Y17DT / Y17DTL pump controller repair

Added: 11.04.2010 12:13 Page Views: 1019

Hello, I wanted to publish these instructions on how to repair the pump controller. And
here are the current instructions: The injection control device of the diesel engine Y17DT /
75 HP 1.7 DTI and Y17DTL / 68 hp 1.7 DI has ncher I would like in this paper some
well-known series on the error. This document is a revised version of the document is
known for a year. The aim of the revision is to make more and more information as clear
as possible. A faulty pump controller will have following effects / errors noticeable judder
when the car is hot or goes ... Error code p0251 can be set (cold solder joint) engine can
not be started ... Error code p0251 set (Cold junction) motor "sawed" at idle and takes no
gas on or running extremely out of true (FET defective) Each electrical engineer /
electrician is to perform in a position this repair soon and get the pump control unit back
into "transition" . Operation of the pump control device: the pump control device is the
engine control unit as the final stage in order to actuate the electromagnetic spill valve of
the fuel injection pump. More specifically otherwise acted as an injection signal (which
comes from the engine control unit) to strengthen and adapt that at that precise timing
and duration of the overflow valve is actuated and ultimately injection can take place.
The pump control unit has only 8 unused terminals on the plug, which have the following
meaning. - Pin 4 & 7 are the +12 V supply voltage - pin 12 & 17 is ground or 0V - Pin 14 &
20 are the outputs to the overflow valve (High Voltage!) - Pin 22 is the valve control signal
from the engine control unit coming ("injection signal)
-

Pin 25 - probably return information signal to the engine control unit (function not
known) The pump control device consists essentially of the following components /
modules: - throttle and Siebelko to stabilize the supply voltage - an OEM voltage
regulator (8.6V) and a voltage regulator (5V) for the control Panel - control
electronics / monitoring of several OPs 4 times and still unknown control ICs - Step
uP converter for generation of 130V (depending on the measurement method differs
from the voltage to 160V ...) - a complex bridge amplifier with power supply of 12V
and 130V
Thus, the pump controller can ever operate the electromagnetic spill valve quickly
enough, it requires a very high current in a very short time - ergo a high voltage.
The internern Step UP converter generates the necessary 130V. The 130V will be
applied to a bridge circuit in the overflow valve in "see dosage"
- The overflow valve is initially given a brief surge 130V and 12V applied afterwards
(holding current) - so that the valve can close fast enough, a 130V "counter"-shock
is applied
Oszilogram the output voltage at the overflow valve

Disassembly / Open the pump control unit:

Position the pump control unit: The pump control unit sits on the back of the
engine, near the bottom (see picture). It can be expanded with a lot of fumbling
to "Top".
Expanded pump controller: After do when removing the pump control unit
almost broke his fingers, you should be rewarded with the sight.
Open the pump control unit:
Desoldering of components: Carefully desolder all components and
gekenntzeichneten attention to "clearance" of the pins, so that when removing
the PCB vias are not damaged. The ground connections need "much attention"
because they can be very difficult to heat.

Removal of the board: After you have all components and clean the connector desoldered,
you can lift the board without violence and remove. Now all components are visible and
you can start the actual repair.

Error 1: Almost every controller has (the thick, orange Elko with 3 pins) burnt the
contacts of the filter capacitors. The electrolytic capacitor can be used again after cleaning
the connector pins and vias. Alternatively replace with 2200uF 35V Capacitor 105 degrees.
Error 2: The main reason for the error p0251 is 99% a cold solder joint / Schmorstelle on
the converter inductance of the 130V power supply. The solder / via and the connector
pins must be extremely well cleaned (free from scale). Then stop the paint on the track to
scrape a little diode, so as to increase the solder joint - then clean solder
Error 3: An FET in the preamp is like a bridge transistor is defective. He then has a final.
The control of the following power transistor
no longer is ... the overflow valve is still operated, but due to the lack of full control no
longer correct - an irregular engine running is the result. The transistor SMD TYPE SD
(N-channel) can be replaced by a BSS138N. (Update 06 July, 2008
Measuring / checking on the pump control unit:

Measurement points / points of reference:

For all measurements below I refer to those specified in the adjacent picture data points.
For the tests, the pump control unit with 12V (at least 10A power supply) must be supplied
(Pin 4 = +12 V and pin 17 = ground / GND)
MP1 -> Mass (multimeter) 12V min
MP2 -> Mass (multimeter) 12V min
MP3 -> Weight (with oscilloscope) approximately 130V
MP5 -> mass (multimeter) approximately 8.6 V
Current consumption of the pump control device in the idle about 180mA

List of parts and replacements.

Description of The datasheet Replacement
SMD transistor marked "SD" N channel FET BSS 138 SMD transistor marked "M02" N channel FET BSS 138 SMD transistor marked "AK" NPN Trans. BCX 70K IC 8-pin SO bottom row "34629" positive 5V Voltage regulator 78L05
SO IC 14 pin "LM2901D" or the top row of "89551" Quad operational amplifier 14 pin LM2901D
TO220 myth of "31045" Spannungsregler 8.6 V positive voltage stabilizer stabilizer circuit 9V 1A 7809 (1A)
YV 32/200 V, tranz buz 91
-Pin 4 & 7 is a +12 V power supply current consumption 10A - idling about 180 mA
- Pin 12 & 17 weight or 0 Volt
- Pin 14 & 20 it is going to overflow valve coil (note the high voltage! 130 V)
- Pin 22 solenoid valve control signal to the engine control unit