# -920
.6 Acce$e#!to# *ed!$ *ositio seso# -29-
.. C$utch *ed!$ sitch >09
.9 +#!e *ed!$ sitch 2-00
.> 5#e4*ost he!tig uit --.0
.@ Fue$ coo$e# 44
. Fue$ "i$te# 44
90 Egie s*eed seso# --9- C!msh!"t *ositio seso# ---.
92 5#ehe!te# *$ugs --90
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C#8$-&% 17
REF. DESCRIPTIONPART NUMBER IN THE 0IRING
DIAGRAMS
9 High *#essu#e "ue$ commo iectio #!i$ 44
96 High *#essu#e "ue$ seso# -2-
9. Fue$ tem*e#!tu#e seso# --099 High *#essu#e "ue$ #egu$!to# -22
9> High *#essu#e "ue$ *um* 44
9@ High *#essu#e "ue$ *um* #d *isto de!cti'!to# -2>>
9 Diese$ iecto#s -- 4 -2 4 - 4 -6
>0 ,i#$ cot#o$ e$ect#o'!$'e -296
>- ,i#$ cot#o$ di!*h#!gm 44
>2 I$et !i# he!te# th#ott$e 44
> Th#ott$e housig =EGR? 44
>6 Ai#B!i# he!t e3ch!ge# 44
>. Th#ott$e housig cot#o$ e$ect#o'!$'e =EGR? -29
>9 I$et m!i"o$d *#essu#e seso# --2
Note: (! depending on version.
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II PARTICLE FILTER
A 4 ROLE
The *!#tic$e "i$te# t#!*s c!#)o *!#tic$es !s e3h!ust g!ses *!ss th#ough%
+ 4 DE,CRI5TION
,DI0->D
@
& =
,
8
9
8
9
! 4 C!#)o *!#tic$es
) 4 Ce#ie
c 4 Fi$te#ed e3h!ust g!ses
d 4 5o#ous ce#!mic !$$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 !$$s%
Com*oets #et!ied i the *!#tic$e "i$te#:
• c!#)o *!#tic$es/
• ce#ie/
• de*osits "#om the egie oi$ !d egie e!#%
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Esseti!$$& 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!$&tic co'e#te#?%
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III CATALYTIC CONVERTER
A 4 ROLE
The c!t!$&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#%
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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 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 4 ELECTRICAL FEATURE,
A$$oc!tio o" coecto# ch!e$s:
• ch!e$ -: . 'o$ts/
• ch!e$ 2: e!#th%
Resist!ce !t -00°C 9 000 ohms%
Resist!ce !t 6.0°C >92 ohms%
08%*!*" The e$ect#ic!$ i"o#m!tio *#o'ided )& the u*st#e!m tem*e#!tu#eseso# is t#!smitted di#ect$& to the iectio ECU%
D 4 LOCATION
The tem*e#!tu#e seso# is $oc!ted u*st#e!m o" the c!t!$&tic co'e#te#%
The tem*e#!tu#e seso# is sc#eed oto ! )!se%
IMPORTANT Use the co##ect tighteig to#ue%
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V EHAUST GAS TEMPERATURE SENSOR DO0NSTREAM OF THECATALYTIC CONVERTER/ 1343/
A 4 ROLE
The tem*e#!tu#e seso# i"o#ms the iectio ECU o" the tem*e#!tu#e o" thee3h!ust g!ses =dost#e!m o" the c!t!$&tic co'e#te#?%
+ 4 DE,CRI5TION
The dost#e!m tem*e#!tu#e seso# is idetic!$ to the u*st#e!m tem*e#!tu#eseso#%
C 4 ELECTRICAL FEATURE,
08%*!*" The e$ect#ic!$ i"o#m!tio *#o'ided )& the dost#e!m
tem*e#!tu#e seso# is t#!smitted )& i#e to the !dditi'e ECU !dset to the iectio ECU 'i! the mu$ti*$e3ed eto#s%
D 4 LOCATION
The tem*e#!tu#e seso# is $oc!ted )etee the c!t!$&tic co'e#te# !d the*!#tic$e "i$te#%
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VI DIFFERENTIAL PRESSURE SENSOR 1341/
A 4 ROLE
The seso# *e#m!et$& me!su#es the *#essu#e di""e#ece o" the e3h!ustg!ses/ )etee the i$et !d the out$et o" the *!#tic$e "i$te#/ to dete#mie the
st!tus o" the "i$te# =c$oggig *#o)$ems o# d!m!ge to "i$te#?%+ 4 DE,CRI5TION
,DI0-D#
"
HI
REF
)
g 4 HI: 5!#tic$e "i$te# u*st#e!m i"o#m!tio i*ut =di!mete# 6%2 mm?h 4 REF: 5!#tic$e "i$te# dost#e!m i"o#m!tio i*ut =di!mete# 6%2 mm? 4 1hite m!#ig 4 E$ect#ic!$ coecto# $ 4 Mem)#!e
The seso# com*#ises the "o$$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$$oig *#essu#es:
• the i$et *#essu#e o" the *!#tic$e "i$te# =u*st#e!m?/
• the out$et *#essu#e o" the *!#tic$e "i$te# =dost#e!m?%
The seso# *#o'ides ! 'o$t!ge *#o*o#tio!$ to the *#essu#e di""e#eti!$me!su#ed )& the mem)#!e =*#essu#e di""e#eti!$ u*st#e!m *#essu#e 4dost#e!m *#essu#e?%
IMPORTANT Do ot i'e#t the u*st#e!m !d dost#e!m i"o#m!tio *i*es=m!$"uctio o" the "i$t#!tio s&stem?% M!!gemet o" the*!#tic$e "i$te# de*eds o this i"o#m!tio%
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C 4 ELECTRICAL FEATURE,
A$$oc!tio o" coecto# ch!e$s:
• ch!e$ -: *#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$e?%
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VII AIR TEMPERATURE SENSOR 1317/
The !i# tem*e#!tu#e seso# i"o#ms the ECU o" the tem*e#!tu#e o" the i$et !i#%
08%*!*" The !i# tem*e#!tu#e seso# is ico#*o#!ted ito the !i# "$omete#%
Ro$e o" the iectio ECU de*edig o the i"o#m!tio #ecei'ed:
• 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!.
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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%
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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$$oig e$ect#o'!$'es:
• tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e/
• e3h!ust g!s #ec&c$ig e$ect#o'!$'e =EGR?/
• th#ott$e housig cot#o$ e$ect#o'!$'e =EGR?%
*
$
*
,DI022C
m 4 ;use#; out*ut
4 '!cuum *um* '!cuum i$et
* 4 hite m!#ig
4 !tmos*he#ic *#essu#e i$et
The e$ect#o'!$'e is cot#o$$ed ith ! OCR =o*e c&c$e #!tio?%
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The *#o*o#tio!$ e$ect#o'!$'e cot#o$$ed ith ! OCR 'o$t!ge is coected tothe "o$$oig:
• !tmos*he#ic *#essu#e/
• '!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$$ed? =imode#!te !m)iet tem*e#!tu#e?%
Note: The inlet air heater throttle can be controlled outside the regenerationassistance operating phase (engine cold- moderate ambienttemperature!.
C 4 ELECTRICAL FEATURE,
Cot#o$: iectio ECU =e!#th?%
7!#i!)$e 'o$t!ge cot#o$ =OCR?:
• "u$$ su**$& =m!3imum OCR? m!3imum '!cuum/
• o su**$& =miimum OCR? o '!cuum =!tmos*he#ic *#essu#e?%
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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#%
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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$$ut!t *!#tic$e "i$t#!tio s&stem/
• it #eiiti!$ises the s&stem !"te# ! m!ite!ce o*e#!tio%
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+ 4 DIAGRAM
SDI024P
79
77
80
8182
83
78
89
88
BSI1
87
86
1282
A
B
C
1320
84
85
:&;
A 4 7AN eto#
+ 4 CAN eto#
C 4 1i#e coectio
+,I- 4 +ui$t4i s&stems ite#"!ce
-2@2 4 Fue$ !dditi'e ECU
-20 4 Iectio ECU
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CONNECTIONS
CONNECTIONN
SIGNALSIGNAL NATURE
>> O*e#!tig st!tus o" the !dditi'e ECU CAN
Lo !dditi'e $e'e$ #e!ched !#ig CANTot!$ u!tit& o" !dditi'e iected sice st!#t o"*!#tic$e "i$te#s $i"e
CAN
E3h!ust g!s tem*e#!tu#e =dost#e!m o" thec!t!$&tic co'e#te#?
CAN
Reuest to "o#ce "! uit =!t $o s*eed? CAN
Reuest to "o#ce *#e4*ost he!te# *$ugs CAN
>@ Reuest to i$$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!$&tic co'e#te#?
7AN
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CONNECTIONS
CONNECTIONN
SIGNALSIGNAL NATURE
@. Egie s*eed seso# sig!$ =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$$ o# othig
=J? de*edig o eui*met%
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III INJECTION ECU 1327/
A 4 ROLE
The ECU so"t!#e *e#"o#ms:
• the "uctios "o# cot#o$$ig iectio !d de*o$$utio/
• the cot#o$ o" *!#tic$e "i$te# #egee#!tio/
• the d#i'ig *$e!su#e st#!tegies/
• the eme#gec& st#!tegies/
• the cot#o$ o" the "! uits !d !#ig LEDs =J?/
• the di!gostic "uctio ith memo#isig o" "!u$ts/
• the di!$ogue ith the "ue$ !dditi'e ECU/
• the di!$ogue ith the !utom!tic ge!#)o3 ECU =J?/
• the di!$ogue ith the e$ect#oic st!)i$it& *#og#!m ECU =J?%
=J? de*edig o eui*met%
+ 4 DE,CRI5TION
The ECU is #es*osi)$e "o# e$ect#ic!$$& 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%
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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?%
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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$$ig: #e"e# to the *#ocedu#e gi'e i the mech!ic!$ "i$e o" the 'ehic$e i
uestio%
+ 4 LOCATION
Loc!tio: ude# the "ue$ t!%
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III ADDITIVE INJECTION PUMP 123/
A 4 ROLE
The !dditi'e iectio *um* su**$ies the *#essu#e !d the "$o #eui#ed i the!dditi'e ci#cuit%
+ 4 DE,CRI5TION
,DI0:0D
4
3
2
51
A
B
A 4 Additi'e #etu# ci#cuit+ 4 Additi'e $o *#essu#e ci#cuit
,u**$ie#: MAR1ALThe !dditi'e iectio *um* com*#ises the "o$$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
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C 4 ELECTRICAL FEATURE,
Cot#o$$ed )& the "ue$ !dditi'e ECU%
A$$oc!tio o" coecto# ch!e$s:
•
ch!e$ -: =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$$oig:
• #euest to "$!sh the se#'ice LED o the cot#o$ *!e$ =J?/
• #euest to dis*$!& ! mess!ge o the mu$ti"uctio sc#ee =J?%
Note: 0.3 litres of additive is sufficient to fill up the tan/ 5 times with 90 litresof fuel (!.
=J? de*edig o 'ehic$e eui*met%
+ 4 DE,CRI5TION
The seso# cosists o" ! the#misto#%
The i"o#m!tio *#o'ided '!#ies/ de*edig o hethe# the the#misto# is ithe !dditi'e o# i !i# =miimum $e'e$ #e!ched?%
C 4 LOCATION
The seso# is ico#*o#!ted ito the !dditi'e iectio *um*%
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IV SAFETY VALVE
A 4 ROLE
Ro$e o" the s!"et& '!$'e:
• se!$ig "uctio =*#e'ets the so$'et "#om e'!*o#!tig !d the ig#ess o"dust/ mud !d !te#?/
• o'e#tu# s!"et& "uctio/
• )#e!the# "o# the !dditi'e t! de*edig o the !dditi'e $e'e$%
+ 4 DE,CRI5TION
,DI0:-D
6
6
9 4 7!cuum '!$'e =0%09 )!#?
> 4 5#essu#e #e$ie" '!$'e =0%0. KB4 0%0- )!#?
@ 4 7!cuum '!$'e #etu# s*#ig
4 5#essu#e #e$ie" '!$'e #etu# s*#ig
O*e#!tio:
• the '!$'e =9? !cts !s ! )#e!the# "o# the !dditi'e t! de*edig o the!dditi'e $e'e$/
• the '!$'e =@? *e#"o#ms the se!$ig !d o'e#tu# s!"et& "uctio%
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C 4 LOCATION
,DI0:2C
The s!"et& '!$'e is $oc!ted i the #e!# $e"t h!d hee$ !#ch =)ehid the mud"$!*?%
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V ADDITIVE INJECTOR 124/
A 4 ROLE
The iecto# is used to iect ! set !mout o" !dditi'e ito the "ue$ t!%
+ 4 DE,CRI5TION
SDI033D A 4 Additi'e #etu# ci#cuit
B 4 Additi'e $o *#essu#e ci#cuit
T&*e: 1E+ER I15 06
Note: 1afety valve rating: 3 bars.
C 4 ELECTRICAL FEATURE,
Cot#o$$ed )& the "ue$ !dditi'e ECU%
A$$oc!tio o" coecto# ch!e$s:
• ch!e$ -: K-2 'o$ts su**$&/
• ch!e$ 2: cot#o$%
E$ect#ic!$ s*eci"ic!tios: #esist!ce !t 2. °C -6%> ohms%
C 4 LOCATION
The !dditi'e iecto# is $oc!ted o the "ue$ t!%
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VI FUEL FILLER CAP PRESENCE SENSOR 4327/
A 4 ROLE
The "ue$ "i$$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$osed/ the m!get iso**osite the cot!ct%
C 4 ELECTRICAL FEATURE,
,u**$&: "ue$ !dditi'e ECU%
A$$oc!tio o" coecto# ch!e$s:
• ch!e$ -: . 'o$t su**$&/• ch!e$ 2: sig!$/
• *#esece o" the m!get o**osite the cot!ct: #esist!ce -.0 000 ohms/
• !)sece o" the m!get o**osite the cot!ct: #esist!ce -. ohms%
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VII FUEL SENDER 1211/
A 4 ROLE
The "ue$ sede# i"o#ms the !dditi'e ECU o" ! '!#i!tio i "ue$ $e'e$/ th#ough
the )ui$t4i s&stems ite#"!ce%Ro$e o" the !dditi'e ECU de*edig o the i"o#m!tio #ecei'ed:
• to dete#mie the !mout o" !dditi'e to )e iected/
• to cot#o$ the !dditi'e iectio *um*/
• to cot#o$ the !dditi'e iecto#%
+ 4 DE,CRI5TION
,DI0:.C
H
Cot#o$$ed )& the "ue$ sede#%
,u**$ie# 7DO:
HEIGHT OF THE FLOAT AIS INRELATION TO THE BASE LEVEL
RESISTANCE
-6 mm .0 ± . ohms
66 mm 00 ± . ohms
>. mm 2.0 ± . ohms
--0 mm 200 ± . ohms
- mm -.0 ± . ohms
->- mm -00 ± . ohms
202 mm .0 ± . ohms
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,u**$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.
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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 $i"e/
• the eme#gec& st#!tegies/
• di!gostic ith memo#isig o" "!u$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$$e# c!* *#esece cot!ct/
• c!t!$&tic co'e#te# dost#e!m e3h!ust g!s tem*e#!tu#e seso#%
,u**$ie#: MAGNETTI MARELLI%
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C 4 ELECTRICAL FEATURE,
A$$oc!tio o" coecto# ch!e$s:
CHANNEL N DESCRIPTION
- K -2 'o$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$e?%
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OPERATING PHASESHDI DIRECT INJECTION SYSTEM
I COMPONENTS COMMON 0ITH DOCUMENT <BOSCH EDC 15C2 HDIINJECTION SYSTEM<
Com*oets commo ith the documet:
• "o#eo#d/
• iectio di!g#!m/
• #o$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%
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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# $oo*%
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IV EHAUST GAS RECYCLING REGULATION
,DI0:9C
2
13 4
6
5
- 4 Ai# "$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$$ed )& ! c!#tog#!*hicm!*%
Ro$e o" the iectio ECU de*edig o the i"o#m!tio #ecei'ed =e3h!ust g!s#ec&c$ig #!te dete#mied i the c!#tog#!*hic m!*?:
• to cot#o$ the e3h!ust g!s #ec&c$ig e$ect#o'!$'e ith ! OCR 'o$t!ge/
• to dete#mie the e3h!ust g!s #ec&c$ig #!te/
• to co##ect the OCR !**$ied to the e3h!ust g!s #ec&c$ig e$ect#o'!$'e so !s too)t!i the theo#etic!$ #ec&c$ig #!te eu!$ to the me!su#ed #!te%
Note: &%haust gas recycling rate difference between the measurement from theair flowmeter and the calculation of the amount of air entering the engine(depending on engine speed and air temperature!.
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Coditios !$$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$& !d usig ! c!#tog#!*hic m!*=iectio ECU?%
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V PREPOST HEATING
The *#ehe!tig !d *osthe!tig times !#e dete#mied )& the ECU de*edig othe coo$!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$$oig c!ses:
• coo$!t tem*e#!tu#e )e$o 2.°C
• egie s*eed $ess th! >0 #*m "o# 0%2 secods%
Note: ;fter the *&< e%tinguishes- if the starter motor is not operated- the preheater plugs remain energised for a ma%imum of 20 seconds.
VIII POSTHEATING OPERATION5osthe!tig c! e3ted the o*e#!tio o" the *$ugs !"te# the c#!ig *h!se%
COOLANT TEMPERATURE POSTHEATING TIME
4 2.°C -@0 secods
->°C -@0 secods
-°C 600 secods
2.°C 600 secods
.0°C 0 secods
5!#!mete#s hich c! ite##u*t *osthe!tig:
• coo$!t tem*e#!tu#e !)o'e .0°C/
• egie s*eed !)o'e -.00 #*m%
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I ADDITIONAL HEATING
As the egie is high$& e""iciet/ ! s&stem is #eui#ed to !ssist the #ise item*e#!tu#e i the *!ssege# com*!#tmet i co$d c$im!tes%
The *!ssege# com*!#tmet tem*e#!tu#e #ise !ssist!ce s&stem is cot#o$$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$$oig *!#!mete#s:
• coo$!t tem*e#!tu#e/
• e3te#io# !i# tem*e#!tu#e%
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+ 4 5RE,ENTATION OF THE ADDITIONAL HEATING ,8,TEM,
1 E)&,-%!,8) %&'!'-%'
SDI038C
BSI1
1327
D!". * DBAT
7 7 7
Assem)$& ith #e$!&s !d #esisto#s
-20 4 Iectio ECU
@0@ 4 E$ect#ic!$ #esisto#s
+,I- 4 +ui$t4i s&stems ite#"!ce
The #esisto#s c! e!ch su**$& ! *oe# o" 0 !tts%This !ssem)$& !$$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%
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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%
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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?%
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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!$$& $oced 20 secods m!3imum !"te# the igitiois sitched o""%
P8%-' %&$)8,&&*- $%,&@(%&
Re"e# to the #e*!i# sectio%
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II DISPLAYING FAULTS DO0NGRADED MODES OPERATION
A 4 DI,5LA8ING FAULT,
The !**e!#!ce o" ce#t!i "!u$ts i the iectio s&stem $e!ds to the
i$$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$$oig dog#!ded modes:
• ! o*e#!tig mode ith ! #educed "ue$ "$o/
• the othe# mode $e!ds to the egie )eig sto**ed immedi!te$&%
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C 4 REDUCED FUEL FLO1
This dog#!ded o*e#!tig mode $imits the "ue$ "$o !d the egie s*eedc!ot e3ceed 2200 #*m =ith the iected "ue$ "$o )eig $ess th! 0 mm?%
The iectio s&stem sitches to ;#educed "$o; mode he ! "!u$t is *#eset
o oe o" the "o$$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$$oig com*oets:
• E*#om i the iectio ECU
• egie s*eed seso#
• c!*!cito# N°- 'o$t!ge
• c!*!cito# N°2 'o$t!ge
• high *#essu#e "ue$ moito#ig
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III COOLANT TEMPERATURE 0ARNING LED V4727/ FEATURE
The coo$!t tem*e#!tu#e !#ig LED c! )e cot#o$$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 "!$$s )e$o -->°C%
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IV CRUISE CONTROL
The c#uise cot#o$ de'ice is used to m!it!i the 'ehic$e s*eed !t ! '!$ue*#og#!mmed )& the d#i'e# i the "o$$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$o$&%
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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%
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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
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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
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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$$oig*!#!mete#s:
• *#essu#e di""e#eti!$/
• i$et !i# "$o/
• !tmos*he#ic *#essu#e/
• e3h!ust g!s tem*e#!tu#e =dost#e!m o" the c!t!$&tic co'e#te#?%
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C 4 5ARTICLE FILTER LOAD LE7EL,
,DI06-D
8
9
,
@
&=
77
D
E
D 4 E3h!ust g!s 'o$ume "$o =$Bh?
E 4 5#essu#e di""e#eti!$ =m)!#?
! 4 Fi$te# *uctu#ed
) 4 Fi$te# #egee#!ted
c 4 Ite#medi!te oed 4 Fi$te# $o!ded
e 4 Fi$te# o'e#$o!ded
" 4 Fi$te# c$ogged
Note: These statuses can be read using the diagnostic tool- in parametermeasurements.
Poes ;!; 4 ;"; #e*#eset the *ossi)$e c$oggig $e'e$s o" the *!#tic$e "i$te#% The!im o" the iectio ECU is to )e *e#m!et$& i oe ;); o# ;c; =#eg!#d$ess o"
'ehic$e mi$e!ge?%1he $e!'ig oe ;c; to go to oe ;d; =!t ! '!#i!)$e s*eed de*edig od#i'ig coditios?/ the iectio ECU #euests #egee#!tio !ssist!ce to#etu# to oe ;); o# *ossi)$& ;c; =de*edig o d#i'ig coditios?%
Note: >ones ?a? and ?f? are )ones where the pressure differential isabnormal.
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The iectio ECU #euests !cti'!tio o" the #egee#!tio "uctio i the"o$$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.
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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!& '!#&%
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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$$ed )& the iectioECU/ the !im o" hich is to ic#e!se the tem*e#!tu#e o" the e3h!ust g!ses tothe #egee#!tio $imit%
+ 4 1ORING OUT THE REUIRED REGENERATION A,,I,TANCE LE7EL
The#e !#e 2 t&*es o" #egee#!tio !ssist!ce/ de*edig o the the#m!$ st!teo" the e3h!ust *i*e:
• $e'e$ - #egee#!tio !ssist!ce =c!#tog#!*hic m!*s "o# co$d e3h!ust *i*e!d c!t!$&tic co'e#te#? =c!t!$&tic co'e#te# *#e4he!tig?/
• $e'e$ 2 #egee#!tio !ssist!ce =c!#tog#!*hic m!*s "o# !#m e3h!ust *i*e?%
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C 4 LE7EL - REGENERATION A,,I,TANCE
1he the moito#ig "uctio detects ! ch!ge i o*e#!tig oe/ it #euests!cti'!tio o" $e'e$ - #egee#!tio !ssist!ce =e%g% ch!gig "#om oe ;c; to;d;?%
E'e#& time !cti'!tio is #euested/ the iectio ECU *e#"o#ms the "o$$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$$oig coditios:
• u*st#e!m !d dost#e!m e3h!ust tem*e#!tu#e/
• "o# !s $og !s the tem*e#!tu#e h!s ot #e!ched ! $imit%
It is im*ossi)$e to sitch "#om $e'e$ - to $e'e$ 2 #egee#!tio !ssist!ce i" $e'e$- h!s ot )ee !cti'e "o# ! gi'e time%
E 4 CA,E OF REUE,TING REGENERATION A,,I,TANCE IN ECONOMICCONDITION, =+8 THE MONITORING FUNCTION?
The !im o" this #euest is to !cti'!te #egee#!tio !ssist!ce ude# o*timumd#i'ig coditios/ i o#de# to #educe "ue$ cosum*tio%
The *#ici*$e is the s!me !s $e'e$s - !d 2 #egee#!tio !ssist!ce )ut ith !sho#te# *ost4iectio time%
5!#!mete#s #eui#ed:
• *!#tic$e "i$te# i oe ;c;/ ;e; o# ;";/
• su""iciet 'ehic$e s*eed o# egie s*eedB$o!d "o# ! gi'e time
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F 4 CONDITION, FOR ACTI7ATING REGENERATION A,,I,TANCE =+8 THEMONITORING FUNCTION?
5!#!mete#s hich c! !cti'!te #egee#!tio !ssist!ce:
• *#essu#e di""e#eti!$/
• dist!ce t#!'e$$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%
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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$$ed )& the *!#tic$e "i$te# =m?
< 4 Regee#!tio "#euec& =m?
I 4 OTHER CONDITION,
Othe# coditios !utho#isig !cti'!tio o" #egee#!tio !ssist!ce:
• coo$!t tem*e#!tu#e !)o'e 90°C/
• su""iciet egie s*eed B $o!d%
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V EFFECTS OF ACTIVATING REGENERATION ASSISTANCE
A 4 5ROHI+ITION OF EHAU,T GA, REC8CLING REGULATION =EGR?
E'e#& time #egee#!tio !ssist!ce is !cti'!ted/ the iectio ECU *#ohi)its
e3h!ust g!s #ec&c$ig #egu$!tio:• e3h!ust g!s #ec&c$ig '!$'e c$osed =*#e'ets !& hutig *heome!?/
• th#ott$e housig o*e =e3ce*t i" c$osig is #euested to "o#ce !i# to "$o itothe he!te#?%
+ 4 ACTI7ATION OF ELECTRICAL CON,UMER,
1 R)&
Re!so "o# !cti'!tig e$ect#ic!$ cosume#s:
• to ic#e!se the #esist!t to#ue o" the !$te#!to#/ thus $e!dig to !ic#e!se i egie $o!d/
• to "!ci$it!te the #ise i tem*e#!tu#e o" the e3h!ust g!ses/
• to uic$& *$!ce the egie o*e#!tig *oit ithi coditios !$$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?%
=J? de*edig o 'ehic$e eui*met%
O#de# i hich cosume#s !#e !cti'!ted )& the +,I =JJ?:
• he!ted #e!# sc#ee cot#o$/
• #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? !$$oed )& the $o!d sheddig $e'e$ o" the 'ehic$e =*#o'ided th!t the)!tte#& 'o$t!ge is !)o'e -2%@ 'o$ts?%
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C 4 INLET AIR HEATER
The i$et !i# he!te# is used:
• to "!ci$it!te the #ise i tem*e#!tu#e o" the e3h!ust g!ses/
• to uic$& *$!ce the egie o*e#!tig *oit ithi coditios !$$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 "$o !d time !#e dete#mied )& c!#tog#!*hic m!*s/ t!igito !ccout the egie o*e#!tig coditios%
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O*e#!tig cu#'e:
SDI044P
E
L1
L2
E1
M :
L
E 4 5#essu#e di""e#eti!$ =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?%
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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$$oigst#!tegies:
• #eductio o" the m!i iectio "$o/
• tu#)och!#gig *#essu#e #egu$!tio%
1 R&@(,-!* = -#& 8!* !*+&,-!* =)>
,DI06.D
N
:
)
*
4 Time =s?
N 4 C&$ide# *#essu#e =)!#?
4 5#e4iectio
4 M!i iectio
$ 4 5ost4iectiom 4 Reductio i m!i iectio time
4 Reductio i c&$ide# *#essu#e
Reducig the m!i iectio "$o c!ce$s out the ic#e!se i to#ue due to*ost4iectio%
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2 T(%9,#8%"!*" $%&''(%& %&"()8-!*
To m!it!i the s!me egie to#ue du#ig #egee#!tio !ssist!ce/ thetu#)och!#gig *#essu#e is #egu$!ted%
3 O$&%8-!* = -#& #!"# $%&''(%& =(&) $($ 3%@ $!'-* @&8,-!?8-%
The high *#essu#e "ue$ *um* o*e#!tes o *istos du#ig #egee#!tio!ssist!ce%
Aim o" the s&stem: to *#o'ide the "$o #eui#ed )& *ost4iectio%
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VI FUEL ADDITIVE FUNCTION
A 4 O5ERATION
To $oe# the #egee#!tio $imit/ ! ce#ie )!sed !dditi'e =Eo$&s? is !dded to
the "ue$/ hich $oe#s the *!#tic$e com)ustio tem*e#!tu#e "#om ..0°
C to6.0°C%
Ce#ie is used i ! o#g!ic so$utio sto#ed i ! !dditio!$ t!/ $oc!ted e!#to the "ue$ t!%
A !dditi'e s&stem h!s )ee de'e$o*ed i o#de# to iect ! !mout o"!dditi'e *#o*o#tio!$ to the !mout o" "ue$ iected%
The s&stem com*#ises the "o$$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$$ig the !dditi'e "uctio%
,ede# "i$te#ig #eui#es ! *um*ig $imit eu!$ to > $it#es o" "ue$%
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O*e#!tio:
FUEL ADDITIVE FUNCTIONENGINE STATIONARY
FUEL ADDITIVE FUNCTIONENGINE RUNNING
Egie o"" No e#o 'ehic$e s*eed
Memo#isig o" the "ue$ $e'e$ ;-; Pe#o 'ehic$e s*eedO*eig o" the "ue$ "i$$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%
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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$$oigcom*oets is "!u$t&:
• *!#tic$e "i$te# c$ogged/
• *!#tic$e "i$te# *uctu#ed/
• e3h!ust g!s tem*e#!tu#e seso#s =u*st#e!m !d dost#e!m o" the
c!t!$&tic co'e#te#? =J?/
• di""e#eti!$ *#essu#e seso# =J?%
=J? 200 m !"te# the "!u$t !**e!#s%
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D 4 FUEL ADDITI7E FUNCTION 4 O5ERATION IN DO1NGRADED MODE,
m!i st#!tegies !#e used i" the !dditi'e s&stem de'e$o*s ! "!u$t%
F(&) =!))&% ,8$ =8()-
The !dditi'e ECU uses the 'ehic$e s*eed i"o#m!tio i couctio ith the"ue$ sede# i"o#m!tio to iect the !dditi'e%
F(&) '&*@&% =8()-
The !dditi'e ECU !dds ! !mout o" !dditi'e eu!$ to th!t !dded "o# ! "u$$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%
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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)$em?%
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C 4 MINIMUM LE7EL OF ADDITI7E REACHED
The iectio ECU i"o#ms the +,I hich:
• #euests th!t the se#'ice LED is "$!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?%
=J? de*edig o 'ehic$e eui*met%
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MAINTENANCEHDI INJECTION SYSTEM
I RECOMMENDED FUEL
The iectio s&stem #eui#es the use o" diese$ 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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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$$oig ist#uctios%
Do ot smoe e!# to the high *#essu#e ci#cuit du#ig #e*!i#s%
A'oid o#ig e!# to "$!mes o# s*!#s%
1he the egie is #uig:
• do ot o# o the high *#essu#e "ue$ ci#cuit/
• !$!&s #em!i out o" the #!ge o" ! *ossi)$e "ue$ et hich m!& c!usese#ious iu#&/
• e'e# *ut &ou# h!d e!# to ! $e! o the high *#essu#e "ue$ ci#cuit%
A"te# sitchig o"" the egie/ !it "o# 0 secods )e"o#e st!#tig o#%
Note: It is necessary to wait for 30 seconds to allow the high pressurefuel circuit to return to atmospheric pressure.
A$$ 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$ight si i##it!t%
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2 F(&) 8@@!-!?& ,!%,(!-
Do ot smoe e!# to the "ue$ !dditi'e ci#cuit du#ig #e*!i#s%
A'oid o#ig e!# to "$!mes o# s*!#s%
The !dditi'e is ! s$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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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$te#/
• high *#essu#e "ue$ *um*/
• high *#essu#e "ue$ commo iectio #!i$/
• high *#essu#e "ue$ $ies/
• diese$ 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$ seso#/
• 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**$& !d #etu# *i*es/
• !dditi'e iecto#%
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III MAINTENANCE
A 4 IN<ECTION ,8,TEM
+$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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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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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 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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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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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$$oig com*oets
must )e )$!ed/ *$!ced i ! *$!stic )!g !d *!c!ged i thei# o#igi!$*!c!gig:
• diese$ iecto#s/
• high *#essu#e "ue$ *um*/
• high *#essu#e "ue$ commo iectio #!i$/
• high *#essu#e "ue$ seso#/
• "ue$ "i$te#%
+ 4 IN<ECTION ECU
The iectio ECU i$$ !utom!tic!$$& $oc i" it is discoected%
IMPORTANT 1he #etu#ig *!#ts ude# !##!t&/ #etu# the iectio ECUith its !ccess code%
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C#8$-&% 15
0IRING DIAGRAM
I LAYOUT DIAGRAM
,DI0695
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C#8$-&% 15
II PARTS LIST
++00 4 +!tte#&
+M6 4 Egie #e$!& uit ith 6 "uses
+,I- 4 +ui$t4i s&stems ite#"!ce
C00- 4 Di!gostic coecto#CA00 4 Igitio sitch
MC-- 4
MC0 4
MC6 4 E!#ths
MC. 4
MM0- 4
0006 4 Cot#o$ *!e$
---. 4 C&$ide# #e"e#ece seso#
--.0 4 5#e4*ost he!tig uit
--90 4 5#ehe!te# *$ugs
-20@ 4 High *#essu#e *um* #d *isto de!cti'!to#
-2-- 4 Fue$ sede# *um*
-220 4 Coo$!t tem*e#!tu#e seso#
-22- 4 Diese$ the#misto#
-2 4 Tu#)och!#gig *#essu#e #egu$!tio e$ect#o'!$'e-2. 4 A$$ 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# ° -
BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER
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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
BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER
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C#8$-&% 15-66