Epic Service Manual

Service Workbook
EPIC D.I. Engine Management System

i
EPIC
ELECTRONIC PROGRAMMED INJECTION CONTROL
Service Workbook
This Service Workbook covers the EPIC engine fitted to LDV vehicles. It is primarily designed to assist skilled
technicians in the efficient repair and maintenance of this system, but can also be used as a reference workbook for
training purposes.
This Service Workbook should always be consulted prior to servicing or repair work.
SPECIFICATION
LDV (the Company) reserves the right to change the procedures, material, specification, dimensions or design of the
vehicles shown, described or referred to herein at any time and without prior notice in accordance with the Companys
policy of constant product improvement.
Every reasonable effort is made to ensure that the Companys publications are accurate, but nothing shown,
described or referred to herein should be regarded as an infallible guide to the procedures, materials, specifications,
dimensions, design or availability of any particular vehicle, nor does this publication constitute an offer for the sale
of any particular vehicle. No liability can be accepted by the Company or any Distributor or Dealer for any
malfunction, damage, loss, injury, or death caused by the use of incorrect or misinterpreted information, omissions
or errors that may have arisen during the preparation of this workbook.
Purchasers are advised that the specification details set out in this publication apply to a range of vehicles and not
to any particular vehicle. For the specification of any particular vehicle, purchasers should consult their LDV
Distributor or Dealer. Please note that LDV Distributors and Dealers are not agents of the Company, and have no
right or authority whatsoever to bind the Company in any way, or to assume on its behalf any obligation expressed
or implied.
COPYRIGHT
LDV 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any
form, whether electronic, or mechanical, or by photocopying, recording or other means without prior permission in
writing of LDV.
Published by LDV. Further copies may be obtained through your normal literature ordering procedure.
LDV Limited
Training & Publications
Bromford House
Drews Lane
Birmingham
B8 2QG June 2001 DW03963004
EPIC DI Engine Management System Diagnostics
i
iii
Notes
In some circumstances it may be possible for an
electrical connector pin to become displaced axially, thus
creating a poor connection or an opencircuit. That
action is referred to in this Manual as Backing off.
The expression ground refers to any metallic part of the
engine or vehicle structures which is electrically
connected to the battery negative terminal.
Certain signals which may be displayed on the Laser
2000 screen are known as internal variables. For
clarification, their names are shown in uppercase letters
in this Manual e.g.: EGR VALVE POSN which
represents the feedback from the EGR valve position
sensor.
BOB BreakOutBox
CVT CurrenttoVacuum Transducer
EVR Electrical Vacuum Regulator
DCU Diesel Control Unit
EGR Exhaust Gas Recirculation
EMS Engine Management System
ESOS Electric Shut Off Solenoid
HPDS High Pedal Demand Switch
LPDS Low Pedal Demand Switch
NOx Nitrous Oxide
PATS Passive Antitheft System
PDS Pedal Demand Sensor
PWM Pulse Width Modulation
SCP Standard Communications Protocol
TP Transfer Pressure
Key on The action of turning the Ignition key
Key off to the on/off positions
Precrank Ignition key on, engine stationary prior
to starting
Stalled Engine has stopped for reasons other
than being switched off
OV Chassis Ground
+Bat Battery Voltage
Wiggle Test A test used to find intermittent wiring
faults. It involves agitation of the wiring
harness, particularly close to
connections.
Abbreviations
ii
Contents
Introduction
1
Diagnostics Procedure
2
Noncoded Faults
3
Coded Faults
4
Technical Information
5
i
Contents
i
iv
Introduction
1.1 The EPIC Dl system 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Safety precautions .... 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Tools and training 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 System 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1 Coded faults. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2 Noncoded faults 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Prcoedure 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Initial inspection .. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Flowchart 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Laser 2000 and examination of fault codes 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Location of the DCU . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5 Electrical testing 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.6 Actuator tests 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Repair 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Idle trim setting ... 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Backleak trim setting ... 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noncoded Faults
3.1 EMS warning lamp fails to switch on 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Engine stops whilst driving or idling, and will not restart whilst cranking 7 . . . . . . . . . . . . . . . . . .
3.3 Engine will not start, or is difficult to start after normal engine stop 7 . . . . . . . . . . . . . . . . . . . . . . .
3.4 Unstable hot idle, low power, slow acceleration, stalling or poor pull away 8 . . . . . . . . . . . . . . . .
3.5 Reduced power (excessive smoke) . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Smoke at low engine speed (fullload) 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Reduced power (with no smoke) 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Engine does not stop instantly on key off 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coded Faults
4.1 Pump rotor control 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Electric shutoff solenoid (ESOS) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Pump cam control and pump temperature sensor 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Calibration resistor 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Pump speed sensor (drive shaft position) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Pedal sensor control 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Engine speed sensor (crankshaft position) 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Engine coolant temperature sensor 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Air charge temperature sensor 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Exhaust gas recirculation (EGR) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 Boost pressure sensor 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Power hold relay, keyswitch and battery circuit 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Enginetopump synchronisation (pump boltup limits) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 DCU 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Passive antitheft system (PATS) 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Dynamic data 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Vehicle wiring diagram (MY95) 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Component location 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 DCU multiplug pin identification 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Resistance values 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Pulsewidth modulation 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
1
Introduction
1
1.1 THE EPIC Dl SYSTEM
The Lucas EPIC Diesel Fuel injection system provides
electronic control of both the amount of fuel injected and
the timing of injection in order to optimise exhaust
emissions and fuel economy. The system comprises a
rotary fuel injection pump (with electrical actuators and
sensors), a Diesel Control Unit (DCU), various engine
and vehicle sensors, a power hold relay, battery, key
switch, and harness.
NOTE When a DCU is fitted to a vehicle/engine
combination, it must be configured to suit that
specific application. A DCU may not be
transferred between vehicles fitted with Passive
AntiTheft (PATS).
The LDV 4EA 2.5TC engine is fitted, rated at 100 PS.
The Laser 2000 communicates with the DCU using the
Standard Communications Protocol (SCP). The Laser
2000 requires hardware and software modules,
diagnostic lead, and Break Out Box (BOB) to connect to
the 55pin DCU.
Vehicle Configuration
Screen
Refer to Section 2.6 Refer to Section 2.5
Start Up Menu
Title Screen
Diagnostic Menu Display Stored Data Backleak Trim Mode Idle Trim Mode
Display/
Clear
Faults
Clear Fault Codes
Read Fault Codes
Print Fault Codes
Store Fault Codes
Dynamic
Display
Dynamic
Recording
EXIT SETUP PAGE TRIG LIVE
1. Select Displayed Parameters
2. Select Position of Trigger
3. Select Trigger Type
4. Wiggle Tests
Actuator
Tests
Gearbox Shift Solenoid
Gearbox Kickdown Solenoid
'Check Engine' Lamp
Air-Conditioning Clutch
Power Hold Relay
Pump Cam Actuator
Gearbox Shift Solenoid
Gearbox Kickdown Solenoid
EGR Current-to-Vacuum
Air-Conditioning Clutch
Engine Shut-Off Solenoid
Pedal Demand
Key on,
engine
running
Key on,
engine
stationary
Diagnostic Charts
DCU-Identification
Fig. 1 Laser 2000 Menu Structure
A045-002
Transfer Stored Data
Introduction
1
2
1.2 SAFETY PRECAUTIONS
1 For on the road tests using a LASER 2000, the
vehicle must be driven by an assistant.
NOTE UNDER NO CIRCUMSTANCES MAY
THE LASER 2000 BE LEFT CONNECTED
TO THE VEHICLE SYSTEM FOR ANY
TESTING BY THE OWNER/DRIVER. IT
SHOULD ONLY BE USED BY AN
EXPERIENCED TECHNICIAN.
2 Observe normal Health and Safety precautions
when working with fuel systems, e.g. no smoking,
no naked lights, and beware of the very high
pressures generated within the injection system.
3 Ensure that the gear selector is in neutral and
the parking brake is on when working on a
stationary vehicle with the engine running.
4 If working in a confined area use exhaust fume
extraction, or ensure adequate ventilation, whilst the
engine is running.
5 Beware of moving engine parts when the engine
is running.
6 Cleanliness should be observed at all times.
7 Ensure that any spilt fuel is thoroughly cleanedup.
8 Incorrect electrical connections may damage
sensitive electronic devices fitted to the vehicle.
9 Do not work on a vehicle whilst the battery is
being charged from an external power source.
10 Ensure that all cables are clear of hot or moving
parts. For ontheroad tests ensure that all cables
and test equipment are secure and will not impede
driving.
11 DO NOT disconnect the battery whilst the engine
is running.
12 DO NOT fast charge the battery without
disconnecting it from the vehicles electrical system.
13 Switch off the vehicle key switch before making
or breaking electrical connections.
NOTE REFER TO THE PRECAUTIONS
AND PRELIMINARY TESTS LISTED IN
THE LASER 2000 OPERATING
INSTRUCTIONS (Pub. No. XXB875).
2
3
2.1 TOOLS AND TRAINING
To enable faultfinding the following tools are required:
Laser 2000 Equipment
Laser 2000 kit YWB700 . . . . . . . . . . . . .
Diagnostic Cable YWB776 . . . . . . . . . . .
Software Module YDS120 (language) . . . . . . . . . . .
Hardware Module YWB722 . . . . . . . . . .
BOB Equipment
BOB YWB741 . . . . . . . . . . . . . . . . . . . . . .
Adaptor Box YDA200 . . . . . . . . . . . . . .
PumptoBOB Cable YDA287 . . . . . .
Static Timing Device YWB317 . . . . . .
Pressure & vacuum test kit LDV141 . .
NOTE If a Laser 1500 is available, the BOB (YWB741)
is not required but Adaptor Box YDA200 and
Cable YDA287 are.
During testing of the electrical and electronic equipment
a digital multimeter is essential, preferably with the facility
for measuring duty cycles (such as Lucas YWB208).
NOTE If the YWB208 multimeter is not available, any
good quality digital multimeter may be used.
However, if the instrument is not of the autoranging
type, ensure that its sensitivity is set to suit the range
of the parameter being measured. (In addition, the
meter must have a dutycycle measuring facility).
Users of this publication must have previously attended
a LDVapproved training course and be fully conversant
with the use of the Laser 2000 diagnostic equipment.
2.2 SYSTEM
The DCU controls all the major functions of the EPIC
fuel injection system. It also detects when the system is not
functioning correctly. When that happens, a faultcode
related to the fault is logged within the DCU and the Engine
Management System (EMS) lamp on the dash board (see
fig. 3) is illuminated. The logged code(s) may be retrieved
using the Laser 2000. A fault which is recognised by the
DCU is known as a coded fault; any other faults are known
as noncoded faults and are not displayed by the Laser
2000.
Fig. 3 EMS lamp Symbol
A045-007
2.2.1 Coded Faults
Coded Faults occur when:
An input is outside preprogrammed limits. That could be
due to faulty connectors, wiring or sensor.
An input is within preprogrammed limits but is not changing
as is expected by the DCU. A possible fault could be that of
an actuator that is seized or worn.
Fault Codes are split into two types:
Current Faults The fault persists and continues
during fault diagnosis. That could be
due to a complete disconnection of a
wire or connector.
Intermittent Faults The fault will be logged by the DCU
but may not be apparent during
subsequent diagnosis. That type of
fault could be due to a loose or
partiallydamaged wire.
2.2.2 NonCoded Faults
Not all faults which occur on the vehicle will be logged by
the DCU. Those faults can be diagnosed with the aid of
the Diagnostics Flowchart (see fig. 4) and section 3 of this
Manual.
HARDWARE
MODULE
(YWB722)
DIAGNOSTIC
CABLE
(YWB776)
TO VEHICLE
DIAGNOSTIC
CONNECTOR
SOFTWARE
MODULE
(YDS 120)
LASER 2000
Fig. 2a Connection of the LASER
A045-005
1500
BREAK-OUT BOX
(YWB741)
or
LASER 1500
(YWB703)
YDA287
TO PUMP
YDA200
TO VEHICLE
120 WAY BOB
Fig. 2b Connection of the BOB
A045-006
2
4
Intermittent fault codes
Yes
No
No Fault Logged
Current
fault
codes
Yes
No
No
Yes
Vehicle satisfactory
Use Snap-Shot mode
on Laser 2000
Drive vehicle or
agitate harness
Read Fault
Logged
Use original Fault Codes
for guidance
Go to relevant section
of Manual
Fault
Diagnosed
Read
fault
codes
Fault
rectified
Refer to
Coded Faults
section of
Manual
Refer to
Non-Coded
Faults section
of Manual
Repair Repair
Vehicle Fault
Read safety instructions in Section 1.3
Initial Inspection
Connect Laser 2000
Read Fault Codes
Record Codes
Clear Codes on Laser 2000
B
B
A
A
Fig. 4 Diagnostics Flowchart
A045-008
2
5
2.3 PROCEDURE
2.3.1 Initial inspection
Before connecting the Laser 2000 carry out an initial
inspection of the vehicle to ensure that there is fuel in the
tank, that there are no blocked airways, and no fuel leaks
or loose pipes.
2.3.2 Flowchart
The Diagnostic Flowchart (see fig. 4) indicates the
procedure which should be followed when diagnosing
problems.
2.3.3 Laser 2000 and examination of Fault Codes
The Laser 2000 may display more than one fault code. If
that is the case, investigate the codes in the sequence
that the Laser 2000 displays them.
Remember that if a sensor is disconnected whilst the
ignition is on, a fault code will be logged by the DCU. Fault
codes could be induced by the driver tampering with
engine components and disconnecting sensors. Clear
these codes using the Laser 2000, then retest the
vehicle to ensure that only genuine fault codes are
displayed.
For future reference, record all fault codes.
If coded faults are displayed, go directly to the section of
this Manual relevant to that code using the index on the
inside rear cover.
If the vehicle is not running correctly, and codes are
not displayed by the Laser 2000, refer to the NonCoded
Fault section of this Manual.
SNAP SHOT MODE is of particular use when
diagnosing intermittent faults. The Laser 2000 records
data internally until a fault is identified. All the data is then
stored in memory and can be examined later. When
examining stored data after SNAP SHOT look for:
Outoflimits values.
Sudden changes to the data.
Current faults cause all the dynamic data to lock at
their default values when the engine is running.
However the dynamic data is still valid during
cranking. This is of use for faultfinding on engines
which will not start.
2.3.4 Location of the DCU
See section 5.3 & 5.4 for the location of the DCU.
2.3.5 Electrical Testing
Only basic testing is required to determine if the
electrical circuits are functional. The tests below describe
the procedures:
(If the result of the test is the same as that described,
there is a fault.)
a) Opencircuit.
Check the resistance between the pins specified in the
diagnostic procedure. Infinite resistance indicates an
opencircuit.
A resistance reading higher than specified, but less than
infinity, indicates either corroded or loose connections, or
a partial break in the wire strands.
b) Shortcircuit.
Check the resistance between the pins specified in the
diagnostic procedure. Measured resistances below
infinity can indicate a partial shortcircuit.
A resistance reading lower than specified indicates a
short circuit.
c) Shorttoground.
Check the resistance between the pin(s) specified in
the diagnostic procedure and BOB connection 54.
A low resistance indicates a shorttoground.
d) Short to +BAT.
Turn the ignition switch to position ll. Check the voltage
between the pin(s) specified in the diagnostic procedure
and BOB connection 54 (OV). If the meter reads battery
voltage a short to +BAT exists.
Whilst carrying out these tests, agitate the harness close
to the connections. If the results are unstable there is an
intermittent break in the circuit.
2.3.6 Actuator Tests
Using the ACTUATOR TESTS option, accessed from
the Diagnostics Menu, individual actuators can be tested
and their operation confirmed. The following items can be
tested:
ENGINE RUNNING
Gearbox shift solenoid
Gearbox kickdown solenoid
EGR CVT
Airconditioning clutch
ESOS
PDS
ENGINE STATIONARY (KEYSWITCH ON)
Gearbox shift solenoid
Gearbox kickdown solenoid
EMS lamp
Airconditioning clutch
Powerhold relay
Advance actuator
2
6
2.4 REPAIR
After diagnosis it may be possible to repair a fault in
the workshop. Procedures for all the possible workshop
repairs are documented in the relevant Lucas Workshop
Manual.
2.5 IDLE TRIM SETTING
Using the IDLE TRIM MODE option, the idle speed can
be adjusted within a range of 50 rpm from the nominal
idle speed to eliminate or reduce vehicle body vibrations.
Check the following items before carrying out the idle
setting procedure:
There must be no CURRENT or
lNTERMlTTENT faults.
The engine must be running.
The engine coolant temperature must be
above 70 C.
The accelerator pedal must be fully
released.
If airconditioning is fitted it must be switched
off.
The vehicle must be in neutral with the clutch
engaged, or in PARK if automatic.
1 Connect the LASER 2000 to the diagnostic plug in
the vehicle fuse box (see Section 5.4).
Start the engine and allow it to idle.
2 Switch on the Laser 2000, select IDLE TRIM
MODE from the MAIN MENU.
3 Control the idle speed using the accelerator pedal
(fully raised = minimum idle speed, fully depressed
= maximum idle speed).
4 When the idle speed is correct, set it using key F5.
The revised idle speed will then be stored in the
DCU.
2.6 BACKLEAK TRIM SETTING
Using the BACKLEAK TRIM option, finetuning of the
idling delivery can be achieved to eliminate or reduce
body vibrations and improve other pump characteristics.
Before carrying out this procedure
There must be no CURRENT or
INTERMITTENT faults.
The engine must be running.
The engine must be at normal operating
temperature (i.e. coolant temperature must be
above 77C, or the pump temperature must be
above 30C).
The accelerator pedal must be fully released.
If airconditioning is fitted it must be switched off.
The vehicle must be in neutral with the clutch
engaged, or in PARK if automatic.
1 Connect the LASER 2000 to the diagnostic plug in
the vehicle EPIC fuse box (see Section 5.3 & 5.4).
Start the engine and allow it to idle.
2 Switch on the Laser 2000, select BACKLEAK TRIM
MODE from the MAIN MENU.
3 The DCU will be set to the backleak trim mode; this
will take approximately 10 seconds to execute.
On completion, LASER 2000 will display the status,
i.e. BACKLEAK TRIM SUCCESSFUL or
UNSUCCESSFUL and return to the MAIN MENU.
3
Noncoded Faults
7
3.1 EMS WARNING LAMP FAILS TO SWITCH
ON
Ensure that the EMS warning lamp is illuminated for a
short period after keyon. If the bulb fails to illuminate
then:
Check for failed bulb
Check that the EMS lamp is not obscured
Check EMS lamp electrical connections.
Check on BOB connector pins 44 and 47 for continuity
of the lamp circuit, and pins 45 and 20, with key switch
on, for battery voltage (+BAT).
3.2 ENGINE STOPS WHILST DRIVING OR
IDLING, AND WILL NOT RESTART
WHILST CRANKING
Check for fuel in tank, and type i.e. not petrol.
Check that the ducting to the air filter and
turbocharger is clear.
Ensure that there is no water in the fuel. If so:
Drain the fuel filter (and the tank if necessary),
Check that the water sensor is operating.
Check for fuel leaks or loose fuel pipe connections.
Check for restriction in the fuel tank vent causing the
tank to implode, i.e. remove the filler cap.
Fit a pressure/vacuum gauge in the fuel feed line to
the pump, and crank the engine. The pressure should
read positive. If it does not, check the following:
Restriction in the fuel feed or return.
The age of the fuel filter. Replace it if any doubt.
Failed mechanical fuel pump.
The key power circuit (refer to SCP fault code 1191).
The powerhold relay circuit (refer to SCP fault code
1606) .
The battery supply to the DCU (refer to SCP fault code
9671).
Operation of the fuel injection pump by slackening
the injector pipe at any injector and note the fuel
discharge at the connector whilst cranking.
3.3 ENGINE WILL NOT START, OR IS DIFFICULT
TO START AFTER NORMAL ENGINE STOP
Check cranking speed and battery condition.
Check operation of the fuel injection pump.
Slacken the injector pipe at any injector and note
fuel discharge at connector whilst cranking.
If fitted, check the Flamestart system (see fig. 5).
Disconnect the fuel supply from the Flamestart
heater element. Activate the system and check fuel flow
to the element.
Check the voltage supply to the element.
Remove the element, reconnect the fuel supply
and ensure that the voltage supply to the element
is disconnected. Activate the system and if fuel does
not flow from the element, rectify or replace the element.
Remove the element, connect the voltage supply
and earth, and ensure fuel supply is disconnected.
Activate the system and renew the element if it does not
glow.
Check pumptoengine timing.
Follow procedures as for section 3.2.
Noncoded Faults
3
8
3.4 UNSTABLE HOT IDLE, LOW
POWER, SLOW ACCELERATION,
STALLING OR POOR PULL AWAY
Check that the air ducting to the air filter
and turbocharger is clear.
Read FUEL DEMAND on LASER 2000 whilst idling
hot and carry out BACKLEAK TRIM.
Check that correct grade of fuel is being used. If
Winter grade or City class fuel is being used, carry
out BACKLEAK TRIM.
If CYL3 IDL FUEL, CYL1 OFFSET, CYL2 OFFSET,
CYL4 OFFSET readings on the LASER 2000 show
one value significantly different to the others, check the
injectors and engine condition i.e. valve clearances
etc.
For a high mileage vehicle that has had no fuel
injection pump or pump actuator changes, read and
note the LASER 2000 DYNAMIC DISPLAY Values; If
the ROTOR DELAY A value is greater than 35, change
the pump horizontal actuator pair. If the ROTOR
DELAY B value is greater than 50, change the pump
vertical actuator pair.
Check cylinder compressions.
3.5 REDUCED POWER (EXCESSIVE SMOKE)
Check that the air ducting to the air filter
and turbocharger is clear.
Check that the throttle valve is operating.
Check for restrictions in the exhaust system.
Check that the boost sensor hose is attached, and
for leaks from, and restrictions in, it.
Check that the EGR valve is closing by removing the
pipe to the valve, and noting if the valve makes a click
when it closes.
If no faults are found, replace the boost sensor.
3.6 SMOKE AT LOW ENGINE SPEED (FULL
LOAD)
Carry out BACKLEAK TRIM (see Section 2.6).
Check throttle operation.
Replace the boost sensor.
3.7 REDUCED POWER (WITH NO SMOKE)
Check that the ducting to the air filter and turbocharger
is clear.
Fit a pressure/vacuum gauge in the fuel feed line to
the pump, and crank the engine. The pressure should
read positive. If it does not, check the following:
Restriction in the fuel feed or return.
Age of the fuel filter. Replace if any doubt.
The mechanical pump.
For fuel leaks.
Check that the EGR valve is closing by removing the
pipe to the valve, and noting if the valve makes a click
when it closes.
Check that the airconditioning is not
permanently operating.
Check the fuel injection pump.
3.8 ENGINE DOES NOT STOP INSTANTLY ON
KEYOFF
DCU pin 38 shorted to +BAT (DCU pin 47). This will
cause the fuel injection pump ESOS to overheat and
burn out.
The springloaded plunger of the ESOS will not
close possibly due to debris contamination.
If the engine does not stop within 10 seconds then
fault code 1170 will be logged by the DCU.
4
Coded Faults
9
4.1 PUMP ROTOR CONTROL
Applicable codes : 1171, 1172, 1173, 1198
Description of Operation:
The Rotor A and Rotor B actuators control the
axial displacement of the pump rotor, and hence the
quantity of fuel injected. Opening Rotor A (feed) actuator
decreases fuel, and opening Rotor B (drain) actuator
increases fuel. The rotor sensor monitors the axial
position of the rotor. Either rotor A or rotor B actuator is
driven with a pulse from the DCU, whose duration is
related to the difference between the required
rotor position, (ROTOR DEMAND), and the measured
rotor position, (ROTOR FEEDBACK) . Calculation of the
required rotor position is based upon some or all of the
following input signals:
Throttle pedal demand
Internal fuel mapping
Boost pressure
Engine air inlet temperature
Engine speed
EGR valve position
The temperature compensation resistor is built into the
rotor position sensor. Its thermal characteristic is in
opposition to that of the sensor, thus eliminating drift of
the rotor position signal due to temperature changes.
Functions and Components Involved:
Transfer pressure
Rotor A (feed) actuator
Rotor B (drain) actuator
Rotor/drive shaft assembly
Rotor position sensor (including the temperature
compensation resistor)
Backleak
DCU
Harness
1171 ROTOR POSITION
This fault code will be displayed if the DCU identifies
either:
i) that the sensor resistance is outside limits e.g.
opencircuit, shortcircuited to ground or to +BAT.
ii) an accidental connection to ground or +BAT.
iii) that the temperature compensation resistor is outside
limits e.g. opencircuit or shortcircuit.
iv) that there is no feedback to the DCU.
The vehicle will show symptoms of greatly reduced power
and impaired driveability.
Perform the following:
1 Ensure that the keyswitch is off. Remove the
connector from the DCU and check pins for
damage, incorrect engagement etc.
If there are no faults, go to 3, otherwise, go to 2.
2 If damage is apparent, repair it and retest the
vehicle.
9
12
6
41
42
47
48
14
13
17
10
7
11
6
2 1
3
4
1 Rotor position sensor
2 Temperature compensation resistor
3 Rotor feed actuator
4 Rotor drain actuator
DCU
Connector
Pins
Pump
Connector
Pins
A045-009
3 Fit the BOB. Test and record values for:
a) opencircuit
b) shortcircuit
c) shorttoground
d) short to +BAT
on BOB pins 9 & 6, and 9 & 12 (see table 1 in Section
5.6 for Rotor Position Sensor and Rotor
Compensation Resistor values).
4 Remove the BOB and reconnect the harness to the
DCU . Clear any fault codes and retest the vehicle. If the
fault(s) still occurs change the DCU.
5 Remove the connector from the pump and check the
pins for damage, incorrect engagement etc.
6 If damage is apparent, repair it, and retest the vehicle.
7 Fit the BOB, with the adaptor cable, to the pump
connector. Test and record resistance values for:
a) opencircuit
b) shortcircuit
on BOB pins 14 & 17, 14 and 13. (See table 1 in
Section 5.5 for Rotor Position Sensor and Rotor
Compensation Resistor values).
8 There is a fault with the rotor sensor assembly.
Repair the pump and retest the vehicle.
9 There is a fault with the vehicle harness. Repair it,
and retest the vehicle.
Coded Faults
4
10
1172 PUMP ROTOR CONTROL OVERFUELLING
1198
PUMP ROTOR CONTROL UNDERFUELLING
The vehicle symptoms are:
i) For code 1172 the engine will stop
ii) For code 1198 unstable idling and stalling.
For intermittent faults go to test 1.
For current faults go to test 2.
1 Start the engine and allow it to idle, connect the
LASER 2000 and read the DYNAMIC DISPLAY
values, ROTOR DEMAND, and ROTOR
FEEDBACK. Note the difference between the two
values. Use the SNAP SHOT facility to assist in this
test.
If the DEMAND and FEEDBACK difference is 5 or
less, go to test 2. If greater than 5, got to test 6.
2 Fit a pressure/vacuum gauge in the fuel feed line to
the pump and run the engine. In neutral gear and at
full throttle, the pressure should read positive,
approx. 0.2 bar when warm and less when cold.
3 If the pressure reading is below zero (i.e. a vacuum),
check the fuel supply circuit from tank to pump e.g.
filter and lift pump, and for imploded fuel tank or
pipes etc., and rectify. Retest the vehicle.
4 Remove the 24 mm A/F blanking plug, situated
beside the inlet and outlet connectors, and fit
adaptor, 640864 with an Oring. Fit, preferably, a
0 to 14.0 bar pressure gauge. At idle, the transfer
pressure should read between 4.8 to 6.9 bar.
5 If the pressure is low either the transfer pressure
(TP) regulator is stuck open (see Workshop Manual
XNB100 for repair) or the transfer pump is worn or
broken (remove the pump assembly and replace it).
If the TP is high, the TP regulator is stuck closed
(see Workshop Manual XNB100 for repair).
Remove the TP adaptor, refit the TP plug (ensure
that the Oring is fitted) and tighten it to 23 Nm (204
Ib in). Retest the vehicle.
connector from the DCU and check pins for damage,
incorrect engagement etc.
vehicle.
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to + BAT
Fit on BOB pins 41 & 47, and 42 & 47 (see table 1 in
Section 5.5 for Rotor A and Rotor B actuator resistance
values).
DCU. Clear any fault codes and retest the vehicle. If
the 2 fault still occurs, go to 12.
10 Remove the connector from the pump and check pins
for damage, incorrect engagement etc. If there are no
faults, go to 12, otherwise, go to 11.
11 If damage is apparent, repair it and retest the vehicle.
12 Fit the BOB with the adaptor cable to the pump
connector. Test and record values for:
a) opencircuit
b) shortcircuit
on BOB pins 10 & 6, and 7 & 11 (see table 1 in
Section 5.5 for Rotor A and Rotor B actuator resistance
values).
If test 12 is correct and test 8 is incorrect go to 14; if
both tests 12 and 8 are correct go to 15, if test 12 is
incorrect go to 13.
13 Fault with an actuator. Identify which actuator from
its resistance value (see Section 5.6). Repair the pump
and retest the vehicle. If the fault is still present go to 1.
14 Fault with the vehicle harness. Repair and retest
the vehicle. If the fault is still present go to 1.
15 Remove the BOB and refit the DCU. Use the
LASER 2000 to read the DYNAMIC DISPLAY values;
ROTOR DELAY A (feed) and ROTOR DELAY B (drain)
and note the values. ROTOR DELAY A should be less
than 35 and ROTOR DELAY B less than 50.
16 If either of the DELAYS is above limits, the
relevant actuator is at fault. Repair the pump and retest
17 Clear any fault codes present. Retest the vehicle and
if the fault is still present, change the DCU.
4
Coded Faults
11
1173 PUMP ROTOR CALIBRATION
This fault code will be displayed if:
i) In the precrank state (keyon), the DCU
indicates when the rotor sensor is above or below
limits.
NOTE At rest, the rotor sensor core is on its end
stop (maximum fuel).
ii) In the engine running state, the DCU indicates, in
the zero fuel condition, that the rotor sensor is
outside an allowed range.
NOTE When the pedal is fully released, the rotor
is driven to the zero fuel endstop.
The cause may be due to the following:
A fault in the harness or the rotor sensor
connector
Roller shoes tight in the drive shaft
Misalignment of the drive shaft and rotor
The vehicle will show symptoms of greatly reduced power
and impaired driveability.
For intermittent faults go to test 1.
For current faults go to test 6.
Fit the BOB and connect the Laser 2000.
1 Stop the engine. When it is stationary, keyon and
note the ROTOR FEEDBACK value.
If the FEEDBACK value is within 212 to 240 go to
test 2.
If it is outside those limits go to 3.
2 Whilst agitating the harness at the pump and the
DCU, note any ROTOR FEEDBACK variation.
If the ROTOR FEEDBACK differs by more than +/ 2
go to test 5. If inside limits, go to test 6.
3 Ensure that the key switch is off. Rotate the engine
clockwise manually through 90_, using a spanner or
wrench on the front pulley bolt, and note the ROTOR
FEEDBACK value.
If the FEEDBACK value has changed by more than
5 from that noted in test 1, go to 4. If no change, go
to test 6.
4 Fault with the pump rotor. Repair the pump and
retest the vehicle.
5 Start, stop and keyon a couple of times and note
the ROTOR FEEDBACK at keyon.
If the ROTOR FEEDBACK varies by more than +/ 5
go to 4. If the FEEDBACK does not vary, go to
test 6.
6 Drive the vehicle in third gear, downhill. With
the vehicle driving the engine (foot off the pedal), note
the ROTOR FEEDBACK in this condition.
If the value is less than 5 go to 8. If the value is
greater than 4, go to 7.
7 Fault with the pump rotor. Repair the pump and retest.
incorrect engagement etc. If there are no faults, go to
10, otherwise, go to 9.
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to + BAT
on BOB pins 9 & 6 (see table 1 in Section 5.5 for
Rotor Sensor resistance values).
11 Remove the BOB and reconnect the harness to
the DCU. Clear any fault codes and retest the vehicle.
If the fault still occurs change the DCU.
12 Remove the connector from the pump and check pins
for damage, incorrect engagement etc. If there are no
faults, go to 14, otherwise go to 13.
14 Fit the BOB with the adaptor cable to the pump. Test
and record values for:
a) opencircuit
b) shortcircuit
on BOB pins 14 and 17 (see table 1 in Section 5.5
for Rotor Sensor resistance values).
If test 14 is correct go to test 16, if incorrect go to 15.
If both tests 10 and 14 are correct go to 17.
15 Fault with rotor sensor assembly. Repair the pump
16 Fault with the vehicle harness. Repair it and retest
the vehicle.
17 Mechanical fault with the pump. Repair the pump
Coded Faults
4
12
4.2 ELECTRIC SHUTOFF SOLENOID (ESOS)
Connector Applicable code: 1170
The ESOS plunger is held closed by a spring. Lifting of
the plunger requires energisation of the ESOS coil. The
supply to the ESOS is pulsewidth modulated (PWM).
See Section 5.7 for an explanation of PWM. The ratio of
on to off periods is varied by the DCU to provide the
current level required for the three modes in which the
ESOS operates.
The modes are:
a) Engine stationary, keyswitch on. The DCU supplies
a small current to check the integrity of the ESOS
circuit.
b) When, during cranking, the DCU is satisfied that
the rotor is in the position required for starting it will
supply maximum current for rapid opening of the
ESOS.
c) When the ESOS is fully open, less current is required
to maintain that position. The DCU will reduce the
current accordingly.
Low resultant current
(testing & precrank)
Max. resultant current
(lifting)
Medium resultant current
(holding)
A045-010
To minimise black smoke on startup above 0_C, the
ESOS is not operated until the pump rotor is in the correct
position for starting. Below 0_C, the ESOS is operated
instantly on startup.
Functions and Components involved:
Transfer pressure
Backleak value
ESOS
DCU
Harness
Failure may be due to one or more of the following:
Restricted fuel supply to the pump
Restricted backleak return to the filter
Air venting through the system after a filter change.

TP regulator fault
TP cassette fault
ESOS fault
Harness/connector fault
1170 ESOS DRIVE CURRENT
The vehicle symptoms are that the engine will not start, it
stops, or it will not restart. If the engine does restart, only
limited power 12 will be available
1 If the engine stops and will not restart, go to 8.
If the engine stops and can be restarted, but runs
either erratically with stalling or with reduced power,
go to 2.
38
47
48
3
2
DCU
Connector
Pins
Pump
Connector
Pins
ESOS
A045-011
2 Connect the LASER 2000, start and idle the engine.
Set the LASER 2000 to DIAGNOSTICS
MENU/ACTUATOR TESTS/KEY ON ENGINE
RUNNING/ENGINE SHUT OFF SOLENOID. Operate
the ESOS by pressing STOP (F2). Restart the engine
and allow it to idle. If in test 2 the engine does not stop,
go to 3. If in test 2 the engine stops instantly but will not
restart or starts sluggishly, go to test 4.
3 Fault with the ESOS. Repair it and retest the vehicle.
the pump and run the engine. In neutral gear and
full throttle, pressure should read positive, approx.
0.2 bar when warm and less when cold.
If test 4 is correct go to 6, if incorrect go to 5.
5 If the pressure reading is below zero (vacuum),
check the fuel supply circuit from tank to pump e.g filter,
lift pump, collapsed fuel tank, pipes etc. and rectify.
Retest.
6 Remove the 24 mm A/F blanking plug, situated beside
the inlet and outlet connectors, and fit adaptor 640864,
with an Oring. Fit, preferably, a 0 to 14.0 bar pressure
gauge. At idle, the transfer pressure should read
between 4.8 to 6.9 bar.
If test 6 is correct go to 8, if incorrect go to 7.
7 If the pressure is low then either the transfer
pressure (TP) regulator is stuck open (see Workshop
Manual XNB100 for repair) or the transfer pump is worn
or broken (remove the pump and repair). If the TP is
high, the TP regulator is stuck closed (see Workshop
Manual XNB100 for repair). Remove the TP adaptor,
refit the TP plug (ensure that the Oring is fitted) and
tighten it to 23 Nm (204 Ib in). Retest the vehicle.
backingoff etc. If test 8 shows no fault go to 10, if
incorrect go to 9.
4
Coded Faults
13
10 Fit the BOB. Test and record resistance values for:
a) Opencircuit
b) Shortcircuit
c) Shorttoground d) Short to +BAT
on BOB pins 38 & 47 (see table 1 Section 5.5 for
ESOS resistance value). If test 10 is correct go to 11,
if incorrect go to 12.
11 Remove the BOB, reconnect the harness to the DCU
and retest the vehicle. If the fault is still present
change the DCU.
12 Remove the connector from the pump and check
pins for damage, backingoff etc. If test 12 shows no
fault go to test 14, if incorrect go to test 13.
vehicle.
14 Fit the BOB with adaptor cable to pump connector.
Test and record resistance values for:
a) Opencircuit
b) Shortcircuit
ESOS resistance value). If test 14 is correct go to 16,
if incorrect go to 15.
15 Fault with the ESOS. Repair the pump and retest
the vehicle. If the fault still present go to 1.
Coded Faults
4
14
4.3 PUMP CAM CONTROL AND
PUMP TEMPERATURE SENSOR
Applicable codes : 1174, 1175, 1176, 0185, 1185, 1186
The advance piston is engaged with the cam advance
screw and rotates the cam ring. Injection timing is
determined by the position of the cam ring, which is
controlled by the DCUdriven cam actuator (CAM
DEMAND). The position of the cam is determined from
the cam sensor feedback (CAM FEEDBACK).
The current flowing through the actuator coil determines
how far the plunger opens. The current is derived from a
PWM supply (see Section 5.6 for explanation of PWM).
The DCU controls the cam position in such a way as to
reduce any difference between CAM DEMAND and CAM
FEEDBACK.
To resist cam reaction during the pumping cycle, the cam
ring is locked hydraulically by the lockoff ball assemblies.
A small orifice is positioned in parallel with the lockoff
assembly to allow the advance piston to retard, when
required, during the non pumping part of the cycle.
The pump temperature sensor is built into the cam
position sensor and functions independently of it.
Functions and Components involved:
Transfer pressure
Pump cam control actuator
Pump cam position sensor
Pump cam position sensor core
Pump temperature sensor
Cam advance screw
Cam position sensor core drive pin.
Advance piston (includes control orifice)
Advance piston spring Lockoff assemblies and
orifice plug
Backleak
DCU
Harness
1174 PUMP CAM POSITION
This fault code will be displayed if the DCU identifies
either:
i) That the sensor resistance is outside limits e.g.
opencircuit, shortcircuit to ground or +BAT.
ii) That there is no feedback to the DCU.
The vehicle will show symptoms of reduced power and
impaired driveability.
backingoff etc. If there are no faults, go to 3,
otherwise, go to 2.
2 If damage is apparent, repair it and retest vehicle.
18
19
6
43
47
48
19
15
18
12
16
2 1
3
1 Cam sensor
2 Pump temperature sensor
3 Cam advance actuator
DCU
Connector
Pins
Pump
Connector
Pins
A045-012
a) Shortcircuit
b) Opencircuit
c) Shorttoground
d) Short to +BAT
on pins 6 & 18 (see table 1 in Section 5.5 for Cam
Sensor resistance value). If there are no faults, go to 4,
otherwise, go to 5.
5 Fit the BOB to the pump using the adaptor cable.
Test and record resistance values for: a) Opencircuit
b) Shortcircuit on BOB pins 18 & 19 (see table 1 in
Section 5.5 for Cam sensor resistance value). If no fault
is apparent go to 7, if faulty then go to 6.
6 Fault with the cam sensor assembly. Repair the
pump and retest the vehicle.
7 Fault with the vehicle harness. Repair it and retest the
vehicle.
4
Coded Faults
15
1175 PUMP CAM CONTROL
This code will also be displayed if the cam ring drifts from
its CAM DEMAND position.
Failure may be due to one or more of the following:
Restricted fuel supply to the pump
Restricted backleak return to the filter
Harness/connector fault
TP regulator fault
Transfer pump assembly fault
Actuator seat worn
Air venting through the fuel system after filter
change.
Lockoff assemblies worn, damaged, missing,
or incorrectly assembled.
the pump and run the engine. In neutral gear and at
full throttle, pressure should read positive (approx.
0.2 bar when warm and less when cold).
2 If the pressure reading is below zero (i.e. a
vacuum), check the fuel supply circuit from the tank
to the pump e.g filter and lift pump, and for imploded
fuel tank or pipes etc., and rectify. Retest.
3 Remove the 24 mm A/F blanking plug, situated
beside the inlet and outlet connectors, and fit adaptor
640864, complete with an Oring. Fit, preferably, a
0 to 14.0 bar pressure gauge. At idle, the transfer
pressure should read between 4.8 to 6.9 bar.
4 If the pressure is low either the TP regulator is
stuck open (see SIN D047 for repair) or the transfer
pump is worn or broken (replace the pump). If the TP
is high, the TP regulator is stuck closed (see SIN
D047 for repair). Remove the TP adaptor, refit the TP
plug (ensure that the Oring is fitted) and tighten it to
23 Nm (204 Ib in).
Retest the vehicle.
5 Ensure that the keyswitch is turned off. Connect
the LASER 2000, turn the keyswitch on, and set
the LASER 2000 to ACTUATOR TESTS/ PUMP
CAM ACTUATOR. Disconnect the harness from the
pump. Using the DOWN (F2) key, set PUMP CAM
PWM DRIVE to zero. Using the UP (F4) key set
PUMP CAM PWM DRIVE to 1000. Using a
multimeter set to milliamps (mA), measure and
record the current on the harness connector pins 12
and 16.
If the value is between 70 and 80 mA, go to 6. If the
value is outside these limits, go to 7.
6 Fault with the pump. Rectify it and retest.
connector from the DCU and check both DCU and pump
connector pins for damage, backingoff etc. If there are
no faults, go to 9, otherwise, go to 8.
a) Opencircuit
b) Shorttoground
c) Short to +BAT
between BOB pin 43 and harness connector pin 12,
and BOB pin 47 and harness connector pin 16.
10 DCU fault. Replace it and retest the vehicle.
11 Harness fault. Repair it and retest the vehicle.
NOTE If a LASER 2000 is not available, carry
out continuity checks on:
i) DCU connector pins 43 and 47, via the
BOB,
ii) Pump connector pins 12 and 16 (see table
1 in Section 5.6 for the Cam actuator
resistance value)
1176 PUMP CAM CALIBRATION
This fault code will be displayed if, in the precrank state
(keyswitch on), the DCU identifies that the cam calibration is
above or below limits. Note that, at rest, the advance piston is
on its end stop.
The vehicle symptoms are reduced power and impaired
driveability.
1 When the keyswitch is turned on, CAM
FEEDBACK should be between 8 and 16.
If CAM FEEDBACK value is outside limits, go to test 2.
If CAM FEEDBACK value is inside limits, go to 4.
2 Start the engine, stop it and turn the keyswitch on
twice, noting the CAM FEEDBACK values.
If the value changes to that in test 1, go to 3.
If the value does not change, go to 4.
3 Pump sensor, core, or cam ring fault.
connector from the DCU and check the pins for damage,
backing off etc. If there are no faults, go to 6, otherwise,
go to 5.
Coded Faults
4
16
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
Cam sensor resistance values). If there are no faults,
go to 8, otherwise, go to 7.
the DCU. Clear any fault codes and retest the
vehicle. If the fault still occurs change the DCU.
pins for damage, backingoff etc. If there are no
a) Opencircuit
b) Shortcircuit
between BOB pins 18 and 19 (see table 1 in
Section 5.5 for Cam sensor resistance value). If
there are no faults, go to 12, otherwise, go to 11.
the vehicle.
0185 PUMP TEMPERATURE
1185 PUMP TEMPERATURE HIGH
1186 PUMP TEMPERATURE LOW
These fault codes will be displayed if the DCU identifies
that the sensor is outside resistance limits.
The sensor is a negative temperature coefficient
thermistor (its resistance is inversely proportional to
temperature) i.e. Iow resistance = high temperature, high
resistance = low temperature. An opencircuit failure
(infinite resistance) will display a low temperature value
and a shortcircuit failure (low resistance) will display a
high temperature value.
The vehicle will show symptoms of slightly reduced
power.
connector from the DCU and check the pins for
damage, backing off etc.
2 If damage is apparent, repair and retest vehicle.
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
on pins BOB 6 & 19 (see table 1 in Section 5.5 for
pump temperature sensor resistance values). If there
are no faults, go to 4, otherwise, go to 5.
the DCU. Clear any fault codes and retest the vehicle. If
the fault still occurs change the DCU.
the pins for damage, backingoff etc. If there are no
a) Opencircuit
b) Shortcircuit
pump temperature sensor resistance values).
If test 7 shows no fault go to 9, if it is incorrect go to 8.
the vehicle.
4
Coded Faults
17
4.4 CALIBRATION RESISTOR
Applicable codes : 11 90
The calibration resistor is located in the pump connector.
A range of resistances is used for production fuel setting.
The vehicle symptom is a slight loss of power.
Components involved:
Calibration resistor pump connector
(within the harness)
DCU
1190 CALIBRATION RESISTOR
This fault code will be displayed if either:
i) The measured value lies outside the tolerance band
ii) Apparent nominal resistor value differs from
that measured on keyon.
Record the value of the calibration resistor which is fitted,
by referringtotheLASER2000/DlAGNOSTlCSMODE/DYN
AMlC DISPLAY / CALIBRATION. (Refer to table 2 in
Section 5.5 for Calibration Resistor values.)
damage, backingoff etc.
vehicle.
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
on BOB pins 16 & 50. (See table 2 in Section 5.5
for Calibration Resistor values.) If there are no faults,
go to 4, otherwise, go to 5.
5 Remove the connector from the pumpa nd check
pins for damage, backingoff etc. If there are no
vehicle.
16
50
8
9
DCU
Connector
Pins
Pump
Connector
PINS
Vehicle harness
CALIBRATION
RESISTOR
A045-013
a) Opencircuit
b) Shortcircuit
Between BOB pins 9 & 8 (using data from item 3
above, see table 2 in Section 5.6 for value). If there are
no faults, go to 9, otherwise, go to 8.
8 Fault with the connector assembly. Repair the pump
the vehicle.
Coded Faults
4
18
4.5 PUMP SPEED SENSOR
(DRIVE SHAFT POSITION)
Applicable codes : 1644, 1189
The pump speed sensor is a Hall Effect device, note that
the period is the time between identical points on
successive cycles. There are four pulses per pump
revolution.
The vehicle symptom is loss of power (reduced fuel).
Pump speed (drive shaft position) sensor
Harness and connectors
DCU
Test Equipment:
Use the static timing device YWB317 and
the specified BOB.
1644 PUMP SPEED SENSOR
1189 PUMP SPEED LOST
These faults will be displayed if either:
i) The period is not within the allowed limit, or
ii) No pump speed signal is present.
The sensor detects the passage of flags on the pump
timing ring and supplies to the DCU a signal which is
interpreted to provide the following:
i) Pump speed.
ii) Drive shaft angular position (basic timing).
vehicle.
3 Fit the BOB. Plug the timing device into the BOB in
the following order:
Red wire to pin 47
Black wire to pin 50
White wire to pin 7.
Crank the engine and note if the red and green LEDs
on the timing device flash alternately and evenly.

NOTE Every fourth pair of flashes will be slightly
shorter than the others.
If test 3 is correct go to 4, if it is incorrect i.e. uneven
or no flashes, go to 5.
DCU
Connector
Pins
Pump
Connector
Pins
Vehicle
harness Red
White
Black
PUMP
SPEED
SENSOR
STATIC
TIMING
DEVICE
YWB317
47
50
7
1
4
5
A045-024
the pins for damage, backingoff etc.
If there are no faults, go to 7, otherwise, qo to 6.
7 Fit the BOB to the pump connector with the
adaptor cable. Plug the timing device into the BOB in
the following order:
Red wire to pin 1
Black wire to pin 4
White wire to pin 5.
Crank the engine and note if the red and green LEDs
on the timing device flash alternately and evenly.
NOTE Every fourth pair of flashes will be slightly
shorter than the others.
If test 7 is correct go to 9, if it is incorrect go to 8.
8 Fault with the pump speed sensor. Repair the pump
the vehicle.
4
Coded Faults
19
4.6 PEDAL SENSOR CONTROL
Applicable codes : 1180, 1181, 1182, 1183, 1184,
1252, 1253, 1254, 1255, 1256,
1257, 1258
The assembly comprises:
A reverse twinpack potentiometer (PDS1 &
PDS2)
A low pedaldemand (idling position) switch
(LPDS)
A high pedaldemand (kickdown position) switch
(HPDS)
NOTE A reverse twinpack potentiometer comprises
a pair of potentiometers mounted on the same
shaft and arranged so that when one of the pair
presents a high voltage at its output, the other
presents a low voltage.
The two switches are for validating the pedal sensor
values. With no throttle response i.e. engine stationary or
at idle, LPDS is open and HPDS is closed. At
partthrottle, both switches are closed. At full throttle,
LPDS is closed and HPDS is open.
HPDS is also used to initiate automatic gearbox
kickdown.
The potentiometer assembly is part of the LDV pedal
assembly and is nonrepairable. It must be replaced if
faulty.
Pedal assembly
Harness and plugs
DCU
1180 PEDAL DEMAND SENSOR FAILED
1181 PEDAL PDS1 HIGH
1182 PEDAL PDS1 LOW
1183 PEDAL PDS2 HIGH
1184 PEDAL PDS2 LOW
PEDAL CORRELATION BETWEEN PDS1 &
LPDS HIGH
1252
LPDS LOW
1253
LPDS HIGH
1254
LPDS LOW
1255
HPDS
1256
HPDS
1257
PDS2
1258
Coded Faults
4
20
vehicle.
3 Fit the BOB to the harness. With the pedal released
and later fully depressed record resistance values
for:
a) Shorttoground
b) Short to +BAT
on BOB pins 8, 10, 29, 30, 33, 50 and 51.
4 Remove the connector from the sensor and
repeat test 3.
If the fault is still apparent go to 5, otherwise, go to 6.
5 Harness faulty. Repair and retest the vehicle.
6 Check for correct operation of the HPDS and
LPDS switches.
Reconnect the harness to the sensor and measure
the resistance across the BOB terminals listed in the
table below, recording the results.
Pedal Position BOB Result (ideal)
Released 8
30
50
50
opencircuit
shortcircuit
Depressed
fully
8
30
50
50
1.0 k to 5.5 k Ohms
shortcircuit
If the test results differ from those listed go to 9,
otherwise, go to 7.
7 Check for correct operation of the pedal sensor
tracks. Measure the resistance across the BOB pins
listed in the table below and record values.
Pedal Position Grop BOB pins
Released 1a
1b
33
51
10
29
2a
2b
10
29
51
33
Depressed 3a
3b
33
51
10
29
4a
4b
10
29
51
33
If the following pairs of results: 1 a and 4a, 1 b and 4b,
2a and 3a, 2b and 3b differ by more than 400 go to
9. Otherwise go to 8.
8 Reconnect the harness to the DCU. Connect the
LASER 2000 and turn the keyswitch on (do not start
the engine). Set the LASER 2000 to read DYNAMIC
DISPLAY items:
PEDAL POSN 1 and
PEDAL POSN 2, and record values for:
i) Pedal position 1: (a) footoff, and (b) fully
depressed
ii) Pedal position 2: (a) footoff, and (b) fully
depressed Also, note if the values jump, whilst
moving the pedal position slowly.
If the values 1 ) (a) and 2) (a) are outside 7% to 11
%, and 1 ) (b) and 2) (b) are outside 87% to 93%, or
the values change erratically (jump), go to 9. If
otherwise, go to 10.
9 Fault with the pedal sensor assembly. Replace
the assembly and retest the vehicle.
10 Clear all the fault codes and retest the vehicle. If the
fault still occurs go to 1.
4
Coded Faults
21
4.7 ENGINE SPEED SENSOR
(CRANKSHAFT POSITION)
Applicable codes: 0335, 0336 Description of Operation:
The engine speed sensor is an inductive device. The
sensor detects the passage of holes drilled in the engine
flywheel and supplies to the DCU a signal which is
interpreted to provide:
i) Engine speed
ii) Engine crankshaft angular position
The vehicle symptom is loss of power (reduced fuel).
Engine speed sensor
DCU
These faults will be displayed if:
i) The interval between sequences of pulses is
corrupted
ii) The interval between pulses is too small
iii) No engine speed signal is present
0335 ENGINE SPEED SENSOR
0336 ENGINE SPEED LOST
1 Check to see if a shim is fitted between the sensor
body and the bell housing.
If a shim is fitted go to 3, if not go to 2.
2 Clean the mounting faces, fit a new shim, refit the
sensor to the engine, retest the vehicle.
vehicle.
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
the Engine Speed sensor resistance value). Also,
test for opencircuit between BOB pins 3 & 14 and 3
& 53.
If no fault is apparent go to 6, if the screening tests
are incorrect go to 7, if other tests incorrect go to 8.
the DCU. Retest the vehicle.
7 Fault with the harness screening. Repair it and
retest.
14
DCU
Connector
Pins
Sensor
Connector
Pins
Vehicle harness
ENGINE SPEED/
CRANKSHAFT
POSITION SENSOR
Screen
53
3
A045-019
8 Remove the connector from the sensor and check
If no fault is apparent go to 10, if it is incorrect go to 9.
10 Test and record resistance values for:
a) Opencircuit
b) Shortcircuit
on the sensor pins (see table 1 in Section 5.5 for
engine speed sensor resistance value).
11 Fault with the sensor. Replace it and retest the vehicle. If
the fault is still present go to 1.
the vehicle. If fault is still present go to 1.
Coded Faults
4
22
4.8 ENGINE COOLANT
TEMPERATURE SENSOR
Applicable codes: 0116, 0117, 0118
thermistor (its resistance is inversely proportional to
temperature) i.e. Low temperature = high resistance, high
temperature = low resistance. The DCU will vary the
amount of fuel injected and injection timing, dependent
upon engine temperature.
This fault code will be displayed if the DCU identifies that
the sensor is outside resistance limits.
The vehicle symptom is slightly reduced power.
Engine coolant temperature sensor
Harness and plugs
DCU
0116 COOLANT TEMPERATURE
0117 COOLANT TEMPERATURE LOW
0118 COOLANT TEMPERATURE HIGH
vehicle. Fit the BOB. Test and record resistance
values for:
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
the Engine coolant temperature sensor resistance
values).
17
1
2
50
DCU
Connector
Pins
Sensor
Connector
Pins
Vehicle
harness
ENGINE COOLANT
TEMPERATURE
SENSOR
A045-018
a) opencircuit
b) shortcircuit
on sensor pins 1 & 2 (see table 1 in Section 5.5 for
the Engine coolant temperature sensor resistance
values).
8 Fault with the sensor. Replace it and retest the vehicle.
the vehicle.
4
Coded Faults
23
4.9 AIR CHARGE TEMPERATURE SENSOR
Applicable codes: 0110, 0112, 0113
thermistor. (Its resistance inversely proportional to
temperature) i.e. Iow temperature = high resistance, high
temperature = low resistance. The DCU will vary the
amount of fuel injected and injection timing, dependent
upon air charge temperature.
This fault code will be displayed if the DCU identifies that
the sensor is outside resistance limits.
The vehicle symptom is slight loss of power (reduced
fuel).
Air charge temperature sensor
DCU
0110 AIR TEMPERATURE
0112 AIR TEMPERATURE LOW
0113 AIR TEMPERATURE HIGH
2 if damage is apparent, repair it and retest the vehicle.
a) opencircuit
b) shortcircuit
c) shorttoground
d) short to +BAT
on BOB pins 15 & 50 (see table 4 in Section 5.5
for the air charge temperature sensor resistance
values).
vehicle.
50
1
2
15
DCU
Connector
Pins
Sensor
Connector
Pins
Vehicle harness
AIR CHARGE
TEMPERATURE
SENSOR
A045-017
a) Opencircuit
b) Shortcircuit
on sensor pins 1 & 2. Air charge temperature
sensor resistance values can be found in section 5.5.
8 Fault with the sensor. Replace it and retest the vehicle.
the vehicle.
Coded Faults
4
24
4.10 EXHAUST GAS RECIRCULATION (EGR)
0122,0123,1122,1123,1224,1125
The LDV EGR system is designed to reduce nitrous oxide
(NOx) emissions in the exhaust gases by limiting
the amount of oxygen available for combustion at
partload. Reduction of oxygen is achieved by the
admission of a controlled amount of exhaust gas into the
engine inlet manifold, thus limiting combustion
temperature, which is a controlling factor in the formation
of NOx.
The system has a CurrenttoVacuum Transducer
(CVT), controlled by a PWM current (EGR DEMAND) from
the DCU, and which applies a variable vacuum to an EGR
valve (connected to the exhaust manifold), and a throttle
valve which is in the engine air intake system after the
turbocharger compressor. The CVT is connected to the
vehicle braking system vacuum Supply.
A position sensor builtin to the EGR valve provides a
signal to the DCU (EGR VLVE POSN).
Model year 1997 vehicles have a system which uses an
EVR instead of the CVT. These components are not
interchangeable.
See section 5.6 for an explanation of PWM.
CVT
Vacuum supply to CVT
EGR valve
EGR valve position sensor
Pipes
DCU
1402 EGR VALVE POSITION SENSOR
0401 EGR SENSOR LOW
0402 EGR SENSOR HIGH
These fault codes will be displayed if the DCU identifies
that either:
i) The sensor value is above high limit or below low
limit.
ii) EGR valve position does not show movement in
th required direction.
1 Check the vacuum supply (engine at idle) to the CVT
or EVR by removing the pipe to the EGR valve, and
noting if the valve makes a click when it closes.
Check that all pipes are clear and not damaged.
2 If damage is apparent, repair it and retest.
35
2
52
40
47
1
3
2
1-
2+
DCU
connector
pins
Sensor
connector
pins
48
Vehicle harness
EGR VALVE POSITION SENSOR
EGR CURRENT-TO-VACUUM
TRANSDUCER (CVT)
A045-015
4
Coded Faults
25
If no fault is apparent go to 5, if there is a fault go to
4.
vehicle.
5 Fit the BOB and disconnect the boost pressure
sensor. Test and record resistance values for:
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
Section 5.5 for External supply EGR position, and
EGR position sensor resistance values).
If no fault is apparent go to 6, if there is a fault go to
7.
7 Remove the connector from the EGR valve
position sensor and check the pins for damage,
backingoff etc. If there are no faults, go to 9,
otherwise, go to 8.
a) Opencircuit
b) Shortcircuit
on pins 1 & 2, and 3 & 2 (see table 1 in Section 5.5
for External Supply, EGR position and EGR Position
Sensor resistance values).
10 Fault with the EGR position sensor. Repair it and
retest the vehicle.
the vehicle.
0400 EGR CONTROL
1193 EGR DRIVE OVERCURRENT
0122 THROTTLE VALVE LOW
0123 THROTTLE VALVE HIGH
1122 THROTTLE CALIBRATION LOW
1123 THROTTLE CALIBRATION HIGH
1224 THROTTLE CALIBRATION
1125 THROTTLE POSITION FAULT
Fault code 0400 will be displayed because:
i) The EGR VLVE POSN exceeds demand (EGR
DEMAND) and has not reduced since the last reading
ii) EGR DEMAND exceeds EGR VLVE POSN and has
not reduced since the last reading.
Fault code 1193 will be displayed because the DCU
supplied drive current exceeds a maximum limit.
1 Clean the CVT or EVR filter located on the CVT or
EVR, beneath the large removable disc. Ensure that the
keyswitch is off. Connect the LASER 2000, turn the
keyswitch on, start the engine and run at idle. Set
the LASER 2000 to ACTUATOR TESTS/ EGR
CURRENT TO VACUUM. Using the DOWN (F2) key, set
EGR CVT DEMAND to zero. Using the UP (F4) key,
gradually increase the value, noting whether the throttle
valve (situated on the air inlet manifold) is moving.
If the throttle valve does not move, go to 2. Otherwise
go to 3.
2 Ensure that the vacuum pipes are clear, and retest.
Rerun 1 and, if the throttle valve still does not
move, replace the CVT or EVR. Retest.
3 The vacuum supply is correct. At idle, remove the
pipe from the EGR poppet valve, noting whether the
valve closes with an audible click.
If the valve does not operate correctly, go to 4.
Otherwise go to 5.
4 Replace the EGR valve and retest.
backingoff etc.
If there is a fault go to 6. If no fault is apparent, go to 7.
7 Fit the BOB, and test and record resistance values for:
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
on BOB pins 40 and 47 (see table 1 in Section 5.5
for CVT or EVR resistance values). Also pins 49 and 47
for Model Year 97 vehicles.
It there is a fault, go to 8. If no fault is apparent, go to 9.
the DCU. Clear any fault codes and retest the vehicle. If
the fault still occurs change the DCU. Retest.
9 Remove the connector from the CVT or EVR and
check the pins for damage, backingoff, etc. If there is a
fault, go to 10, otherwise go to 11.
11 Test and record resistance values on CVT or EVR
pins 1 and 2 (see the table 1 in Section 5.5 for CVT or
EVR resistance values).
If there are no faults, go to 12, otherwise go to 13.
the vehicle.
13 Fault with the CVT or EVR. Repair it and retest
the vehicle.
Coded Faults
4
26
4.11 BOOST PRESSURE SENSOR
Applicable codes : 0105, 1108, 1109, 1300, 1301, 1302
The boost pressure sensor is provided with a 4.75V
reference voltage from the DCU. Its output voltage is
proportional to boost pressure. The DCU adjusts the
amount of fuel injected and the injection timing according
to boost pressure.
Boost sensor
Turbocharger
DCU
0105 BOOST SENSOR
1108 BOOST SENSOR HIGH
1109 BOOST SENSOR LOW
These fault codes will be displayed if, whilst in precrank
or idle, the DCU identifies that the sensor output signal
is:
i) Above the highlimit threshold, or
ii) Below the lowlimit threshold
A failed turbocharger or blockage in the air inlet could
restrict air flow and thus drop the air pressure below the
lowlimit threshold. If the turbocharger wastegate fails to
open, the boost pressure would exceed the highlimit
threshold.
1300 BOOST CALIBRATION
1301 BOOST CALIBRATION > HIGH LIMIT
1302 BOOST CALIBRATION < LOW LIMIT
These fault codes will be displayed if, whilst in precrank
or idle, the DCU identifies that the sensor output signal
is:
i) Above the highlimit threshold, or
ii) Below the lowlimit threshold
The threshold range is less than for Boost Sensor fault
codes.
1 For BOOST CALIBRATION FAULTS go to test 3.
For BOOST PRESSURE LOW, check the air inlet
for blockage; i.e. at the air fiIter or turbocharger
compressor.
Also check that the turbocharger is rotating.
For BOOST PRESSURE HIGH, check that
the turbocharger waste gate is operating.
35
11
52
A
B
C
DCU
Connector
Pins
Sensor
Connector
Pins
Vehicle harness
Boost Pressure
Sensor
A045-014
2 If blockage or damage is apparent, repair it and
retest the vehicle.
backingoff etc. If there are no faults, go to 5, otherwise,
go to 4.
5 Fit the BOB and disconnect the EGR position sensor.
a) Opencircuit
b) Shortcircuit
c) Shorttoground
d) Short to +BAT
Section 5.5 for External supply (boost sensor) and Boost
pressure sensor resistance values).
DCU and the EGR position sensor. Clear any fault codes
and retest the vehicle. If the fault still occurs change
the DCU.
7 Remove the connector from the boost sensor and
check the pins for damage, backingoff etc.
8 If damage is apparent, repair it, reconnect the
harness and retest the vehicle.
a) Opencircuit
b) Shortcircuit
on pins C & A, and B & A (see Section 5.4 for
pin identification and table 1 in Section 5.5 for
External supply, and boost pressure sensor resistance
values). If no fault is shown then go to 11, if there is a
fault go to 10.
10 Fault with the boost sensor. Replace it, reconnect
the harness and retest the vehicle.
11 Fault with the vehicle harness. Repair it, reconnect
the harness and retest the vehicle.
4
Coded Faults
27
4.12 POWER HOLD RELAY, KEYSWITCH, AND
BATTERY CIRCUIT
9318, 1606
When the keyswitch is turned to position ii (keyon),
+BAT is applied to DCU pin 20. The DCU then takes DCU
pin 45 to ground potential, which energises the power
hold relay. +BAT is then applied to the main DCU power
pins 47 and 48.
During keyoff the ESOS is immediately deenergised
by the DCU. The power hold relay is not deenergised
until the engine has stopped. This means that DCU can
take alternative action if the ESOS (Deenergised) fails to
stop the engine. (e.g. the DCU will ensure that the pump
rotor is driven to the zero fuel position.)
The DCU monitors its power supply and will record fault
codes if +BAT falls outside set limits.
Key switch
Power hold relay
Fuses
Battery and cables
DCU
1191
KEY LINE VOLTAGE
1196
KEYOFF VOLTAGE HIGH
1197
KEYOFF VOLTAGE LOW
These fault codes will be displayed if the sensed voltage on
the keyswitch line (DCU pin 20) is below 8 Volts or above 16
Volts.
NOTE The battery voltage may drop whilst the engine
is running if it is being used as a slave battery to
start another vehicle, thus creating fault codes.
Action
Check the two fuses. Replace if faulty, and retest.
1 Check that battery and earthtovehiclebody
terminals/connectors are clean and tight. With the
multimeter set to measure Volts DC, measure voltage
across the battery terminals.
If below 10 Volts, go to test 2. If above 10 Volts, go to test
3.
2 Carry out battery Voltdrop test using a heavy
discharge tester directly on the battery terminals
(keyoff). If it fails this test, recharge or renew the
battery. Retest the vehicle.
3 Start the engine, using a slave battery if necessary,
and allow it to idle. Ensure that the charge warning light
goes out by increasing engine speed. Return the engine
to idle speed and measure the voltage across the
vehicle battery terminals.
If the voltage exceeds 14 Volts, or the charge
warning light does not go out, go to 4. If the battery
voltage is below 14 Volts, go to 5.
45
47
DCU
Connector
Pins
Switch
Connector
Pins
Vehicle harness
20
48
54
55
+ -
15
0
1
2
3 50
30
5.0 A
5A
KEY-SWITCH
(Position 2)
To starter solenoid
VEHICLE
BATTERY
POWER
HOLD
RELAY
Link these
two pins in
order to pull-
in the relay
A045-020
Coded Faults
4
28
4 There is a fauIt with the charging circuit e.g. the
alternator regulator has failed. Rectify it and retest
vehicle.
5 Disconnect the plug from the DCU and check pins
for damage, backing off etc.
6 Rectify the fault and retest the vehicle.
7 Fit the BOB with the adaptor cable and turn on the
keyswitch. Test and record values for opencircuit
between pin 20 and the battery positive terminal.
If the resistance is greater than 3 Ohms, go to 8. If
the resistance is less than 3 Ohms go to 9.
8 Fault with the key switch; rectify or replace it and
retest.
9 Test and record values for opencircuit between pin
54 and battery negative terminal, and between pin
55 and the battery negative terminal.
If, in test 9, the resistance is greater than 3 Ohms, go
to 10. If the resistance is less than 3 Ohms go to 11.
10 Fault with the harness. Rectify it and retest.
11 Remove the BOB, reconnect the DCU and retest the
vehicle. If the fault persists change the DCU.
9671 BATTERY VOLTAGE
9317 BATTERY VOLTAGE HIGH
9318 BATTERY VOLTAGE LOW
These fault codes will be displayed if the sensed voltage
on the power line (DCU pins 47 and 48) is below 8 Volts
or above 16 Volts.
For low voltage, the symptoms will be a noticeable drop
in cranking speed when hot, and no crank when cold.
NOTE The battery voltage may drop if it is being used as
a slave battery to start another vehicle, thus
creating fault codes.
1 With the engine at rest, check the condition of the
following cables and connectors between the battery
terminals and the vehicle electrical system:
D Battery positive to the starter motor
D Battery negative to the engine and the vehicle
body/chassis
With the multimeter set to measure Volts DC,
measure the voltage across the battery terminals.
If it is below 10 Volts, go to test 2. If it is above 10
Volts, go to test 3.
2 Carry out a battery Volt drop test using a heavy
discharge tester directly on the battery terminals
(keyoff). If it fails this test, recharge or renew the
battery. Retest the vehicle.
3 Start the engine, using a slave battery if necessary,
and allow it to idle. Ensure that the charge warning light
goes out by increasing engine speed. Return the engine
to idle speed and measure the voltage across the
vehicle battery terminals.
If the voltage exceeds 14 Volts or the charging
warning light does not go out, go to test 4. If the battery
voltage is below 14 Volts go to 5.
4 There is a fault with the charging circuit e.g.
alternator regulator failed. Rectify it and retest the
vehicle.
5 Disconnect the plug from the DCU and check pins
for damage, backing off etc.
If there are no faults, go to 6, otherwise, go to 7. Rectify
the fault and retest the vehicle.
7 Fit the BOB with the adaptor cable. Link BOB pins
54 and 45 (this action energises the power hold relay).
Test and record values for opencircuit between BOB
pin 47 and the battery positive terminal.
If the value is greater than 3 Ohms, go to test 8. If
the value is less than 3 Ohms, go to test 9.
8 Fault with the power hold relay. Rectify or replace it
and retest.
a) Opencircuit
b) Short to +BAT
between BOB pin 54 and the battery negative
terminal, and BOB pin 55 and the battery negative
terminal.
If the resistance is greater than 3 Ohms, go to 10.
If resistance is less than 3 Ohms go to 11.
10 Fault with the harness. Rectify and retest.
11 Remove the BOB, reconnect the DCU and retest
the vehicle. If the fault persists change DCU.
1606 ECU POWER HOLD RELAY
This fault will be recorded if the DCU is unable to switch off
the power hold relay after keyoff.
1 Fit the BOB to the harness. Test and record
resistance values for an opencircuit between BOB pin
45 and the battery positive terminal. Power hold relay
drive resistance values should be between 80 and
100 .
If the value is incorrect, go to 2. If the value is correct,
go to test 3.
2 Fault with the power hold relay. Rectify it and retest.
a) opencircuit
b) short to +BAT
between BOB pin 54 and the battery negative
terminal, and BOB pin 55 and the battery negative
terminal.
If, in test 3, the resistance is greater than 3 Ohms, go
to 4. If the resistance is less than 3 Ohms go to 5.
4 Fault with the harness. Rectify it and retest.
5 Remove the BOB, reconnect the DCU and retest
the vehicle. If the fault persists change the DCU.
4
Coded Faults
29
4.13 ENGINETO PUMP SYNCHRONISATION
(PUMP BOLTUP LIMITS)
Applicable codes : 1177, 1178
1178 PUMP BOLTUP LIMITS
This fault indicates that the boltup angle has exceeded a
high or low threshold. The boltup angle is the difference
between the positions of the pump and engine position
sensors.
This fault is usually rectified by retiming the pump to the
engine.
1177 ENGINEPUMP SYNCHRONISATION
This fault indicates that there is a speed event error, i.e.
an error in synchronisation between the pump timing ring
and the flywheel drillings.
It is also displayed if the narrower of the four pump speed
ring vanes is not detected once per revolution.
The possible faults could be:
i) The pump has been incorrectly fitted to the engine.
Re time the pump.
ii) The pump timing wheel is loose or broken away.
The pump must be repaired.
iii) The drive shaft position sensor is loose. The pump
must be retimed using the method described in
Page 18, Section 4.
NOTE A speed event is the point at which a pump
or engine speed signal is passed to the DCU.
Coded Faults
4
30
4.14 DCU
Applicable codes : 1187, 1192, 1195, 0605, 1194, 1605,
1608
1187 DCU VARIANT SELECTION
This will indicate that the DCU was not configured when
fitted.
Check the configuration using the LASER 2000
procedure.
1192 EXTERNAL VOLTAGE (VEXT)
1195 SCPHBCC FAILED TO INITIALISE
0605 DCU PROCESSOR ROM/RAM
1194 DCU A TO D CONVERTER
1605 DCU EEPROM
1608 DCU WATCHDOGS (SEE NOTE BELOW)
If any of these codes are logged, change the DCU.
NOTE The DCU watchdog is a section of the
circuitry which maintains surveillance over all
DCU operational activity and which has the
authority to close down the system (stop the
engine) in the event of a major malfunction.
To achieve a lower gear (kickdown) for faster acceleration or
for driving uphill, the throttle pedal is fully depressed and the
High Pedal Demand Switch (HPDS) instructs the DCU to
operate the kickdown relay and the hold relay. The high
current required by the kickdown solenoid is supplied by the
kickdown relay. The lower current required to hold the
solenoid in the kickdown position is supplied by the hold
relay. The hold solenoid remains on until the throttle pedal is
released or the vehicle achieves 100 kph.
NOTE Under no circumstances should the pullin relay
and solenoid be supplied from a power source
other than the DCU.
ATX Solenoid
Failure of this circuit will result in poor/sluggish gear changes
or higher vehicle speeds will have to be achieved before
gear changes take place.
Kickdown pullin circuit
Failure of this circuit will result in no kickdown.
Kickdown hold circuit
Failure of this circuit will result in no hold. Transmission
will change and then release.
Incorrect DCU configuration
If the DCU is incorrectly configured, that is, if the vehicle
has manual transmission but the DCU is programmed for
automatic transmission, fault codes will be logged. Check the
configuration using the LASER 2000.
Acceleration test
The DCU drives the electrical system which actuates
the gearbox shift control and kickdown. The diagnostic facility
only detects failures up to the gearbox control solenoid and
the kickdown pullin and hold relays. The outputs of these
devices are not monitored.
Correct operation of the system will be confirmed by
carrying out a fullthrottle acceleration test without kickdown
requested (approximately 95% throttle travel), and with
kickdown requested (100% throttle travel). The transmission
will shift between gears at the speeds defined by the table
below.
Full throttle acceleration
1st to 2nd 2500 rpm. With kickdown operating at 3800 rpm.
2nd to 3rd 3300 rpm. With kickdown operating at 3950 rpm.
Direct drive engagement 4th gear 2900 rpm.
3rd to 4th 2900 rpm. With operating at 3900 rpm.
Any failure related to the transmission should be referred to
a dealer.
4
Coded Faults
31
4.15 PASSIVE ANTI THEFT SYSTEM (PATS)
Applicable codes: 9342
This is a vehicle immobilisation system. The introduction
of Passive AntiTheft means that vehicles are now fitted
with a PATS module which communicates with the DCU
upon vehicle keyon. The module interrogates the DCU
and if the code stored in the DCU does not match that of
the ignition key used then the vehicle is put into a
failsafe mode and will not start. An immobiliser
diagnostic light can be found above the windscreen in the
centre of the passenger compartment in failsafe mode
this will flash a LDV fault code (otherwise known as blink
code).
Functions and Components Involved:
DCU PATS Module
PATS NULL CODE
9342 PATS NULL CODE
When the ignition is first switched on, a transponder on
the key transmits a key code to the PATS module. This
keycode is compared with both that held in the PATS
module and that stored in the DCU . The above fault code
appears when the code in the DCU and PATS module
does not match.
The fundamental question as to why the DCU and
PATS module do not match should be asked. Verify the
vehicle history. Check the Vehicle Identification Number (VIN)
against the engine number on the chassis; ensure that there
is no evidence of theft.
Check the blink code flashed on the immobiliser
diagnostic light. A twodigit number will be flashed:
The first digit will be flashed followed by a onesecond
pause and then the second digit. After a threesecond pause
the code will be repeated.
Code 3.1 Indicates a wrong code received from the
DCU. Please contact a Lucas National
Distributor for assistance.
Code 3.2 Indicates a wiring fault in the PATS circuitry
or faulty PATS module. No attempt should be
made to investigate this; the vehicle must be
referred to a LDV dealer.
Starting Procedure
Fault Codes
9342 PATS nullcode
Vehicle system
KEY/IGN. Switch
Passive Anti-Theft System
Key on
PATS module checks key response
If OK
PATS module requests DCU
response
DCU checks message from PATS
module
If OK
DCU enter run mode
DCU responds to PATS module
If OK
PATS module enables engine crank
A045-026
5
32
5.1 DYNAMIC DATA
Screen Message Units Description
ENGINE SPEED
VEHICLE SPEED
COOLANT
AIR TEMP
PUMP TEMP
BOOST
PEDAL FUEL
MAX A/F DENS.
MAX FUEL
FUEL DEMAND
CYL 3 IDL FUEL
CYL 1 OFFSET
CYL 2 OFFSET
CYL 4 OFFSET
IDLE REF
IDLE REFT
ROTOR DEMAND
ROTOR F/B
ROTOR DELAY
ROTOR DELAY +
CALIBRATION
CAM DEMAND
CAM FEEDBACK
CAM INTEGRAL
BOLT UP TRIM
PEDAL POSN. 1
PEDAL POSN. 2
PEDAL
EGR DEMAND
EGR VLVE POSN
RAW EGR POSN
BATTERY
KEYVOLTS
STATUS
RECOVERY MODES
ENGINE STOPS
REDUCED FUEL
O/LOOP ROTOR
OPEN LOOP CAM
RPM
kph
_C
_C
_C
mbar
mm3
mm3
mm3
mm3
mm3
mm3
mm3
mm3
RPM
RPM
units
units
units
units
units
units
units
units
Degrees
%
%
%
units
units
units
Volts
Volts
Status
ON/OFF
ON/OFF
ON/OFF
ON/OFF
Input signal to the DCU from the engine speed sensor.
Input signal to the DCU from the vehicle speed sensor.
Input signal to the DCU from the engine coolant temperature sensor.
Input signal to the DCU from the air charge temperature sensor.
Input signal to the DCU from the pump temperature sensor.
Input signal to the DCU from the boost pressure sensor.
Input signal to the DCU from the pedal position sensor.
Maximum air/fuel ratio. Maximum fuel is limited by air density.
This is the maximum fuel permitted.
Above idle, the value displayed will be the lowest of PEDAL FUEL, MAX A/F DENS or
MAX FUEL.
Idling fuel on cylinder 3.
This offset value plus the CYL3 IDL FUEL gives the idle fuel on cylinder 1.
Target idle RPM (as set when in the IDLE TRIM mode).
Idle RPM for all temperatures.
This is the desired rotor axial position.
This is the measured rotor axial position. (If all the conditions are correct, ROTOR DEMAND and
ROTOR FEEDBACK follow each other closely).
These values determine the pulse width required to allow the actuators to achieve the
rotor demand.
Refer to table 2 in Section 5.6 to obtain the calibration resistance value.
This is the desired cam position.
This is the measured cam position. (CAM FEEDBACK should follow CAM DEMAND closely).
This value will be between 45 and 55.
This is an indication of pumptoengine timing. A change will result in a fault code being logged.
Pedal position potentiometer track 1. The value indivcates the position of the wiper on the track.
Pedal position potentiometer track 2. The value indivcates the position of the wiper on the track.
Relate this value to PEDAL FUEL.
This is the desired EGR valve position.
Result of processing by the DCU of the RAW position.
Actual EGR valve position.
Battery voltage as measured on DCU pins nos. 47 and 48 (+BAT).
Battery voltage as measured on DCU pin 20 (switch line).
Engine staus; PRE CRANK, RUNNING or STALLED.
Engine stopped due to a major fault.
Reduced fuel mode to a fault.
Openloop rotor control due to a fault.
Openloop cam control due to a fault.
5
33
5.2 VEHICLE WIRING DIAGRAM (MY97)
Fig. 7 EPIC System Wiring Diagram
5
34
5
35
5.3 COMPONENT LOCATION
W
P
W
P
W
P
W
B
W
G
B
R
B
W
B
U
B
G
N
R
W
U
W
U
W
U
W
R
W
U
W
U
W
R
W
B
W
G
B
R
B
W
B
U
B
G
N
R
W
G
N
G
W
G
W
R
W
U
Y
R
N
R
N
R
N
U
N
R
P
Y
P
Y
WYSNW
B
1
7
1
9 9
1
2
3
8
4
1
4
2
4
3 672
1
8 1
1
4
5
3
1
1
4
0 8
3
5
5
2
5
0
4
8
4
7
1
0
3
3
2
9
5
1
3
0
N U
N Y
W U
W
Y
S
N
W B
U
S
U
B Y
B Y
W P
S
B
B
B
B
B U
K W
P Y
B Y
2
1
5
5
5
4
1
5
2
2
3
4
4
2
0
4
5
B Y
B U
R Y
R O
B K
G U
B O
O
R O
O
B
N
W
Y
R
Y
U
N
W
E
C
U
P
U
P
U
W
P
W
G
N
G
W
G
W
R
N
U
N
Y
W
P
W
R
W
G
N
U
W
W
M
a
i
n

H
a
r
n
e
s
s
C
o
n
n
e
c
t
i
o
n
B
U
W
W
P
Y
P
U
G
U
N
W
W
P
P U
P W
P O
P B
P
N U
N R
N U
N Y
Y U
N G
W U
N W
W P
W R
P U
N G
W G
Y GY G
W G
N GN G
R Y
E
n
g
.
M
a
n
a
g
m
e
n
t
W
a
r
n
i
n
g

L
i
g
h
t
B
a
t
t
e
r
y
P
o
s
i
t
i
v
e
T
e
r
m
i
n
a
l
B
a
t
t
N
e
g
.
T
e
r
m
.
F
r
o
n
t

R
H
B
o
d
y

E
a
r
t
h
S
h
e
i
l
d
s

f
o
r
E
n
g
.

S
p
e
e
d

&
I
n
j
e
t
o
r

P
u
m
p

S
e
n
s
o
r
s
B

=

B
l
a
c
k
G

=

G
r
e
e
n
K

=

P
i
n
k
N

=

B
r
o
w
n
P

=

P
u
r
p
l
e
R

=

R
e
d
U

=

B
l
u
e
W

=

W
h
i
t
e
Y

=

Y
e
l
l
o
w
w
i
r
e

c
o
d
e
s
A045-027
2
3
4
5
6
8
9
1
0
7
5
5
5
1
123456789
1
0
i
l
l
u
s
t
r
a
t
i
o
n

k
e
y
F
u
s
e

b
o
x

a
n
d

d
i
a
g
n
o
s
t
i
c

s
o
c
k
e
t
A
c
c
e
l
e
r
a
t
o
r

p
e
d
a
l

p
o
s
i
t
i
o
n

s
e
n
s
o
r
E
n
g
i
n
e

s
p
e
e
d

c
r
a
n
k

p
o
s
i
t
i
o
n

s
e
n
s
o
r
B
o
o
s
t

p
r
e
s
s
u
r
e

s
e
n
s
o
r
C
u
r
r
e
n
t

v
a
c
u
u
m

t
r
a
n
s
d
u
c
e
r
A
i
r

c
h
a
r
g
e

t
e
m
p
e
r
a
t
u
r
e

s
e
n
s
o
r
E
n
g
i
n
e

c
o
o
l
a
n
t

t
e
m
p
e
r
a
t
u
r
e

s
e
n
s
o
r
E
G
R

v
a
l
v
e

p
o
s
i
t
i
o
n

s
e
n
s
o
r
F
u
e
l

p
u
m
p
D
i
e
s
e
l

c
o
n
t
r
o
l

u
n
i
t
W
h
e
n

i
m
m
o
b
i
l
i
s
e
r
f
i
t
t
e
d
5
36
5.4 CONNECTOR PIN IDENTIFICATION
DCU
1 3
2
20
38 55 37
19
1
17
8
4
1 3
AIR CHARGE TEMPERATURE SENSOR
ENGINE SPEED SENSOR
CURRENT-TO-VACUUM TRANSDUCER
ON-BOARD DIAGNOSTICS CONNECTOR
2 1
(+)
2
1 2
1 2
1
(+)
(A)
(B)
(C)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Fig. 8
A045-022
FUEL PUMP
PEDAL DEMAND SENSOR
BOOST PRESSURE SENSOR
EGR VALVE POSITION SENSOR
ENGINE COOLANT TEMPERATURE SENSOR
1
5
4
8
5
37
5.5 RESISTANCE VALUES
Table 1
CIRCUIT
DESCRIPTION
BREAKOUT BOX
Pin + Pin
PUMP PIN
Pin +
RESISTANCE ()
Min + Max DESCRIPTION Pin + Pin Pin +
Pin
Min + Max
Rotor A (feed) Actuator 41 47 6 10 25 35
Rotor B (drain) Actuator 42 47 11 7 25 35
Cam Actuator 43 47 16 12 25 35
ESOS 47 38 2 3 1 3
Rotor Position Sensor 20 C 9 6 14 17 48 60
Pump Temperature Sensor 19 6 15 9 690 3.5k
Cam Position Sensor
18 6 18 19 45 55
Engine Speed Sensor 14 53 1 2 300 1.2k
Engine Coolant Temperature 17 50 See table 3
Air Charge Temperature 15 50 See table 4 (MY97) >
EGR Position Sensor
(disconnect Throttle Sensor
and Boost Pressure Sensor)
2
35
52
52
300
1.5k
1k
2k
EMS Lamp 44 47 12 55
EVR Valve Actuator (MY97) 47 40 28 38
EVR Throttle Actuator (MY97) 47 49 28 38
EVR CVT (MY95) 47 40 4 10
Boost Pressure Sensor
(disconnect Throttle Sensor
and EGR Position Sensor)
52
52
35
11
500
10k
3k
300k
LPDS (Idle) 8 50 2 8 Opencircuit (o/c)
HPDS (Idle) 30 50 4 8 0 3
Pedal Demand Sensor 1
(Full throttle)
10 51 1 7 3k 7k
Pedal Demand Sensor 2
(Idle)
29 51 5 7 3k 7k
PATS Module 4 GND 4k 7k
Power GND Battve GND 0 3
Power Supply 47, 48 Batt +ve Opencircuit (o/c) o/c
Abbreviations
LPDS Low Pedal Demand Switch HPDS High Pedal Demand Signal
CVT Currenttovacuum Transducer
5
38
Table 2 Calibration Resistor Range
Number Resistance Value (Ohms)
0 8230 9090
1 6320 6980
2 4970 5490
3 3910 4330
4 3080 3400
5 2420 2680
6 1850 2150
7 1540 1700
8 1210 1330
9 950 1050
10 725 805
11 545 575
12 400 445
13 280 310
14 180 200
15 95 105
Table 3 Engine Coolant Temperature Sensor
Temp C Resistance Value (Ohms)
10 58,750
20 37,300
30 24,270
40 16,150
50 10,970
60 7,600
70 5,370
80 3,840
90 2,800
100 2,070
110 1,550
120 1,180
Table 4 Air change Temperature Sensor (MY97) >
Temp C Resistance Value (Ohms)
40 965,530
30 512,947
20 283,651
10 162,585
0 96,248
10 59,173
20 37,387
30 24,216
40 16,043
50 10,581
60 7,487
70 5,269
80 3,775
90 2,750
100 2,038
110 1,523
120 1,155
130 886,8
5.6 PULSE WIDTH MODULATION
The EPIC Cam Control and ESOS actuators, and the EGR
CVT, rely upon a fixedfrequency pulsewidthmodulated
(PWM) supply, generated within the DCU, for their operation. A
PWM voltage supply consists of a series of squarewave
singlepolarity pulses, the durations of which are varied by the
DCU in response to demand.
Low resultant current Medium resultant current Max. resultant current
on off on off 12 Volts
0
A045-021
The current which results from the PWM voltage varies in
proportion to the MarkSpace Ratio. The markspace ratio is
the relationship between the supplyon and supplyoff periods.
This ratio may be expressed as a percentage, which is then
referred to as the Duty Cycle.
i
41
FAULT CODE QUICK REFERENCE
SCP Description Page No.
0105 BOOST SENSOR 26
0110 AIR TEMPERATURE 23
0112 AIR TEMPERATURE LOW 23
0113 AIR TEMPERATURE HIGH 23
0116 COOLANT TEMPERATURE 22
0117 COOLANT TEMPERATURE LOW 22
0118 COOLANT TEMPERATURE HIGH 22
0122 THROTTLE VALVE LOW 25
0123 THROTTLE VALVE HIGH 25
0185 PUMP TEMPERATURE 16

0335 ENGINE SPEED SENSOR 21
0336 ENGINE SPEED LOST 21
0400 EGR CONTROL 25
0401 EGRSENSOR LOW 24
0402 EGRSENSOR HIGH 24
0605 DCU PROCESSOR, ROM/RAM 31
1108 BOOST SENSOR HIGH 26
1109 BOOST SENSOR LOW 26
1122 THROTTLE CALIBRATION LOW 25
1123 THROTTLE CALIRATION HIGH 25
1125 THROTTLE POSITION FAULT 25
1170 ESOS DRIVE CURRENT 12
1171 ROTOR POSITION 9
1172 PUMP ROTOR CONTROL OVERFUELLING 10
1173 PUMP ROTOR CALIBRATION 11

1174 PUMP CAM POSITION 14
1175 PUMP CAM CONTROL 15
1176 PUMP CAM CALIBRATION 15
1177 ENGINE PUMP SYNCHRONISATION 29
1178 PUMP BOLT UP LIMITS 29
1180 PEDAL DEMAND SENSOR FAILED 19
1181 PEDAL PDS1 HIGH 19
1182 PEDAL PDS1 LOW 19
1183 PEDAL PDS2 HIGH 19
1184 PEDAL PDS2 LOW 19
1185 PUMP TEMPERATURE HIGH 16
1186 PUMP TEMERATURE LOW 16
1187 DCU VARIANT SELECTION 3132
1189 PUMP SPEED LOST 18
1190 CALIBRATION RESISTOR 17
1191 KEYLINE VOLTAGE 27
SCP Description Page No.
1192 V EXT (External Voltage) 31
1193 EGR DRIVE OVERCURRANT 25
1194 DCU AD CONVERTER 31
1195 SCPHBCC FAILED TO INITIALISE 11 31
1196 KEYOFF VOLTAGE HIGH 27
1197 KEYOFF VOLTAGE LOW 27
1198 PUMP ROTOR CONTROL UNDERFUELLING 10
1224 THROTTLE CALIBRATION 25
1252 PEDALCORRELATION BETWEEN PDS1
AND LPDS HIGH
19
AND LPDS LOW
19
AND LPDS HIGH
19
AND LPDS LOW
19

AND HPDS
19
AND LPDS
19
AND PDS2
19
1300 BOOST CALIBRATION 26
1301 BOOST CALIBRATION>HIGH LIMIT 26
1302 BOOST CALIBRATION<LOW LIMIT 26
1402 EGR VALVE POSITION SENSOR 24
1605 EEPROM 31
1606 POWER HOLD RELAY 28
1608 WATCHDOGS 31
1644 PUMP SPEED SENSOR 18
9317 BATTERY VOLTAGE HIGH 28
9318 BATTERY VOLTAGE LOW 28
9342 PATS NULLCODE FAULT 33
9671 BATTERY VOLTAGE 28
9682 PATS COMMUNICATION FAULT
(REFER TO PATS WORKSHOP MANUAL)
Note: PDS1 Pedal Demand Sensor 1
PDS2 Pedal Demand Sensor 2
LPDS Low Pedal Demand Switch
LPDS High Pedal Demand Switch
NOTE For noncoded faults refer to Section 3

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EPIC D.I. Engine Management System

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