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Basic manual: Workshop Repair Manual 323
SAGEM
DIESEL INJECTION FAULT FINDING
S9W 700 engine
77 11 298 582
FEBRUARY 2001
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
EDITION ANGLAISE
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
RENAULT 2001
Contents
Page
13 DIESEL INJECTION
Introduction
Calculator connectors key
Fault interpretation
Conformity check
Help
Customer complaints
Fault finding chart
Help
13-1
13-3
13-4
13-15
13-17
13-18
13-19
13-25
TPP EGR
Program No.: B1
Vdiag No.: 04
SAGEM DIESEL113
INJECTION
Fault finding - Introduction
13
This document introduces the diagnostic procedures applicable to all TPP EGR SAGEM S9W 700 engine
computers
The following are thus required to carry out fault finding on this system:
the Fault finding Technical Note,
the wiring diagram for the function on the vehicle concerned,
the tools listed in Special tooling required.
TPP041.0
13-1
TPP EGR
Program No.: B1
Vdiag No.: 04
13
In this new application, the, TPP EGR SAGEM S9W 700 EVOLUTION computer uses the TRANSVERSE
INSTRUMENT PANEL
SPEED INFORMATION
The rev-counter is controlled by the TPP EGR computer applications, not by the alternator W terminal.
The preheating and cold start functions are controlled by the preheating unit.
For these reasons, actuator commands AC014, AC101, AC102 are not activated on this engine S9W 700
(preheating and cold start functions are controlled by the preheating unit).
SPECIAL TOOLING REQUIRED FOR OPERATIONS ON THE DIESEL INJECTION TTP EGR SAGEM SYSTEM:
Fault finding tools: NXR, CLIP and OPTIMA.
Multimeter.
TPP041.0
13-2
TPP EGR
Program No.: B1
Vdiag No.: 04
13
CONNECTOR 4
A1
A2
A3
A4
B1
B2
B3
B4
C1
C2
C3
C4
CONNECTOR 3
CONNECTOR 2
CONNECTOR 3
1
2
Not used
Not used
CONNECTOR 1
CONNECTOR 4
1
TPP041.0
13-3
TPP EGR
Program No.: B1
VDiag No.: 04
DF001
PRESENT
OR
STORED
NOTES
13
Computer
1.DEF: Atmospheric pressure sensor breakdown
2.DEF: Storage area breakdown
Conditions for applying the fault finding procedure to the fault stored:
Apply the fault finding strategy whether the fault is present or stored.
Replace the TPP EGR engine management computer following the instructions given in the Help section.
If necessary, modify the configuration of the new computer to match the Air conditioning system and Heated
windscreen options fitted on the car.
AFTER REPAIR
Perform a road test then check with the fault finding tool.
TPP041.0
13-4
TPP EGR
Program No.: B1
VDiag No.: 04
DF002
PRESENT
OR
STORED
NOTES
CO.1
13
Conditions for applying the fault finding procedure to the fault stored:
Apply the fault finding strategy whether the fault is present or stored.
NOTES
None
CC.0
NOTES
None
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-5
TPP EGR
Program No.: B1
VDiag No.: 04
DF003
PRESENT
OR
STORED
NOTES
CO.0
13
Conditions for applying the fault finding procedure to the fault stored:
Apply the fault finding strategy whether the fault is present or stored.
NOTES
None
CC.1
NOTES
None
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-6
TPP EGR
Program No.: B1
VDiag No.: 04
DF012
PRESENT
OR
STORED
NOTES
13
Battery voltage
Conditions for applying the fault finding procedure to the fault stored:
Apply the fault finding strategy whether the fault is present or stored.
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-7
TPP EGR
Program No.: B1
VDiag No.: 04
DF023
PRESENT
OR
STORED
NOTES
13
Conditions for applying the fault finding procedure to the fault stored:
Clear the computer memory. The fault is declared present after
the engine is started and accelerated to reach a potentiometer position value >30 %
over more than 60 seconds.
Measure the resistance of the flywheel signal sensor at its connector. Replace the sensor if the resistance is
not approximately 250 ohms.
Ensure the continuity and insulation of the following connections:
grey computer connector track A4
track A of the flywheel signal sensor connector
grey computer connector track A3
track B of the flywheel signal sensor connector
Also ensure insulation across these two connections.
Test the connections on the two connectors.
Carry out a visual inspection of the general condition of the wiring and its routing for possible interference.
Check the positioning and condition of the sensor.
Check the condition of the target (deformation, mounting....).
Check the conformity of the target: four slots at 90C.
If the fault persists after these tests, replace the flywheel signal sensor.
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-8
TPP EGR
Program No.: B1
VDiag No.: 04
DF026
PRESENT
OR
STORED
13
Before checking these faults, ensure that the computer is correctly configured with
regard to the Air conditioning and Heated windscreen options (read configurations).
NOTES
Conditions for applying the fault finding procedure to the fault stored:
Apply the fault finding strategy whether the fault is present or stored.
CC.0
NOTES
None
Measure the resistance of the fast idle solenoid valve coil at its connector.
Replace the fast idle solenoid valve if the resistance is not approximately 45 ohms.
Ensure insulation against earth of the connection between:
black computer connector track B1
track 2 of the fast idle solenoid valve connector
Test the connections on the two connectors.
If the fault persists after these tests, replace the fast idle solenoid valve.
CO.1
NOTES
None
Measure the resistance of the fast idle solenoid valve coil at its connector.
Replace the fast idle solenoid valve if the resistance is not approximately 45 ohms.
Ensure the continuity and insulation against + 12 volts of the connection between:
black computer connector track B1
track 2 of the fast idle solenoid valve connector
Ensure continuity against earth on track 1 of the solenoid valve connector (wiring harness side).
Test the connections on the two connectors.
If the fault persists after these tests, replace the fast idle solenoid valve.
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-9
TPP EGR
Program No.: B1
VDiag No.: 04
13
NOTES
CO.0
Conditions for applying the fault finding procedure to the fault stored:
The fault is declared present after the engine has been started and an engine speed of
more than 1000 rpm has been maintained for 20 seconds with the engine coolant
temperature > at 30C.
NOTES
None
Measure the resistance of the EGR solenoid valve coil at its connector.
Replace the EGR solenoid valve if the resistance is not approximately 45 ohms.
Ensure the continuity and insulation against earth of the connection between:
black computer connector track C3
track 1 of the EGR solenoid valve connector
Ensure the presence of + after ignition feed on track 2 of the EGR solenoid valve connector, wiring side.
Test the connections on the two connectors.
Replace the EGR solenoid valve if the fault persists after these tests.
CC.1
NOTES
None
Measure the resistance of the EGR solenoid valve coil at its connector.
Replace the EGR solenoid valve if the resistance is not approximately 45 ohms.
Ensure insulation against +12 volts of the connection between:
black computer connector track C3
track 1 of the EGR solenoid valve connector
Replace the EGR solenoid valve if the fault persists after these tests.
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-10
TPP EGR
Program No.: B1
VDiag No.: 04
DF033
PRESENT
OR
STORED
13
CC.1
NOTES
None
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-11
TPP EGR
Program No.: B1
VDiag No.: 04
DF039
PRESENT
OR
STORED
13
Before checking these faults, ensure that the computer is correctly configured with
regard to the Air conditioning and Heated windscreen options (read configurations).
NOTES
Conditions for applying the fault finding procedure to the fault stored:
The fault is declared present after the Fast idle solenoid valve actuator command.
CO.0
NOTES
None
Ensure the continuity and insulation against earth of the connection between:
grey computer connector track B1
the electric heated windscreen timed unit
Test the connections on the two connectors. Repair if necessary.
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-12
TPP EGR
Program No.: B1
VDiag No.: 04
13
Start signal
DF063
STORED
NOTES
1.DEF
Conditions for applying the fault finding procedure to the fault stored:
The fault is declared present after the engine is started.
NOTES
None
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-13
TPP EGR
Program No.: B1
VDiag No.: 04
13
NOTES
CC.1
Conditions for applying the fault finding procedure to the fault stored:
The fault is declared present after the Preheating/electronic fault warning light"
actuator command.
NOTES
None
CO.0
NOTES
None
AFTER REPAIR
Clear the computer memory, switch off the ignition, then carry out a road test.
Complete the operation by performing a test using the fault finding tool.
TPP041.0
13-14
TPP EGR
Program No.: B1
VDiag No.: 04
NOTES
Order
Function
Instrument
panel warning
light
Only proceed to a conformity check after a complete check with the fault finding tool.
Parameter or status
Check or action
PR002
2
Battery voltage
Load
potentiometer
Computer
configuration
Starter signal
13
PR005
Computer supply
voltage
Load
potentiometer
ET011
configuration with
heated
windscreen
ET012
computer
configuration with
air conditioning
Fault finding
No load value:
engine cold ~26%
engine warm ~15%
Full load value
> 76%
Statuses confirmed
according to
equipment
ET014
computer
configuration
without air
conditioning
ET015
configuration
without heated
windscreen
ET009
Starter signal
TPP041.0
13-15
TPP EGR
Program No.: B1
VDiag No.: 04
NOTES
Order
Function
Only proceed to a conformity check after a complete check with the fault finding tool.
Parameter or status
Check or action
ET001
10
ET002
Preheating relay
unit 2 command
ET003
Cold start
solenoid valve
command
PR003
Engine speed
Cold start
solenoid valve
Statuses confirmed
during the preheating
stage
800 rpm 25
with compressor or
heated windscreen
operation
880 rpm 25
ET010
PR006
EGR solenoid
valve control
EGR function
ET006
Fault finding
Preheating relay
unit 1 command
Preheating relay
Engine speed
13
EGR solenoid
valve control
>0
with status confirmed
TPP041.0
13-16
TPP EGR
Program No.: B1
VDiag No.: 04
13
AFTER REPAIR
13-17
TPP EGR
Program No.: B1
VDiag No.: 04
NOTES
13
Only consult this customer complaint after a complete check using the fault finding tool.
CHART 1
CHART 2
CHART 3
CHART 4
CHART 5
CHART 6
TPP041.0
13-18
TPP EGR
Program No.: B1
VDiag No.: 04
CHART 1
NOTES
13
None
Try to establish dialogue with a computer on another vehicle to make sure that the fault finding tool is not faulty.
Check the battery voltage and carry out any necessary operations to ensure the correct voltage (U battery >
10.5 volts).
Check that the 7.5A injector fuse in the passenger compartment connection unit has not blown.
Check the connection and condition of the connectors at the computer connector.
Check that the computer is correctly supplied:
Earth on track A3 of the black computer connector.
+ after ignition on track A4 of the black computer connector (test the 70A fuse in the engine compartment
connection unit + relay + after ignition).
Also check the engine earth.
Change the computer if dialogue has still not been established after these various checks.
Clear the new computer's fault memory at the end of the operation.
If necessary, modify the configuration of the Air conditioning and Heated windscreen options.
AFTER REPAIR
Perform a road test then check with the fault finding tool.
Deal with any faults found.
TPP041.0
13-19
TPP EGR
Program No.: B1
VDiag No.: 04
13
CHART 2
NOTES
The TTP EGR SAGEM computer only controls the EGR function and the preheating/
electronic fault warning light on this application.
The heater plugs are controlled by the preheating unit.
AFTER REPAIR
None
TPP041.0
13-20
TPP EGR
Program No.: B1
VDiag No.: 04
STARTING PROBLEMS
(not starting or difficulty in starting engine)
CHART 3
NOTES
13
None
Check that the heating system is operating correctly as described in the Help section.
AFTER REPAIR
None
TPP041.0
13-21
TPP EGR
Program No.: B1
VDiag No.: 04
13
CHART 4
NOTES
Only consult this customer complaint after a complete check using the fault finding tool.
AFTER REPAIR
Perform a road test then check with the fault finding tool.
TPP041.0
13-22
TPP EGR
Program No.: B1
VDiag No.: 04
13
CHART 5
NOTES
Go to the parameter screen on the fault finding tool and check for any disparity
between the engine speed reading on the tool and the rev-counter on the instrument
panel. The engine must be running at idle speed (800 rpm 25) for this check.
With the connectors disconnected, check the continuity and insulation against earth of the connection
between:
grey computer connector track C2
the rev-counter the on instrument panel
Check that a frequency is present on track C2 of the grey computer connector with the engine running at idle
speed (800 25 = 26.6 Hz).
AFTER REPAIR
None
TPP041.0
13-23
TPP EGR
Program No.: B1
VDiag No.: 04
CHART 6
NOTES
13
Ensure the continuity and insulation against + 12 volts of the connection between:
black computer connector track B4
the air conditioning relay earth
Select the air conditioning request on the control panel.
Check for the presence of + 12 volts on tracks 1 and 3 of the air conditioning relay.
Relay disconnected.
Check the resistance across tracks 1 and 2 of the air conditioning relay.
Replace the relay if its resistance is not approximately 65 ohms.
If the fault persists, consult the document dealing with air conditioning fault finding.
AFTER REPAIR
None
TPP041.0
13-24
TPP EGR
Program No.: B1
VDiag No.: 04
13
Function/component
to check
Preheating operation
Actions/test
conditions
Customer complaint/
test values
Remedy
Check the control unit
support to ensure that
track 6 is earthed and
+ after ignition is
supplied to track 4 (20
A Engine stop fuse in
the fuse and relay box)
Ensure that there is
continuity between
track 3 of the unit
support and the warning
light. Check the
condition of the bulb.
Ensure that there is
continuity between
track 8 of the unit
support, the solenoid
valve and the diesel
igniter.
Check for the presence
of + before ignition on
track 2 of the unit
support (70 A fuse in the
engine compartment
connection unit).
TPP041.0
13-25
TPP EGR
Program No.: B1
VDiag No.: 04
13
Function/component
to check
Return to normal
operation of preheating
Actions/test
conditions
Customer complaint/
test values
Remedy
Engine started up
Wait for the coolant
temperature to rise
above 6 C if
necessary.
ADDITIONAL CHECKS:
Resistance of diesel igniter filament
R = 8 1 ohm
R = 6.5 1 ohm
TPP041.0
13-26