Diesel Injection Pump
SERVICE MANUAL
OPEL Z17DT TYPE ENGINE
COMMON RAIL SYSTEM (CRS)
OPERATION
January, 2007
00400588E
© 2006 DENSO CORPORATION
All Rights Reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher.
Table of Contents
Table of Contents
Operation Section
1. PRODUCT APPLICATION INFORMATION
1.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3
System Component Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. SUPPLY PUMP
2.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.2
Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
3. RAIL
3.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
4. INJECTOR
4.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
4.2
QR Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
5. CONTROL SYSTEM COMPONENTS DESCRIPTION
5.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
5.2
Engine ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
5.3
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
6. DIAGNOSIS
6.1
Diagnostic Trouble Code (DTC) Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
7. EXTERNAL WIRING DIAGRAM
7.1
Engine ECU External Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
7.2
Engine ECU Connector Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Operation Section
1 1
1. PRODUCT APPLICATION INFORMATION
1.1 Outline
The Common Rail System (CRS) used with the OPEL Z17DT* engine has been redesigned. Basic system configuration is identical to that of the CRS used with the OPEL 4EE2 engine. This service manual only addresses changes/additions from the CRS used with the 4EE2 engine. For details on other parts, refer to the service manual entitled, "Common Rail
System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
1.2 Application
Model Year
2007 MY
Vehicle Name
Corsa
Meriva
Engine Model
Z17DT*
Engine Displacement
1.7L
1.3 System Component Part Numbers
The EGR valve has been changed from a DENSO product to that of another manufacturer.
Part Name
Supply Pump
Rail
Injector
DTR
Engine ECU
DT
Crankshaft Position Sensor
Cylinder Recognition Sensor
Boost Pressure Sensor
Corsa
Vehicle Model
Meriva
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
DENSO Part Number
HU294000-050#
HU095440-090#
HU095000-613#
MB275800-467#
MB275800-475#
MB275800-476#
949979-120#
949979-120#
079800-783#
Reference
Made in Europe
Car Manufacturer
Part Number
97376269
97376271
97376270
98000820
98002896
98025828
97321620
97321620
97381191
Operation Section
1 2
2. SUPPLY PUMP
2.1 Outline
This HP3 supply pump is equipped with a compact Suction Control Valve (SCV). Parts other than the SCV have not changed. For details, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc
ID: 00400028).
New Model
Old Model
Operation Section
1 3
2.2 Suction Control Valve (SCV)
A linear solenoid type valve has been adopted. The ECU controls the duty ratio (the length of time that the current is applied to the SCV), in order to control the quantity of fuel that is supplied to the high-pressure plunger.
Because only the quantity of fuel that is required for achieving the target rail pressure is drawn in, the drive load of the supply pump decreases.
When current flows to the SCV, variable electromotive force is created in accordance with the duty ratio, moving the armature to the left side. The armature moves the cylinder to the left side, changing the opening of the fuel passage and thus regulating the fuel quantity.
With the SCV OFF, the return spring contracts, completely opening the fuel passage and supplying fuel to the plungers.
(Full quantity intake and full quantity discharge)
When the SCV is ON, the force of the return spring moves the cylinder to the right, closing the fuel passage (normally opened).
By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the actuation duty ratio, and fuel is discharged by the plungers.
(1) Short duty ON duration
Short duty ON duration => large valve opening => maximum intake quantity
(2) Long duty ON duration
Long duty ON duration => small valve opening => minimum intake quantity
Operation Section
1 4
Operation Section
1 5
3. RAIL
3.1 Outline
The shape of the rail as well as the installation positions for the fuel pressure sensor and pressure limiter have been changed. The shape and characteristics of the rail pressure sensor and pressure limiter have not changed. For details, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
New Model
Old Model
Operation Section
1 6
4. INJECTOR
4.1 Outline
The shape of the injector as well as the QR code (ID code) correction point have been changed. Other specifications and operations have not changed. For details, refer to the service manual entitled, "Common Rail System for OPEL
4EE2 Type Engine" (Doc ID: 00400028).
Operation Section
1 7
4.2 QR Code
QR code correction points are as per the figure below.
Operation Section
1 8
5. CONTROL SYSTEM COMPONENTS DESCRIPTION
5.1 Outline
Changes/additions to control-related parts are explained herein. For details on other parts, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
5.2 Engine ECU
The shape of the engine ECU has been changed. As a result, the shape of the connector has also been changed. For details on the connector, refer to "7. EXTERNAL WIRING DIAGRAM".
5.3 Boost Pressure Sensor
The boost pressure sensor detects intake air pressure. The boost pressure sensor also includes a thermistor-type temperature sensor.
Operation Section
1 9
6. DIAGNOSIS
6.1 Diagnostic Trouble Code (DTC) Table
Read symptom codes using the manufacturer's diagnostic tool.
(1) For Corsa
DTC
P0100
P0095
P0115
P1120
P1122
P1120
P0235
P0180
P0190
P0409
P2226
P0110
Failure Part
Mass airflow sensor
Intake air temperature sensor
Coolant temperature sensor
Accelerator position sensor 1
Accelerator position sensor 2
Accelerator position sensor
Boost pressure sensor
Fuel temperature sensor
Rail pressure sensor
EGR lift (position) sensor
Atmospheric pressure sensor
Intake air temperature frequency sensor
Intake air temperature analog sensor
07
03
52
07
03
07
03
Symptom
27
26
52
07
03
07
03
52
07
03
07
03
52
52
07
03
07
03
27
26
01
02
Failure Mode
Mass airflow sensor signal too high
Mass airflow sensor signal too low
Mass airflow sensor performance invalid
Intake air temperature sensor signal too high
Intake air temperature sensor signal too low
Coolant temperature sensor signal too high
Coolant temperature sensor signal too low
Coolant temperature sensor performance invalid
Accelerator position sensor 1 signal too high
Accelerator position sensor 1 signal too low
Accelerator position sensor 2 signal too high
Accelerator position sensor 2 signal too low
Accelerator position sensor signal performance invalid
Boost pressure sensor signal too high
Boost pressure sensor signal too low
Boost pressure sensor performance invalid
Fuel temperature sensor signal too high
Fuel temperature sensor signal too low
Rail pressure sensor signal too high
Rail pressure sensor signal too low
Rail pressure sensor signal keeping the middle range
EGR lift (position) sensor signal too high
EGR lift (position) sensor signal too low
Atmospheric pressure sensor signal too high
Atmospheric pressure sensor signal too low
Intake air temperature frequency sensor frequency too long
Intake air temperature frequency sensor frequency too short
Intake air temperature analog sensor signal too high
Intake air temperature analog sensor signal too low
Operation Section
1 10
DTC
P0530
P0571
P0168
P0704
P0520
P0335
P0340
P0685
P1625
Failure Part
A/C pressure sensor
Brake switch
Fuel injection quantity reduction
Clutch switch
Oil pressure switch
Crankshaft position sensor
Cylinder recognition sensor
P0016
Crankshaft position sensor / Cylinder recognition sensor
P0685
Main relay
P1625
P0641
P0651
P0380
P0683
P0645
P0403
Sensor reference voltage 1
Sensor reference voltage 2
Glow system
Main relay
A/C relay output
EGR control DC motor
Symptom
07
03
57
08
5B
08
05
04
08
04
08
08
02
62
07
03
07
03
01
06
02
04
01
63
01
06
08
04
Failure Mode
A/C pressure sensor signal too high
A/C pressure sensor signal too low
A/C pressure sensor GND signal open
Brake switch diagnostics; Cruise control brake switch no signal
Fuel quantity reduction by injector leak temperature
Clutch switch circuit malfunction (manual transmission only)
Oil pressure switch stuck open
Crankshaft position sensor no pulse
Crankshaft position sensor signal invalid
Cylinder recognition sensor no pulse
Cylinder recognition sensor signal invalid
Crankshaft position sensor/cylinder recognition sensor signal synchronization error
Main relay diagnostics; Main relay stuck closed
Main relay diagnostics; Main relay stuck open/relay output open load
Sensor reference voltage output No.1 too high
Sensor reference voltage output No.1 too low
Sensor reference voltage output No.2 too high
Sensor reference voltage output No.2 too low
Glow controller command line short to battery; Glow controller internal malfunction
Glow controller command line open load/short to
GND; Glow controller internal malfunction
Glow plug R side short; Glow diagnosis line short to
GND; Glow controller internal malfunction
Glow plug R side open load; Glow diagnosis line open load; Glow controller internal malfunction
Main relay/relay output short to battery
Main relay/relay output short to GND
A/C relay output short to battery
A/C relay output open load/short to GND
EGR control DC motor output 1 short to battery/ short to GND output 2 short to battery/short to GND motor short
EGR control DC motor output 1 open load output 2 open load motor open load
P2149
P0094
P0088
P0217
P0219
P0601
P0606
P0301
P0302
P0303
P0304
1 11
DTC
P0201
P0203
P0204
P0202
P2146
Operation Section
Failure Part
Injector drive
P0606
P0602
P062F
P0093
P0088
P0087
P0001
QR code failure
Common rail system
Suction control valve (SCV)
SCV valve
Common rail system
Engine overheat
Engine overrun
Engine ECU internal failure
Injector 1
Injector 2
Injector 3
Injector 4
48
33
36
66
52
68
66
4A
37
38
04
5B
5B
5B
04
04
04
Symptom
61
61
61
61
01
02
01
02
58
52
01
06
61
66
Failure Mode
TWV1 output open load; Injector #1 coil open
TWV2 output open load; injector #3 coil open
TWV3 output open load; injector #4 coil open
TWV4 output open load; injector #2 coil open
COM1 output short to battery; TWV 1 or 3 output short to battery, both TWV 1 and TWV 3 open load
COM 1 output short to GND; TWV 1 or 3 output short to GND
COM1 output short to battery; TWV 2 or 4 output short to battery, both TWV 2 and TWV 4 open load
COM 2 output short to GND; TWV 2 or 4 output short to GND
Capacitor charge-up circuit malfunction (insufficient charge)
Capacitor charge-up circuit malfunction (excessive charge)
QR code not programmed
QR code error
QR correction information is abnormal
Pressure limiter activated
Supply pump protection
Supply pump exchange
Supply pump malfunction (insufficient flow)
SCV (+) output short to battery; SCV (-) output short to battery
SCV (+) output open load/short to GND; SCV (-) output open load/short to GND; SCV coil open;
SCV coil short
SCV stuck
Rail pressure sensor performance invalid included fuel leak
Rail pressure exceeds upper limit
Engine overheat
Engine overrun
Check sum error - flash area
CPU fault; -Main CPU fault
CPU fault; -Watchdog IC fault
Cylinder 1 fuel system failure
Cylinder 2 fuel system failure
Cylinder 3 fuel system failure
Cylinder 4 fuel system failure
Operation Section
1 12
DTC
P0400
P0299
P0234
P0243
P0660
P0638
P2620
P0425
P042A
P2452
P0480
P0481
P0482
P0100
P242F
P2002
P2452
Failure Part
EGR system
EGR valve
Turbo system
Electric Vacuum Regulating Valve (EVRV);
Turbo
Variable swirl control (VSS) output (VSV)
Diesel throttle system
Upper Oxygen catalyst temperature sensor
(exhaust gas temperature 1)
Upper DPF temperature sensor (exhaust gas temperature 2)
Differential pressure sensor
Fan relay 1 output
Fan relay 2 output
Fan relay 3 output
Mass airflow sensor
DPF system
66
5B
57
06
01
06
28
61
01
06
01
07
03
5B
Symptom
5B
63
61
52
52
01
06
01
06
01
06
08
07
03
54
07
03
54
52
Failure Mode
EGR excessive flow (EGR positive deviation)
EGR insufficient flow (EGR negative deviation)
EGR valve open/close stuck
Turbo control system (negative deviation)
Turbo control system (positive deviation)
EVRV; Turbo output short to battery
EVRV; Turbo output open load/short to GND
VSS output (VSV) short to battery
VSS output (VSV) open load/short to GND
Diesel throttle controller output signal short to battery
Diesel throttle controller output signal open load/ short to GND
Diesel throttle controller failure status
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) voltage too high
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) voltage too low
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) temperature too high
Upper DPF temperature sensor (exhaust gas temperature 2) voltage too high
Upper DPF temperature sensor (exhaust gas temperature 2) voltage too low
Upper DPF temperature sensor (exhaust gas temperature 2) temperature too high
Voltage too high
Voltage too low
Differential pressure too high
Hose line disconnect upstream
Fan control relay 1 short to battery
Fan control relay 1 open load/short to GND
Fan control relay 2 short to battery
Fan control relay 2 open load/short to GND
Fan control relay 3 short to battery
Fan control relay 3 open load/short to GND
Mass airflow sensor too low
DPF over loaded
DPF over loaded 2
Not ended regeneration
Differential pressure sensor characteristic abnormality
Operation Section
1 13
DTC
P0425
P042A
P2425
P0400
P1610
P1611
P1613
P1614
P1615
P1616
P062F
P0409
U2103
U2108
U2107
U0418
U2108
U0418
P0650
U0405
Failure Part
Upper Oxygen catalyst temperature sensor
(Exhaust gas temperature 1)
Upper DPF temperature sensor (exhaust gas temperature 2)
EGR cooler bypass
EGR DC motor
Immobilizer
DPF system
EGR valve
CAN data error
Vehicle Integrated Function (VIF) related diagnosis
00
50
00
00
4F
00
00
Symptom
52
52
01
06
62
00
31
52
00
70
70
71
72
74
72
74
70
71
72
74
Failure Mode
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) sensor characteristic abnormality
Upper DPF temperature sensor (exhaust gas temperature 2) characteristic abnormality
EGR cooler bypass output short to battery
EGR cooler bypass output open load/short to GND
EGR DC motor lock
Immobilizer 3 Control Unit (ICM3) function in ECU is not programmed or is in function reset mode
ICM3 function in ECU is switched off
Incorrect Security Code input
Response frame not received
Transmitted response was incorrect
Transmitted response was distorted ("0")
Failed power train identification
Failed environment identification
Electronically Erasable and Programmable Read
Only Memory (EEPROM) failure
EGR lift sensor characteristic abnormality
Node error (Bus-off)
ABS General Frame receive is failed
Body Control Module (BCM) General Frame receive is failed
Brake pedal initial travel achieved validity invalid
Traction Control System (TRC) request torque Rolling Counter (RC) error
TRC request torque Protection value error
Brake pedal position RC error
Brake pedal initial travel achieved protection value error
Instrument panel virtual device unavailability
Cruise control switch invalid
Cruise control switch RC error
Cruise control switch protection value error
Operation Section
1 14
DTC
P0602
U2101
P1602
P1600
P0621
P0622
P0571
Failure Part
P1602
P062F
P0299
P1602
P0500
P0501
Microinjection quantity learning (SQL)
Popping-off
Pump learning
ABS
P1602
P1602
(2) For Meriva
Programming
Tuning protection
DTC Failure Part
P0100
P0095
P0115
Programming
Alternator L-terminal system
Alternator F-terminal system
Brake switch signal error
Mass airflow sensor
Intake air temperature sensor
Coolant temperature sensor
Symptom
44
47
45
4A
46
4C
43
4D
00
04
08
07
03
01
56
4B
34
5A
4E
71
71
3B
48
Failure Mode
Security access not armed
Vehicle Identification Number (VIN) not programmed
Variant word not programmed
Tire circumference not programmed
Subnet Configuration List (SCL) is not defined
Engine identifier not programmed
Rejected reprogramming attempt of a critical engine identifier
Maximum Vehicle Speed (Vmax) limitation speed not programmed
Engine ECU internal engine torque supervisions
Alternator L-terminal duty ratio too high (at Key-ON test)
Alternator L-terminal duty ratio too low (at Run-test)
Alternator F-terminal ratio too high (at Key-ON test)
Alternator F-terminal ratio too low (at Run-test)
Permanently active (One or Both Brake error)
Brake switch sequence error {Brake Lamp Switch
(BLS) error}
SQL value not programmed
SQL value error
Variable Nozzle Turbo (VNT) hose popping off
Pump learning incompletion
All wheel signals set to invalid by sender ABS
Both non-driven wheel signals set to invalid by sender ABS
Engine identifier in engine ECU calibration and engine ECU-EEPROM are not matching
Illegal engine tuning protection
Symptom
07
06
02
07
03
07
03
02
Failure Mode
Mass airflow sensor signal too high
Mass airflow sensor signal too low
Mass airflow sensor performance invalid
Intake air temperature sensor signal too high
Intake air temperature sensor signal too low
Coolant temperature sensor signal too high
Coolant temperature sensor signal too low
Coolant temperature sensor performance invalid
Operation Section
1 15
DTC
P1120
P1122
P1120
P0235
P0180
P0190
P0409
P2226
P0110
P0500
P0530
P1571
P0571
P0512
P0704
P0520
P0335
P0340
Failure Part
Accelerator position sensor 1
Accelerator position sensor 2
Accelerator position sensor
Boost pressure sensor
Fuel temperature sensor
Rail pressure sensor
EGR lift (position) sensor
Atmospheric pressure sensor
Intake air temperature frequency sensor
Vehicle speed sensor
A/C pressure sensor
Brake system
Brake switch
Starter switch
Clutch switch
Oil pressure switch
Crankshaft position sensor
Cylinder recognition sensor
07
03
07
03
07
03
02
07
03
07
03
07
06
01
06
08
07
03
04
Symptom
07
03
07
03
08
02
01
08
08
01
06
08
04
04
08
04
08
Failure Mode
Accelerator position sensor No.1 signal too high
Accelerator position sensor No.1 signal too low
Accelerator position sensor No.2 signal too high
Accelerator position sensor No.2 signal too low
Accelerator position sensor signal performance
Invalid
Boost pressure sensor signal too high
Boost pressure sensor signal too low
Boost pressure sensor performance invalid
Fuel temperature sensor signal too high
Fuel temperature sensor signal too low
Rail pressure sensor signal too high
Rail pressure sensor signal too low
Rail pressure sensor signal keeping the middle range
EGR lift (position) sensor signal too high
EGR lift (position) sensor signal too low
Atmospheric pressure sensor too high
Atmospheric pressure sensor too low
Ambient temperature signal too high
Ambient temperature signal too low
Vehicle speed sensor frequency too high
Vehicle speed sensor input open/short
Vehicle speed sensor signal invalid
A/C pressure signal too high
A/C pressure signal too low
A/C pressure GND signal open
Recognition of a permanently active brake contact
(brake test switch)
Evaluation of vehicle deceleration (brake test switch)
Brake switch diagnostics; Cruise control brake switch no signal {Brake Lamp Switch (BLS)}
Starter switch short to battery
Starter switch open/short to GND
Clutch switch circuit malfunction (manual transmission only)
Oil pressure switch stuck open
Crankshaft position sensor no pulse
Crankshaft position sensor signal invalid
Cylinder recognition sensor no pulse
Cylinder recognition sensor signal invalid
Operation Section
1 16
DTC
P0016
Failure Part
Crankshaft position sensor / Cylinder recognition sensor
P0685
Main relay
P1625
P0641
P0651
P0380
P0683
P0685
P1625
P0645
P0403
P0201
P0203
P0204
P0202
P2146
P2149
P0606
Sensor reference voltage 1
Sensor reference voltage 2
Glow system
Main relay
A/C relay output
EGR control DC motor
Injector drive
Symptom
08
02
04
07
03
07
03
01
06
02
04
01
03
01
06
08
04
01
01
01
01
01
02
01
02
09
02
Failure Mode
Crankshaft position sensor/Cylinder recognition sensor signal synchronization error
Main relay diagnostics; Main relay stuck closed
Main relay diagnostics; Main relay stuck open/relay output open load
Sensor reference voltage output No.1 too high
Sensor reference voltage output No.1 too low
Sensor reference voltage output No.2 too high
Sensor reference voltage output No.2 too low
Glow controller command line short to battery; Glow controller internal malfunction
Glow controller command line open load/short to
GND; Glow controller internal malfunction
Glow plug R side short; Glow diagnosis line short to
GND; Glow controller internal malfunction
Glow plug R side open load; Glow diagnosis line open load; Glow controller internal malfunction
Main relay/relay output short to battery
Main relay/relay output short to GND
A/C relay output short to battery
A/C relay output open load/short to GND
EGR control DC motor Output 1 Short to battery/ short to GND output 2 short to battery/short to GND motor short
EGR control DC motor output 1 open load, output 2 open load; motor open load
TWV1 output open load; Injector #1 coil open
TWV2 output open load; injector #3 coil open
TWV3 output open load; injector #4 coil open
TWV4 output open load; injector #2 coil open
COM1 output short to battery; TWV1 or 3 output short to battery, both TWV1 and TWV3 open load
COM1 output short to GND; TWV1 or 3 output short to GND
COM2 output short to battery; TWV2 or 4 output short to battery, both TWV2 and TWV4 open load
COM2 output short to GND; TWV2 or 4 output short to GND
Capacitor charge-up circuit malfunction (insufficient charge)
Capacitor charge-up circuit malfunction (excessive charge)
Operation Section
1 17
DTC
P0602
P062F
P0093
P0088
P0087
P0001
P0094
P0088
P0217
P0219
P0601
P0606
P0301
P0302
P0303
P0304
P0400
P0299
P0234
P0243
P0660
P0638
P2620
Failure Part
QR code failure
Common rail system
Suction control valve (SCV)
SCV
Common rail system
Engine overheat
Engine overrun
Engine ECU internal failure
Injector 1
Injector 2
Injector 3
Injector 4
EGR system
EGR valve
Turbo system
Electric Vacuum Regulating Valve (EVRV);
Turbo
Variable swirl control (VSS) output (VSV)
Diesel throttle system
04
0B
03
01
08
04
04
04
0B
0B
0A
07
02
06
0B
02
02
01
06
01
06
Symptom
01
03
06
06
02
08
06
01
04
01
06
08
Failure Mode
QR code not programmed
QR code error
QR correction information is abnormal
Pressure limiter activated
Supply pump protection
Supply pump exchange
Supply pump malfunction (insufficient flow)
SCV(+) output short to battery; SCV(-) output short to battery
SCV(+) output Open Load/short to GND; SCV(-) output Open Load/short to GND; SCV coil open;
SCV coil short
SCV stuck
Rail pressure sensor performance invalid, Fuel leak
Rail pressure exceeds upper limit
Engine overheat
Engine overrun
Check sum error - flash area
CPU fault; -Main CPU fault
CPU fault; -Watchdog IC fault
Cylinder 1 fuel system failure
Cylinder 2 fuel system failure
Cylinder 3 fuel system failure
Cylinder 4 fuel system failure
EGR excessive flow (EGR positive deviation)
EGR insufficient flow (EGR negative deviation)
EGR valve open/close stuck
Turbo control system (negative deviation)
Turbo control system (positive deviation)
EVRV; Turbo output short to battery
EVRV; Turbo output open load/short to GND
VSS output (VSV) short to battery
VSS output (VSV) open load/short to GND
Diesel throttle controller output signal short to battery
Diesel throttle controller output signal open load/ short to GND
Diesel throttle controller failure status
Operation Section
1 18
DTC
P0425
P042A
P2452
P0480
P0481
P0482
U2100
U2108
U2107
U2104
P1811
U0405
P1610
P1611
P1612
P1613
P1614
Failure Part
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1)
Upper DPF temperature sensor (exhaust gas temperature 2)
Deferential pressure sensor
Fan relay 1 output
Fan relay 2 output
Fan relay 3 output
CAN communication
Torque control safety
Cruise switch
Immobilizer system
07
03
0B
08
01
06
01
06
01
06
0F
Symptom
07
03
04
07
03
04
00
00
01
08
09
00
08
00
04
00
00
00
00
04
Failure Mode
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) voltage too high
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) voltage too low
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1) temperature too high
Upper DPF temperature sensor (exhaust gas temperature 2) voltage too high
Upper DPF temperature sensor (exhaust gas temperature 2) voltage too low
Upper DPF temperature sensor (exhaust gas temperature 2) temperature too high
Differential pressure sensor voltage too high
Differential pressure sensor voltage too low
Differential pressure too high
Hose line disconnect upstream
Fan control relay 1 short to battery
Fan control relay 1 open load/short to GND
Fan control relay 2 short to battery
Fan control relay 2 open load/short to GND
Fan control relay 3 short to battery
Fan control relay 3 open load/short to GND
Node error
Lost communication with ABS/Traction Control System (TRC)
Lost communication with Body Control Module
(BCM)
CAN-bus reset counter overrun
Rolling counter failure
Protection value failure
Torque range resolution (IVLAN only)
Cruise control off switch diagnostics; IVLAN cruise switch status malfunction
Secret key/security code are not programmed yet
The Immobilizer 2 Control Unit (ICM2) function in engine ECU is switched off
Wrong security code received
Immobilizer identification abnormality
Immobilizer code incorrectly transferred
The transmitted transponder response was wrong
The transmitted response was falsified by ICM2
Operation Section
1 19
DTC
P0602
U2101
P0100
P242F
P2002
P2452
P0425
P042A
P2425
P0400
P1615
P1616
P0409
P0168
P0650
P0720
P0500
P062F
P0571
P1571
P1602
P062F
P0299
Failure Part
Programming
CAN communication
Mass airflow sensor
DPF system
Upper oxygen catalyst temperature sensor
(exhaust gas temperature 1)
Upper DPF temperature sensor (exhaust gas temperature 2)
EGR cooler bypass
EGR DC motor
Vehicle ID
EGR valve
Fuel injection quantity reduction
Check engine warning light
NE output
ABS
DPF system
Brake switch signal error
Microinjection quantity learning (SQL)
Popping-off
Symptom
00
04
08
08
08
06
0B
07
02
02
02
01
06
02
00
00
02
0B
01
04
08
04
00
01
01
06
04
0B
04
0A
Failure Mode
System not programmed/seed & key not armed
Vehicle Identification Number (VIN) not programmed
Variant not programmed
Maximum list of control modules or vehicle configuration list is not programmed
Mass airflow sensor too low
DPF over loaded
DPF over loaded 2
Regeneration not completed
Differential pressure sensor characteristic abnormality
Upper oxygen catalyst temperature sensor
(Exhaust gas temperature 1) sensor characteristic abnormality
Upper DPF temperature sensor (exhaust gas temperature 2) sensor characteristic abnormality
EGR cooler bypass output short to battery
EGR cooler bypass output open load/short to GND
EGR DC motor lock
Incorrect Vehicle ID Body Control Module (BCM) received
Incorrect Vehicle ID Immobilizer Control Unit (ICM) received
EGR lift sensor characteristic abnormality
Fuel injection quantity reduction diagnosis by exhaust temperature
Check engine warning light short to battery
Check engine warning light open load/short to GND
Engine speed output to battery
Engine speed output short to GND
All wheel signals invalid by sender ABS
Electronically Erasable and Programmable Read
Only Memory (EEPROM) failure
Permanently active {Brake Lamp Switch (BLS) error}
Brake switch sequence error (BLS error)
Brake switch event error {Brake Test Switch (BTS) error}
SQL value not programmed
SQL value error
Variable Nozzle Turbo (VNT) hose popping off
Operation Section
1 20
DTC
P1602
P0110
P1600
Failure Part
Pump learning
Programming
Tuning protection
Programming
Intake air temperature analog sensor
Programming
Symptom
0E
0A
08
0C
03
01
02
00
Failure Mode
Pump learning incomplete
Engine identifier in engine ECU calibration and engine ECU-EEPROM are not matching
Illegal engine tuning protection
Engine identifier not programmed
Rejected reprogramming attempt of a critical engine identifier
Intake air temperature sensor analog signal too high
Intake air temperature sensor analog signal too low
Engine ECU-internal engine torque supervisions
1 21
Operation Section
7. EXTERNAL WIRING DIAGRAM
7.1 Engine ECU External Wiring Diagram
Operation Section
1 22
Operation Section
1 23
7.2 Engine ECU Connector Diagram
Engine ECU Connector Pin Layout
Terminal Connections (A-side, pins 1-48)
No.
1
3
5
6
7
8
9
Pin Symbol
COMMON2
TWV4
SCV-
THF-GND
THW-GND
LVNT-GND
LVSS-GND
Connections
Injector common 2
Injector #2
No.
Pin Symbol
25 COMMON2
26 TWV2
27
Suction control valve (SCV) (-)
Fuel temperature sensor (GND)
28
29 SCV+
30 THF
Coolant temperature sensor (GND) 31 THW
Variable nozzle turbo position sensor (GND)
32 LVNT
Variable swirl control position sensor
(GND)
33 LVSS
10 LEGR-GND
11 PIM-GND
EGR position sensor (GND)
Boost pressure sensor (GND)
12 PFUEL-GND Rail pressure sensor (GND)
13 PFUEL-SLD Rail pressure sensor (Shield)
34 LEGR
35 PIM
36 PFUEL
37 PFUEL
14 MAF-GND Mass airflow sensor (GND) 38 IAT
15 PExhD-GND Differential pressure sensor (GND)
16 THExh1-GND
Exhaust temperature sensor 1
(GND)
17
18
THExh2-GND
THExh3-GND
39
40
PExhD
THExh1
Exhaust temperature sensor 2
(GND)
Exhaust temperature sensor 3
(GND)
41
42
THExh2
THExh3
Cylinder recognition sensor (Shield) 43 G+ 19 G-SLD
20 NE-SLD
21 VNT-
22 VNT+
23
24
Crankshaft position sensor (Shield)
Variable nozzle turbo DC motor (-)
Variable nozzle turbo DC motor (+)
44
45
46
47
48
G-
NE+
NE-
Connections
Injector common 2
Injector #3
Suction control valve (SCV) (+)
Fuel temperature sensor (Signal)
Coolant temperature sensor (Signal)
Variable nozzle turbo position sensor (Signal)
Variable swirl control position sensor
(Signal)
EGR position sensor (Signal)
Boost pressure sensor (Signal)
Rail pressure sensor (Signal)
Rail pressure sensor (Signal)
Intake air temperature sensor 2
(Signal)
Differential pressure sensor (Signal)
Exhaust temperature sensor 1 (Signal)
Exhaust temperature sensor 2 (Signal)
Exhaust temperature sensor 3 (Signal)
Cylinder recognition sensor (+)
Cylinder recognition sensor (-)
Crankshaft position sensor (+)
Crankshaft position sensor (-)
Operation Section
1 24
Terminal Connections (A-side, pins 49-96)
No.
Pin Symbol
49 COMMON1
50
51 TWV3
52
53
54 SPAD-VCC
Connections
Injector common 1
Injector #4
55
56
57
58
VNT-DI
LOIL-SW
POIL-SW
LVNT-VCC2
Spare
Variable nozzle turbo actuator diagnosis
OIL level SW signal
OIL pressure SW signal
Variable nozzle turbo position sensor (VCC)
59 LVSS-VCC2
Variable swirl control position sensor
(VCC)
60 LEGR-VCC2 EGR position sensor (VCC)
76
77
78
No.
Pin Symbol
73 COMMON1
74 TWV1
75
79
80
81
82
83
84
I/T-DI
ACG-F
ACG-L
S-SW1
S-SW2
S-SW3
61 PIM-VCC2
62 PFUEL-VCC2 Rail pressure sensor (VCC)
63 PExhD-VCC2 Differential pressure sensor (VCC)
64 G-VCC2 Cylinder recognition sensor (VCC)
65 E-VCC1
66
67
68
69
70
IAT-FRQ
MAF-FRQ
CAN-H
CAN-L
71 SP-FRQ
72 EGR-
Boost pressure sensor (VCC)
Crankshaft position sensor (VCC)
Mass airflow sensor air temperature frequency
Mass airflow sensor frequency
CAN High
CAN Low
Spare
EGR DC motor (-)
85 IAT-ANG
86 EGR-GND
87 BY-PASS
88
89
S-REL2
S-LMP1
90 INT-CS
91 VNT
92 VSS
93
94
95 SP-FRQ1
96 EGR+
Connections
Injector common 1
Injector #1
Diesel throttle controller diagnosis
ACG F-terminal (Alternator) *1
ACG L-terminal (Alternator) *1
Spare
Spare
Spare
Mass airflow sensor air temperature
Analog
EGR shield
EGR By-pass Valve
Spare
Spare
Diesel throttle controller (Signal)
Turbo solenoid
Variable swirl control solenoid
Spare
EGR DC motor (+)
< NOTE >
*1 : Meriva only
Terminal Connections (B-side, pin 58)
No.
Pin Symbol
1 GND
2 GND
3 P-GND
4 P-GND
5 +B
6 +B
Signal, sensor GND
Signal, sensor GND
Power GND
Power GND
Power +B
Power +B
Connections No.
33
Pin Symbol
30 LFUEL
31
32 CASE-GND
GL-DI
34 RG-SW
35 LW-SW
36 FAN1
Connections
Fuel level signal
Case GND
Glow controller diagnosis
Reverse gear switch
Water level switch
Fan 1
Operation Section
1 25
No.
Pin Symbol
8 STT-SW
9 IG-SW
10 IG-SW
11
12
13
14 ACCP1-GND
15
16 PAC-GND
17 LFUEL-GND
18
19
20 GMLAN-H
21 GMLAN-L
22
23 CL-SW
24 BK2-SW
25 BK1-SW
26 EH-SW
27
28
29
ACCP2-GND
ACCP1
ACCP2
PAC
< NOTE >
*1 : Meriva only
Starter switch
Ignition 1
Ignition 0
Connections
*1
No.
37 SPD
38 KWP2000
39
Pin Symbol
40 ACCP1-VCC1
41 ACCP2-VCC2
42 PAC-VCC2
Accelerator position sensor 1
(GND)
Accelerator position sensor 2
(GND)
A/C pressure sensor (GND)
Fuel level return
GMLAN High
GMLAN Low
Clutch switch
Brake 2 switch
Brake 1 switch
Electrical heater switch
Accelerator position sensor 1 (Signal)
Accelerator position sensor 2 (Signal)
A/C pressure sensor (Signal)
43
44
45
46
47 ACT-REL
48 FAN3-REL
49 NEOUT
50 FUELOUT
51 MIL
52 FH-REL
53 GL-CS
54 FAN2-REL
55 STT-REL-L
56
57
58
STT-REL-H
M-REL
Connections
Vehicle speed sensor
*1
ISO 14230 *1
Accelerator position sensor 1
(VCC)
Accelerator position sensor 2
(VCC)
A/C pressure sensor (VCC)
Starter relay HSD
A/C cutoff relay
Fan 3 relay
Engine speed output
*1
Fuel quantity output *1
Check engine warning light *1
Fuel heater relay
Glow controller signal
Fan 2 relay
Starter relay LSD
Powertrain main relay
Published : January 2007
Edited and published by:
DENSO CORPORATION
Service Department
1-1 Showa-cho, Kariya, Aichi Prefecture, Japan
