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Lotus Service Notes Section EMR

1. O2 Sensor slow response can be defined in two ways 1 Slow response and 2 Delayed response 1 Slow Response Set when the sensor fails to reach 600mV after 5 seconds of Fuel Enrichment or when the sensor fails to drop below 300mV after 5 seconds of DFCO Enable Criteria Engine run time gt 230 seconds gt 15 g sec MAF only enable criteria when switching rich gt 600mV in fuel enrichment state e DFCO for rich to lean switch Disable Criteria e P0116 P0117 P0118 Coolant Temperature Sensor faults e P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 P0273 P0274 P0276 P02777 Injector faults e P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire faults e P1301 P1302 Misfire faults causing emission or catalyst damage Monitor e Continuous until the test is either passed or failed Potential failure modes e Check and rectify any pre catalyst sensor fault code as they may be causing the fault code to be set e Catalyst damage leak inefficiency O Page 29 aay 2 Delayed Response Set when the sensor fails to switch between 300mV and 600mvV within a specified time of the pre cat O2 sen sor switch Enable Criteria Engine run time gt 230 seconds e Rich for gt 3 seconds prior to switch lean e Pre Cat O2 sensor must be rich for gt 0 5 seconds before post cat O2 sensor switch e DFCO for rich to lean switch Disable Criteria e P0116 P0117 P0118
2. P0461 The ECU calculates the fuel usage and determines whether the fuel level sensor has responded correctly to this usage The ECU also monitors the filtered and unfiltered signal at idle after a 20 second de slosh period and compares the differences Monitor e Continuous Enable Criteria 1 e Vehicle Idling e Vehicle stationary for 20 seconds Disable Criteria 1 e Fuel level lt 3 3 litres 0 9 US gallons Malfunction Criteria 1 e Signal fluctuation gt 10 litres 35 times over 7 second period Page 48 eeee Enable Criteria 2 e 12 litres fuel usage in upper region e 10 litres fuel usage in lower region e 5 litres fuel usage in mid region Disable Criteria e Vehicle stopped for 30 secs Malfunction Criteria e Checks for three conditions stuck when full stuck when empty or stuck midway The ECU determines if the sensor is stuck by calculating the amount of fuel used during the test period If the fuel level does not move by more than 1 litre a fault is flagged Potential failure modes e Fuel level sensor wiring or connector corroded e Fuel level sensor stuck Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips EEE eee Page 49 aa Engine Cooling Fan Control P0480 Fan 1 Control Circuit P0481 Fan 2 Control Circuit Component connections Sensor Connector Description ECU Pin ECU Connector Fa
3. Throttle Actuator Control Module Performance P2108 Throttle actuator control module performance Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e ECU internal failure e Short circuit to throttle actuator Pedal Position Sensor D Circuit Low P2122 Pedal position sensor D circuit low Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU Note that the potentiometers operate on 5 volts Enable Criteria e None Disable Criteria e None Potential failure modes e Signal short circuit lt 0 283 V e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied Eqs Page 73 a Pedal Position Sensor D Circuit High P2123 Pedal position sensor D circuit high Enable Criteria e None Disable Criteria e None Potential failure modes e Signal open circuit gt 4 487 V e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied Pedal Position Sensor E Circuit Low P2127 Pedal position se
4. ENGINE MANAGEMENT SECTION EMR Sub Section Page Diagnostic Trouble Code List EMR 1 3 Component Function EMR 2 7 Component Location EMR 3 9 Diagnostic Guide EMR 4 11 CAN Bus Diagnostics Lotus TechCentre EMR 5 81 Page 1 Updated 2nd July 2010 Cylinder Numbering viewed from above LH cylinder bank 2 Rear of engine Front of engine flywheel end auxiliary drive belt end RH cylinder bank 1 Firing order 12 3 4 5 6 mmm Page EMR 1 DIAGNOSTIC TROUBLE CODE DTC LIST DTC Fault description Page P0011 A Camshaft Position Timing Over Advanced or System Performance Bank 1 11 P0012 A Camshaft Position Timing Over Retarded Bank 1 11 P0014 B Camshaft Position Timing Over Advanced or System Performance Bank 1 11 P0015 B Camshaft Position Timing Over Retarded Bank 1 11 P0016 Crankshaft Position Camshaft Position Correlation Bank 1 Sensor A 12 P0017 Crankshaft Position Camshaft Position Correlation Bank 1 Sensor B 12 P0018 Crankshaft Position Camshaft Position Correlation Bank 2 Sensor A 12 P0019 Crankshaft Position Camshaft Position Correlation Bank 2 Sensor B 12 P0021 A Camshaft Position Timing Over Advanced or System Performance Bank 2 11 P0022 A Camshaft Position Timing Over Retarded Bank 2 11 P0024 B Camshaft Position Timing Over Advanced or System Performance Bank 2 11 P0025 B Camshaft Position Timing Over Retarded Bank 2 11 P0076 Intake Valve Control Sole
5. HEATED OXYGEN O SENSOR FOR BANK 1 VVT SENSOR FOR BANK 2 LH EXHAUST SIDE VVT SENSOR FOR BANK 1 RH EXHAUST SIDE CAMSHAFT TIMING OIL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CONTROL VALVE ASSEMBLY FOR BANK 2 LH EXHAUST SIDE AIR FUEL RATIO O FOR BANK 1 RH EXHAUST SIDE SENSOR FOR BANK 1 Ik Ignition coil noise suppression capacitor Page 9 mm Updated 2nd July 2010 ACIS ACTUATOR THROTTLE BODY THROTTLE POSITION SENSOR KNOCK SENSOR FOR BANK 1 SEENE KNOCK SENSOR m22 FOR BANK 2 m PAGE 10 a EMR 4 DIAGNOSTIC GUIDE Camshaft Timing Control VVT P0011 Camshaft Position Inlet Timing Over Advanced or System Performance Bank 1 P0012 Camshaft Position Inlet Timing Over Retarded Bank 1 P0014 Camshaft Position Exhaust Timing Over Advanced or System Performance Bank 1 P0015 Camshaft Position Exhaust Timing Over Retarded Bank 1 P0021 Camshaft Position Inlet Timing Over Advanced or System Performance Bank 2 P0022 Camshaft Position Inlet Timing Over Retarded Bank 2 P0024 Camshaft Position Exhaust Timing Over Advanced or System Performance Bank 2 P0025 Camshaft Position Exhaust Timing Over Retarded Bank 2 Description The Variable Valve Timing system VVT on the intake camshafts and the exhaust camshafts can vary the timing by approximately 35 The camshaft relative position is varied by a system of vanes mounted on the
6. Oxygen sensor faults e P0300 P0301 P0302 P0303 Misfire faults P0111 P0112 P0113 Intake air temperature faults Disable Criteria P0174 amp P0175 e P0106 P0107 P0108 Baro sensor faults e P0151 P0155 Oxygen sensor faults e P0300 P0304 P0305 P0306 Misfire faults e P0111 P0112 P0113 Intake air temperature faults Malfunction Criteria P0171 amp P0174 These codes will set when the relevant engine bank learned fuel correction has been increased to its maximum limit of 25 and the system still cannot maintain an air fuel ratio of 14 7 1 under normal driving conditions e These codes will also be set if the relevant bank fuel learn injector dead time is greater than 450 micro seconds Potential failure modes e Fuel Pressure too low restriction in fuel line e Air leak in induction system e Water in fuel e Exhaust leak crack before front oxygen sensor Injector fault e Sensor connector and wiring for signs of corrosion or loose connections e MAF fault e Vehicle has previously run out of fuel Diagnostic Mask e The MIL will be illuminated if fault is present for two consecutive trips Page 32 D Malfunction Criteria P0172 P0175 These codes will be set when the relevant bank learned fuel correction has been decreased to its minimum limit of 25 and the system still cannot maintain an air fuel ratio of 14 7 1 under normal driving conditions These codes will also be
7. Coolant Temperature Sensor faults e P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 P0273 P0274 P0276 P02777 Injector faults e P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire faults e P1301 P1302 Misfire faults causing emission or catalyst damage Malfunction Criteria e 3 consecutive switch times gt 700 ms Monitor e Continuous until the test is either passed or failed Potential failure modes e Check and rectify any pre catalyst sensor fault code as they may be causing the fault code to be set e Catalyst damage leak inefficiency Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0140 P0160 Monitor e Continuous Enable Criteria Engine run time gt 30 seconds e Engine is not at idle Engine is in closed loop fuel control e Oxygen sensors ready Disable Criteria e None Malfunction Criteria e Set when the sensor fails to switch above 673mV and below 400mV within 60 seconds Potential failure modes e Check and rectify any front sensor fault code as they may be causing the fault code to be set e Sensor connector and wiring should be checked for corrosion and loose connections e Catalyst e Gas leak in exhaust system Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips Ee Page 30 T P0141 P0161 Monitor e Continuous Enable Criteria Engine run time gt 20 seco
8. Potential failure modes Sensor signal open circuit or short to ground Sensor ground open circuit e Sensor failure e Crankshaft sensor plate e ECU Diagnostic Mask e The MIL will be illuminated if this fault is present for two consecutive trips Notes If a sensor or sensor circuit failure occurs the engine will not fire or start m Page 38 EEEeEeEeEeEeeeeeeeeeeeeeeeeeeOeee Engine Speed Position Sensors P0341 Camshaft Position Sensor A Circuit Bank 1 P0346 Camshaft Position Sensor A Circuit Bank 2 P0366 Camshaft Position Sensor B Circuit Bank 2 P0391 Camshaft Position Sensor B Circuit Bank 2 Description The camshaft position input to the ECU is used to determine engine phase enable sequential fuel injection control and to determine camshaft position for VVT control The inlet camshaft has three teeth spaced 90 apart which are detected by the electromagnetic sensor The valve timing setting is measured in the ECU by measuring time from a fixed position crankshaft tooth to a variable position camshaft tooth As the engine speed and the position is known from the crankshaft sensor signal the camshaft position can be calculated Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Inlet Bank 1 Signal A3 32 Way Left 2 Inlet Bank 1 Ground B3 32 Way Left 3 Supply voltage 5V D1 32 Way Left 1 Exhaust Bank 1 Signal D4 32 Way Left 2 Exhaust Bank 1 G
9. This code is set when the bank 1 knock sensor signal is gt 2 932 V e P0332 This code is set when the bank 2 knock sensor signal is lt 0 586 V e P0333 This code is set when the bank 2 knock sensor signal is gt 2 932 V Potential failure modes e Abnormal engine noise i e damaged engine or exhaust system contacting vehicle Knock sensor fixing too tight e Sensor connector wiring corroded or loose connections e ECU Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips mms PASC 37 poy Engine Speed Position Sensors P0335 Crankshaft Position Sensor A Circuit Range Performance Description Engine speed is calculated by measuring the time between the teeth of the crankshaft sensor trigger disc The disc has 34 teeth and 2 missing teeth spaced at 10 degree intervals around the disc The 2 missing teeth are positioned at 225 degrees before cylinder No 1 and 4 TDC The crankshaft sensor signal is also used to determine misfires events Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor input A4 32 Way Left 2 Ground B2 32 Way Left Monitor e Continuous Enable Criteria Engine running Disable Criteria e None Malfunction Criteria e 15 crank errors in succession This can occur due to no crank signal occurring whilst the cams continue to count or if there is a measured consecutive crank error
10. 18 character licence registration key without which Techcentre will not function This key is non transferable to other PC s Scope of Lotus TechCentre Model Type of Electronic Control Unit Engine ECU PT Communicationcompatible Reprogrammable _ L Jems ABS SRS TPMS IP O8MYon Elise 2004on Y Y Y Y N Y Pp ON Y Europa_2006on N Oy WA N N 11 2007 on Na na ON Y Evora 2009 on Esprit V8 PN N N N Note that TechCentre has no connectivity to Rover powertrain Elise Exige variants and that only limited diagnostics are available for the V8 Esprit No communication is available with the Europa powertrain Diag nostics for these vehicles are accessible using the Lotus Scan 3 tool TOO0T1467F U K EU mmm Page 8l TechCentre Connection TechCentre connection to the car is made via the Vehicle Communication Device VCD and the Data Link Connector DLC located beneath the driver s side fascia at the outboard side of the footwell Data Link Connector DLC Power for the VCD is taken from the vehicle battery via the DLC and when powered a blue tell tale on the unit will light Should updated firmware be available for the VCD usually downloaded as part of an online update TechCentre will automatically update the VCD and display a message to confirm The VCD under part number TO00T1472F is supplied in a black plastic carry case containing the follow ing VCD 16 Pin Ye
11. 1A Signal F2 oOuaRWN Sensor characteristics 0 0 595V 5 100 4 148 V 5 P0122 Monitor e Continuous Enable Criteria e None Disable Criteria e None Malfunction Criteria e Signal voltage lt 0 635V Potential failure modes e Signal short circuit e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Diagnostic Mask e The MIL will be illuminated if fault is present P0123 Monitor e Continuous Enable Criteria e None 48 Way Centre 48 Way Centre 48 Way Centre 48 Way Centre Page 21 aay Disable Criteria e None Malfunction Criteria e Signal voltage gt 4 765V Potential failure modes e Signal open circuit e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Diagnostic Mask e The MIL will be illuminated if fault is present P0222 Monitor e Continuous Enable Criteria e None Disable Criteria e None Malfunction Criteria e Signal voltage lt 2 146V Potential failure modes e Signal short circuit e Reference voltage open circuit e Reference voltage short to ground Sensor failure Diagnostic Mask e The MIL will be illuminated if fault is present Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied P0223 Monitor e Continuous Enable Criteria e None
12. 2000 4080 grams depending on coolant temperature G MM AA Page 41 E Disable Criteria e P0101 P0102 P0103 MAF faults e P0107 P0108 MAP Baro Faults e P0116 P0117 P0118 Coolant temperature faults e P0131 P0132 P0133 P0134 P0135 P0137 P0138 P0139 P0140 PO141 Oxygen sensor faults B1 e P0151 P0152 P0153 P0154 P0155 P0157 P0158 P0159 P0160 P0161 Oxygen sensor faults B2 P0171 P0172 P0174 P0175 Fuelling faults B1 B2 e P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire faults e P0500 Speed sensor fault Malfunction Criteria e Switch ratio between Pre amp Post catalytic converter O2 sensors gt 0 6 Potential failure modes e Exhaust system leak e Oxygen sensor faults e Oxygen sensor heater failure e Catalyst failure Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips Page 42 D TEE Evaporative Emission Control Leak Detection System P0441 Evaporative Emission System Incorrect Purge Flow P0442 Evaporative Emission System Leak Detected small leak P0455 Evaporative Emission System Leak Detected large leak P0456 Evaporative Emission System Leak Detected very small leak Description During an Evaporative Emission System Leak Detection check the vacuum in the system is monitored by ECU using the fuel tank pressure sensor At the appropriate time the ECU starts the test by closing the canister clos
13. 40 P0356 Ignition Coil F Primary Secondary Circuit 40 P0366 Camshaft Position Sensor B Circuit Range Performance Bank 1 39 P0391 Camshaft Position Sensor B Circuit Range Performance Bank 2 39 P0420 Catalyst System Efficiency Below Threshold Bank 1 41 P0430 Catalyst System Efficiency Below Threshold Bank 2 41 P0441 Evaporative Emission System Incorrect Purge Flow 43 P0442 Evaporative Emission System Leak Detected small leak 43 P0444 Evaporative Emission System Purge Control Valve Circuit Open 46 P0445 Evaporative Emission System Purge Control Valve Circuit Shorted 46 P0446 Evaporative Emission System Vent Control Circuit 46 P0447 Evaporative Emission System Vent Control Circuit Open 46 P0448 Evaporative Emission System Vent Control Circuit Shorted 46 P0451 Evaporative Emission System Pressure Sensor Switch Range Performance 46 P0452 Evaporative Emission System Pressure Sensor Switch Low 46 Continued irs ccscennceeceenes Page 4 DTC P0453 P0455 P0456 P0461 P0462 P0463 P0500 P0506 P0507 P0562 P0563 P0601 P0606 P0610 P0628 P0629 P0630 P0638 P0661 P0662 P1301 P1302 P2100 P2102 P2103 P2104 P2105 P2106 P2107 P2108 P2122 P2123 P2127 P2128 P2135 P2138 P2173 Continued Fault description Evaporative Emission System Pressure Sensor Switch High Evaporative Emission System Leak Detected large leak Evaporative Emission System Leak Detected very small leak Fuel Level Sensor
14. A Circuit Range Performance Fuel Level Sensor A Circuit Low Fuel Level Sensor A Circuit High Vehicle Speed Sensor A Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected System Voltage Low System Voltage High Watchdog Checksum Variant Code not Programmed Fuel Pump Control Circuit Low Fuel Pump Control Circuit High VIN not Programmed or Incompatible Throttle Control Error Intake Manifold Tuning Valve Control Circuit Low Intake Manifold Tuning Valve Control Circuit High Misfire level causing emissions increase Misfire level causing catalyst system damage Throttle Actuator Control Motor Circuit Open Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle Actuator Control System Forced Idle Throttle Actuator Control System Forced Engine Shutdown Throttle Actuator Control System Forced Limited Power Throttle Actuator Control Module Processor Throttle Actuator Control Module Performance Throttle Pedal Position Sensor Switch D Circuit Low Throttle Pedal Position Sensor Switch D Circuit High Throttle Pedal Position Sensor Switch E Circuit Low Throttle Pedal Position Sensor Switch E Circuit High Voltage Correlation Error Sensors A amp B Voltage Correlation Error Sensors D amp E Throttle Actuator Control System High Airflow Detected Non MIL Fault codes P0480 P0481
15. Actuates spark plug in cylinder 4 Actuates spark plug in cylinder 5 Actuates spark plug in cylinder 6 Actuates bank 1 inlet camshaft timing control Actuates bank 2 inlet camshaft timing control Actuates bank 1 exhaust camshaft timing control Actuates bank 2 exhaust camshaft timing control Actuates variable intake manifold Removes pollutants from exhaust Removes pollutants from exhaust Removes pollutants from exhaust Regulates fuel tank vapour flow into inlet manifold Actuates fuel pump Actuates engine starter motor EEE Page 7 Ea Component Cooling Fan 1 Relay Cooling Fan 2 Relay Air Conditioning Control Relay Air Conditioning Control Valve Coolant Recirculation Pump Noise Flap Solenoid ABS Battery Function Actuates cooling fan 1 Actuates cooling fan 2 Actuates air conditioning compressor Regulates air conditioning compressor load Actuates coolant recirculation pump Actuates air intake flap vacuum control Provides vehicle wheel speed information Provides electrical power mmm Pages Eee EMR 3 COMPONENT LOCATION VVT SENSOR FOR BANK CAMSHAFT TIMING OIL VVT SENSOR FOR 2 LH INTAKE SIDE CONTROL VALVE ASSEMBLY BANK 1 RH INTAKE SIDE FOR BANK 1 RH INTAKE SIDE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY FOR BANK 2 LH INTAKE SIDE AIR FUEL RATIO O SENSOR FOR BANK 2 IGNITION COIL ENGINE COOLANT FUEL INJECTOR TEMPERATURE SENSOR SENSOR FOR BANK 2 CRANKSHAFT POSITION SENSOR
16. Bank 1 Signal H1 48 Way Centre 2 Bank 1 Ground K4 48 Way Centre 3 Bank 1 Heater K1 48 Way Centre 4 Bank 1 Battery Voltage S 1 Bank 2 Signal H2 48 Way Centre 2 Bank 2 Ground K4 48 Way Centre 3 Bank 2 Heater K2 48 Way Centre 4 Bank 2 Battery Voltage 7 Sensor characteristics Normal operating range is 0 1000mV P0137 P0157 Monitor e Continuous Enable Criteria e None Disable Criteria e DFCO Deceleration Fuel Cut Off AE DE Acceleration Enrichment or Deceleration Enleanment e Misfire Malfunction Criteria e Set when the sensor operates below 15mV for more than 1 5 seconds consecutively for a specified number of times Page 28 MMN Potential failure modes e Check and rectify any pre catalyst sensor fault code as they may be causing the fault code to be set Sensor wire shorted to ground e Catalyst Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0138 P0158 Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Malfunction Criteria e Set when the sensor operates above 1200mV for more than 1 5 seconds consecutively for a specified number of times Potential failure modes e Check and rectify any front sensor fault code as they may be causing the fault code to be set e Catalyst Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0139 P0159
17. DIS is a 1 cylinder system that ignites one cylinder with one ignition coil The ECU determines the ignition timing and outputs the ignition signals IGT for each cylinder Based on IGT signals the power transistors in the igniter cuts off the current to the primary coil which induces a spark at the spark plug connected to the secondary coil The igniter will also send an ignition confirmation signal IGF as a fail safe measure to the ECU Component connections Connector Pin Description ECU Pin ECU Connector 1 Supply Voltage Coil1 Coil2 Coil3 Coil4 Coil5 Coil6 2 Ignition Coil Feedback D2 D2 D2 D2 D2 D2 32 Way Left 3 Coil Output Logic F4 F3 F2 F1 E4 E3 32 Way Left 4 Ground Monitor e Continuous Enable Criteria e Engine running Malfunction Criteria e No IGF signal to ECM while engine is running Potential failure modes e Open or short in IGF1 IGF6 circuits from ignition coil to ECU e Coil failure e ECU Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips i Page 40 a ETE Catalyst System Efficienc P0420 Catalyst System Efficiency Below Threshold Bank 1 P0430 Catalyst System Efficiency Below Threshold Bank 2 Description The ECU compares the waveform of the oxygen sensors located before and after the catalyst to determine whether or not the catalyst has deteriorated If the catalyst is functioning normally the front oxygen sensor will be switching
18. Disable Criteria e None Malfunction Criteria e Signal voltage gt 4 985V i Page 22 E See Potential failure modes e Signal open circuit e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Diagnostic Mask e The MIL will be illuminated if fault is present Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied Eor EEE eee Page 23 a Coolant Thermostat USA onl P0128 Coolant Thermostat Coolant Temperature Below Thermostat Regulating Temperature Description The thermostat diagnostic is enabled after each cold engine start and monitors the rate of temperature rise during warm up relative to the measured engine air flow to check thermostat functioning correctly i e not stuck open Monitor e Continuous Disable Criteria e P0116 P0117 P0118 Engine Coolant Temperature sensor faults Enable Criteria e Engine running Start up Coolant Temperature gt 10 C 14 F Start up Coolant Temperature lt 60 C 140 F Malfunction Criteria Coolant Temperature does not reach 70 C 158 F within specific total airflow during which time the vehicle must be above 20mph for 50 of this warm up time Potential failure modes e Thermostat failure Diagnostic Masks The MIL will be illuminated if the fault is present for 2 consecutive trips m Page 2
19. Lotus TechCentre m Page 6 EMR 2 COMPONENT FUNCTION Component Mass Air Flow Meter Intake Air Temperature Sensor Engine Coolant Temperature Sensor Throttle Position Sensor Pedal Position Sensor Barometric Pressure Sensor O2 Sensor Front Bank 1 O2 Sensor Front Bank 2 O2 Sensor Rear Bank 1 O2 Sensor Rear Bank 2 Crankshaft Position Sensor Camshaft Position Sensor Inlet Bank 1 Camshaft Position Sensor Inlet Bank 2 Camshaft Position Sensor Exhaust Bank 1 Camshaft Position Sensor Exhaust Bank 2 Knock Sensor Bank Knock Sensor Bank2 Fuel Level Sensor Air Conditioning Evaporator Temperature Sensor Clutch Pedal Position Sensor Brake Pedal Position Switch Cruise Control Multi function Input Electronic Throttle Control Motor Injector Circuit Cylinder 1 Injector Circuit Cylinder 2 Injector Circuit Cylinder 3 Injector Circuit Cylinder 4 Injector Circuit Cylinder 5 Injector Circuit Cylinder 6 Ignition Circuit Cylinder 1 Ignition Circuit Cylinder 2 Ignition Circuit Cylinder 3 Ignition Circuit Cylinder 4 Ignition Circuit Cylinder 5 Ignition Circuit Cylinder 6 Variable Valve Timing Actuator Inlet Bank 1 Variable Valve Timing Actuator Inlet Bank 2 Variable Valve Timing Actuator Exhaust Bank 1 Variable Valve Timing Actuator Exhaust Bank 2 Variable Intake Manifold Actuator Primar
20. P0537 P0538 P0564 P0571 P0578 P0616 P0617 P0646 P0647 P0806 P0807 P0808 E PAGE 5 Fan 1 Control Circuit Fan 2 Control Circuit A C Evaporator Temperature Sensor Circuit Low A C Evaporator Temperature Sensor Circuit High Cruise Control Multi function Input Signal Brake Switch A Circuit Cruise Control Multi Function Input A Circuit Stuck Starter Relay Circuit Low Starter Relay Circuit High A C Clutch Relay Control Circuit Low A C Clutch Relay Control Circuit High Clutch Position Sensor Circuit Range Performance Clutch Position Sensor Circuit Low Clutch Position Sensor Circuit High Continued DTC P1113 P2602 P2603 P2612 P2613 B1422 U0101 U0122 U0127 U0316 Continued Fault description Air Intake Control Valve Circuit Coolant Pump Control Circuit Low Coolant Pump Control Circuit High A C Refrigerant Distribution Valve Control Circuit Low A C Refrigerant Distribution Valve Control Circuit High A C Compressor Lock Sensor Circuit Lost Communications with TCM Lost Communications with VDCM Lost Communications with TPMS Software Incompatible with VDCM When applicable reference may be made under the Notes heading to a page in the Toyota service manual This information should be used only for diagnosis and connection detail of the sensor The Evora uses a Lotus ECU the connections for which may be found in circuit diagrams in Section MR Diagnostic Trouble Codes should be read using the
21. Way Left 3 H2 32 Way Left 4 H1 32 Way Left 5 G4 32 Way Left 6 G3 32 Way Left Monitor e Continuous Enable Criteria e Engine running Potential failure modes e Sensor connector or wiring corroded or loose connections Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips Limp home e Limit maximum engine speed to 4000rpm e Return the fuel system of the affected bank to open loop fuel control Notes If an injector goes short circuit it is likely that the ECU injector driver will be damaged i Page 34 D aaa SSeS eS Eee Misfire P0300 Random Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected P0305 Cylinder 5 Misfire Detected P0306 Cylinder 6 Misfire Detected Description A misfiring cylinder can be detected by analysing crank speed variation As a result of a combustion event there will be a net acceleration of the crankshaft Subsequent to a misfire event the engine will decelerate over the period following the missed cylinder event Speed changes can be characterised by observing changes in the time period for a fixed angle of rotation after firing events A significant change in this period assessed by comparison to previous periods may be attributed to misfire on a known cylinder Component connections Connector__Description ECU Pin EC
22. between rich and lean whilst the rear oxygen sensor should also be switching between rich and lean but more slowly When both the oxygen sensor waveforms change at a similar rate it indicates that the catalyst performance has deteriorated The ECU counts the number of pre and post catalyst oxygen sensor switches and divides one by the other to determine a ratio If this ratio is too high a fault will be indicated Sensor connections Pre catalyst oxygen sensor Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal G3 48 Way Centre 2 Bank 1 Ground J2 48 Way Centre 3 Bank 1 Heater Supply H3 48 Way Centre 4 Bank 1 Battery Voltage 1 Bank 2 Signal G4 48 Way Centre 2 Bank 2 Ground J2 48 Way Centre 3 Bank 2 Heater Supply H4 48 Way Centre 4 Bank 2 Battery Voltage z Post catalyst oxygen sensor Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal H1 48 Way Centre 2 Bank 1 Ground K4 48 Way Centre 3 Bank 1 Heater Supply K1 48 Way Centre 4 Bank 1 Battery Voltage 7 1 Bank 2 Signal H2 48 Way Centre 2 Bank 2 Ground K4 48 Way Centre 3 Bank 2 Heater Supply K2 48 Way Centre 4 Bank 2 Battery Voltage Monitor e Continuous Enable Criteria e Closed loop fuel control enabled e Coolant temperature gt 60 C 140 F e Baro gt 756 mbar e Vehicle speed lt 130 km h 81 mph e MAF lt 48 g sec amp MAF gt 2 g sec Air inlet temp gt 10 C 14 F e Accumulated Mass Air gt
23. reduce electromagnetic interference and carrying a square wave voltage signal corresponding to 0 s and 1 s coded in such a way as to identify and prioritise the individual messages On the Evora CAN based systems include engine management anti lock braking and related features tyre pressure monitoring instrument pack and onboard diagnostics A stand alone lap top PC loaded with Lotus Techcentre software allows the CAN based serial data to be read A Vehicle Communication Device T000T1472F introduced for the Europa model is used to connect the vehicle to the laptop Lotus Techcentre Engine programming live data display and systems diagnosis are all carried out via the Lotus Techcentre The minimum specification of the laptop computer for installation of the Lotus Techcentre is as follows Processer 1 70 Ghz 1 GB RAM 40 GB HDD CDRW DVD ROM WIN XP PRO or VISTA USB interface Ethernet or Wireless LAN Note that this laptop should be dedicated soley to the Lotus Techcentre with no other software installed This diagnostic software is designed primarily for use by trained Lotus technicians and is available as a CD under part number TO00T1510F version 4 or later supercessions A monthly Lotus Dealers or annual non Lotus dealers licence and support fee will also be levied providing access to Lotus TechCentre Technical Support phoneline on 0870 9493 668 and e mail on Jotus support uk omitec com Also required is a unique
24. set if the relevant bank fuel learn injector dead time is less than 450 micro sec onds Potential failure modes e Fuel pressure too high e Leaking fuel injector e Restriction in the exhaust system or air intake filter e Erratic throttle position sensor MAF fault Q2 sensor fault e Ignition fault Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips EEE eee Page 33 aa Fuel Injection System P0261 Injector Circuit low voltage Cylinder 1 P0262 Injector Circuit high voltage Cylinder 1 P0264 Injector Circuit low voltage Cylinder 2 P0265 Injector Circuit high voltage Cylinder 2 P0267 Injector Circuit low voltage Cylinder 3 P0268 Injector Circuit high voltage Cylinder 3 P0270 Injector Circuit low voltage Cylinder 4 P0271 Injector Circuit high voltage Cylinder 4 P0273 Injector Circuit low voltage Cylinder 5 P0274 Injector Circuit high voltage Cylinder 5 P0276 Injector Circuit low voltage Cylinder 6 P0277 Injector Circuit high voltage Cylinder 6 Description The ECU has six injector driver circuits each of which controls an injector When the engine is running the ECU continuously monitors the injector circuit feedback signals The monitored feedback signal should be low voltage when the injector is ON and high voltage when the injector is OFF Component connections Injector ECU Pin ECU Connector 1 H4 32 Way Left 2 H3 32
25. 3 Throttle Position Sensor B Circuit High 21 P0261 Cylinder 1 Injector Circuit Low 34 P0262 Cylinder 1 Injector Circuit High 34 P0264 Cylinder 2 Injector Circuit Low 34 P0265 Cylinder 2 Injector Circuit High 34 P0267 Cylinder 3 Injector Circuit Low 34 P0268 Cylinder 3 Injector Circuit High 34 P0270 Cylinder 4 Injector Circuit Low 34 P0271 Cylinder 4 Injector Circuit High 34 P0273 Cylinder 5 Injector Circuit Low 34 P0274 Cylinder 5 Injector Circuit High 34 P0276 Cylinder 6 Injector Circuit Low 34 P0277 Cylinder 6 Injector Circuit High 34 P0300 Random Multiple Cylinder Misfire Detected 35 P0301 Cylinder 1 Misfire Detected 35 P0302 Cylinder 2 Misfire Detected 35 P0303 Cylinder 3 Misfire Detected 35 P0304 Cylinder 4 Misfire Detected 35 P0305 Cylinder 5 Misfire Detected 35 P0306 Cylinder 6 Misfire Detected 35 P0327 Knock Sensor 1 Circuit Low 37 P0328 Knock Sensor 1 Circuit High 37 P0332 Knock Sensor 2 Circuit Low 37 P0333 Knock Sensor 2 Circuit High 37 P0335 Crankshaft Position Sensor A Circuit Range Performance 38 P0341 Camshaft Position Sensor A Circuit Range Performance Bank 1 39 P0346 Camshaft Position Sensor A Circuit Range Performance Bank 2 39 P0351 Ignition Coil A Primary Secondary Circuit 40 P0352 Ignition Coil B Primary Secondary Circuit 40 P0353 Ignition Coil C Primary Secondary Circuit 40 P0354 Ignition Coil D Primary Secondary Circuit 40 P0355 Ignition Coil E Primary Secondary Circuit
26. 4 O2 Sensor Pre Catalyst P0131 O2 Sensor 1 Circuit Low Voltage Bank 1 P0132 O2 Sensor 1 Circuit High Voltage Bank 1 P0133 O2 Sensor 1 Circuit Slow Response Bank 1 P0134 O2 Sensor 1 Circuit No Activity Detected Bank 1 P0135 O2 Sensor 1 Heater Circuit Bank 1 P0151 02 Sensor 1 Circuit Low Voltage Bank 2 P0152 O2 Sensor 1 Circuit High Voltage Bank 2 P0153 02 Sensor 1 Circuit Slow Response Bank 2 P0154 02 Sensor 1 Circuit No Activity Detected Bank 2 P0155 O2 Sensor 1 Heater Circuit Bank 2 Description The oxygen sensors separately monitor the oxygen content in the exhaust gases of each bank of the engine Each sensor is electrically heated to improve response after start The sensor consists of a zirconia electrode between two platinum plates When zirconia comes into contact with oxygen it becomes an electrical conductor The exhaust gases pass through louvers in the sensor One plate is in contact with the outside air and the other plate is in contact with the exhaust gases The platinum plate in contact with the air is electrically negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically positive This will cause a difference in electrical potential to develop between the two plates Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts depending on the oxygen content of the exhaust gases Thus when the air fuel mixture
27. 6 Engine Coolant Temperature Circuit Range Performance P0117 Engine Coolant Temperature Circuit Low P0118 Engine Coolant Temperature Circuit High Description The engine coolant temperature sensor is a thermistor device which changes resistance with temperature As coolant temperature decreases the thermistor resistance value increases and conversely as coolant tempera ture increases so the thermistor resistance value decreases Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Ground C3 48 Way Centre 2 Signal G2 48 Way Centre Sensor characteristics 20 C 4 F 13 84 16 33 KO 20 C 68 F 2 31 2 58 KO 80 C 176 F 0 310 0 326 KO 110 C 230 F 0 1399 0 1435 KO P0116 Monitor e Continuous Disable Criteria e None Enable Criteria 1 e Engine running gt 1000 seconds Malfunction Criteria 1 e Engine coolant temperature lt 40 C 104 F Enable Criteria 2 e Engine running Malfunction Criteria 2 e Engine coolant temperature erratic by more than 30 C 54 F Potential failure modes e Sensor wiring e Sensor failure e Thermostat failure Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0117 Monitor e Continuous Disable Criteria e None C Page 19 aa Enable Criteria e Engine running Malfunction Criteria e Coolant temperature gt 119 C 246 F for time gt 1 5 secs Potenti
28. Bank1 P0077 Intake Valve Control Solenoid Circuit High Bank1 P0079 Exhaust Valve Control Solenoid Circuit Low Bank1 P0080 Exhaust Valve Control Solenoid Circuit High Bank1 P0082 Intake Valve Control Solenoid Circuit Low Bank2 P0083 Intake Valve Control Solenoid Circuit High Bank2 P0085 Exhaust Valve Control Solenoid Circuit Low Bank2 P0086 Exhaust Valve Control Solenoid Circuit High Bank2 Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e P0076 P0079 P0082 P0085 VVT control valve open circuit or short to ground e P0077 P0080 P0083 P0086 VVT control valve circuit short to battery voltage e ECU output circuit failure e VVT control valve Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips E PAGE 13 soy Intake Air Flow P0101 Mass or Volume Air Flow Circuit Range Performance P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input Description The Mass Air Flow MAF sensor is incorporated into the airbox and measures both intake air flow rate and Intake Air Temperature IAT The MAF sensor uses a hot wire exposed to the airflow which is maintained at a constant temperature by a constant current flow This is achieved within the sensor unit by varying the voltage applied to the hot wire This voltage is the output signal from the MAF sensor Sensor connection
29. Pre Catalyst Bank1 25 P0133 O2 Sensor Circuit Slow Response Pre Catalyst Bank1 25 P0134 O2 Sensor Circuit No Activity Detected Pre Catalyst Bank1 25 P0135 O2 Sensor Heater Circuit Pre Catalyst Bank1 25 P0137 O2 Sensor Circuit Low Voltage Post Catalyst Bank1 28 P0138 O2 Sensor Circuit High Voltage Post Catalyst Bank1 28 P0139 O2 Sensor Circuit Slow Response Post Catalyst 28 P0140 O2 Sensor Circuit No Activity Detected Post Catalyst Bank1 28 P0141 O2 Sensor Heater Circuit Post Catalyst Bank1 28 P0151 02 Sensor Circuit Low Voltage Pre Catalyst Bank2 25 P0152 O2 Sensor Circuit High Voltage Pre Catalyst Bank2 25 P0153 O2 Sensor Circuit Slow Response Pre Catalyst Bank2 25 P0154 O2 Sensor Circuit No Activity Detected Pre Catalyst Bank2 25 P0155 O2 Sensor Heater Circuit Pre Catalyst Bank2 25 P0157 O2 Sensor Circuit Low Voltage Post Catalyst Bank2 28 P0158 O2 Sensor Circuit High Voltage Post Catalyst Bank2 28 P0159 O2 sensor Circuit Slow Response Post Catalyst 28 Continued auos asss O A Page 3 aay siddasseedads Continued DTC Fault description Page P0160 O2 Sensor Circuit No Activity Detected Post Catalyst Bank2 28 P0161 O2 Sensor Heater Circuit post Catalyst Bank2 28 P0171 System Too Lean Bank1 32 P0172 System Too Rich Bank 32 P0174 System Too Lean Bank2 32 P0175 System Too Rich Bank2 32 P0222 Throttle Position Sensor B Circuit Low 21 P022
30. U Connector 1 Supply Voltage Coil1 Coil2 Coil3 Coil4 Coil5 Coil6 2 Ignition Coil Feedback D2 D2 D2 D2 D2 D2 32 Way Left 3 Coil Output Logic F4 F3 F2 F1 E4 E3 32 Way Left 4 Ground Malfunction Criteria The operation of all the misfire codes is the same the last digit relates to the misfire involved i e a code P0303 indicates there is a problem with cylinder number 3 P0300 indicates the misfire is random and not linked to one particular cylinder Monitor e Continuous Enable Criteria e Battery voltage between 10 16 V Coolant temperature between 10 120 C 14 248 F e Engine speed between 480 8010rpm e Engine speed transient gt 15rpm e Altitude lt 8000 ft 2438 m Baro gt 756mbar e Fuel level gt 5 litres 1 3 US gallons e Engine load greater than 14 25 depending on engine speed Disable Criteria e DFCO enabled Deceleration Fuel Cut Off e Rough road e MAF faults Malfunction Criteria e Individual cylinder misfire in excess of 10 of total engine misfire P300 set when more than one cylinder misfiring or when CAM error MIL requested Limp home depends on severity and number of cylinders affected Throttle limited and engine continues to run on all cylinders e Fuel system set to open loop control e Affected bank shut down and engine speed limited to 4000 rpm Page 35 a Potential failure modes e Injectors or related codes e VVT system clearance or timing or r
31. able Criteria e None Disable Criteria e None Potential failure modes e Throttle actuator control motor open circuit Throttle Actuator Control Motor Circuit Low P2102 Throttle actuator control motor circuit low Monitor e Continuous Enable Criteria e None Disable Criteria e None Potential failure modes e Throttle actuator control motor short to ground Throttle Actuator Control Motor Circuit High P2103 Throttle actuator control motor circuit high Monitor e Continuous Enable Criteria e None Disable Criteria e None Potential failure modes e Throttle actuator control motor short to supply voltage m A 7 Throttle Actuator Control System Forced Idle P2104 Throttle actuator control system forced idle Description If a problem is detected which could result in faster engine speed than commanded by the pedal the actuator is switched out allowing the throttle valve to default to a 6 mechanically sprung setting This provides a fast idle speed which may be used to effect a limp home mechanism Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e Electronic throttle fault Note This code indicates action taken by the ECU and will always be accompanied by another code which has caused this action Throttle Actuator Control System Forced Engine Shutdown P2105 Throttle actuator control system forced engine sh
32. age lt 0 049V for 1 5 seconds e P0538 Signal voltage gt 4 399V for 1 5 seconds Potential failure modes e Thermistor wiring open circuit or shorted e Thermistor fault Diagnostic Mask e The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips A OGC OS pos Battery Voltage P0562 System Voltage Low P0563 System Voltage High Description With a battery and alternator functioning as normal the system voltage for a running engine should be around 14V The ECM monitors this and will diagnose if the voltage is too high or too low Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Malfunction Criteria e P0562 Voltage Too Low lt 10V for 10 seconds e P0563 Voltage Too High gt 16V for 25 5 seconds Potential failure modes e Alternator fault e Battery fault Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips mm Page 54 eee Cruise Control P0564 Cruise control multi function input signal P0578 Cruise control multi function input A circuit stuck P0571 Brake switch A circuit Description Cruise control requests are made using a multi function switch input Each cruise control function switch selects a different resistive network to a single ECM input From this input the ECM determines the driver request In addition cruise control is canc
33. al failure modes e Signal short circuit e Sensor failure e Thermostat failure e Cooling system problem Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0118 Monitor e Continuous Disable Criteria e None Enable Criteria e Engine running Malfunction Criteria e Coolant temperature gt 38 C 36 F for time gt 1 5 secs Potential failure modes e Signal open circuit e Sensor failure Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips mmm Page 20 Throttle Position P0122 Throttle Position Sensor A Circuit Low P0123 Throttle Position Sensor A Circuit High P0222 Throttle Position Sensor B Circuit Low P0223 Throttle Position Sensor B Circuit High Description The throttle position sensor TPS is mounted on the throttle body and detects the opening angle of the throt tle valve The TPS has 2 sensor circuits each of which transmits a signal VTA1 and VTA2 VTA1 is used to detect the throttle valve angle and VTA2 is used to detect malfunctions in VTA1 The sensor signal voltages vary between 0 V and 5 V in proportion to the throttle valve opening angle and are transmitted to the VTA terminals of the ECU 48 Way Centre 48 Way Centre Sensor connections Sensor Connector Description ECU Pin ECU Connector ETB ve M1 ETB ve L2 Ground C4 TPS 1B Signal F3 TPS 1A BV Ref E4 TPS
34. anister Closure Valve Connector Pins Description ECU Pin ECU Connector A Battery Voltage B CCV Output B4 48 Way Centre Purge Solenoid Connector Pins Description ECU Pin ECU Connector 1 Battery Voltage 2 Solenoid Output B3 48 Way Centre P0444 P0445 Potential failure modes e P0444 Purge valve wiring open circuit e P0445 Purge valve short circuit Diagnostic mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0446 This code can be caused by the canister closure valve CCV being either stuck closed or open CCV stuck open If the CCV is stuck open then there will be minimal tank depression when the leak test is performed Addition check will be performed when the vehicle is being driven before the code is set CCV stuck closed Detection of a stuck closed CCV is implemented by detecting an excessively low tank pressure during normal purge pressure lt 25mbar Detection of this fault will disable further purging Additional checks for CCV stuck closed e Purge Value gt 0 e CCV Open requested Monitor e Until leak check is completed Ee Page 46 D STZ Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0451 P0452 P0453 This code is set when the ECU detects abnormalities in the fuel tank vapour pressure sensor signal The ECU analyses the filtered and unfiltered pressure signal at idle after a de slosh period t
35. ar determined by a table related to fuel level after the 6 6 second timer has expired Monitor e Until leak check is completed Potential failure modes e Leak from pipes or connections e Leaking or damaged seal on filler cap not fitted correctly e Canister Closure valve not fully closing Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0455 This code is set if during the evaporative leak check the system fails to reach the evacuation target pressure The system will perform additional purge checks to determine the nature of the problem The additional purge checks will also run if the leak check fails to complete because the calculated vapour concentration is above the limit Additional Purge Check Enable Criteria e Vehicle not stationary e Engine Load gt 27 3 e Purge value gt 75 e Conditions met for gt 7 5 seconds Monitor e Until leak check is completed Potential failure modes e Fuel filler cap not fitted jammed or not fitted correctly e Leak from pipes or connections e Canister Closure valve stuck open Page 44 D Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0456 This code is set during the evaporative leak check process if the system calculates the measure of leak is above a specified value 2 4 4 3 mbar determined by a table related to fuel level after the 19 7 second timer ha
36. ault Malfunction Criteria e A C compressor speed error greater than 20 Potential failure modes e A C compressor clutch mechanism slipping or seized e A C compressor drive belt slipping e Lock sensor wiring e Lock sensor failure e ECM input circuit failure Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips mmm PA 7 Lost Communications with TCM U0101 Lost Communications with TCM Description The ECM communicates with the Transmission Control Module TCM via the CAN bus If these CAN bus communications have been interrupted the ECM will register a diagnostic code Potential failure modes e CAN wiring e TCM control module failure CAN bus corruption by another module on bus Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault was present on the previous trip Lost Communications with VDCM U0122 Lost Communications with VDCM Description The ECM communicates with the Vehicle Dynamic Control Module VDCM via the CAN bus If these CAN bus communications have been interrupted the ECM will register a diagnostic code Potential failure modes e CAN wiring e VDCM control module failure CAN bus corruption by another module on bus Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault was present on the p
37. ble Criteria e None Disable Criteria e Throttle position greater than 60 Potential failure modes e TPS1 reading incorrectly e TPS2 reading incorrectly Notes A maximum throttle opening of 15 may be imposed Eqs Page 75 ee Pedal Position Sensor Switch D E Voltage Correlation P2138 Pedal position sensor switch D E voltage correlation Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU Two processors within the ECU compare the two output signals which should match within a defined tolerance Note that the potentiometers operate on 5 volts Enable Criteria e None Disable Criteria e None Potential failure modes e PPS1 reading incorrectly e PPS2 reading incorrectly Notes A maximum throttle opening of 15 may be imposed Throttle Actuator Control System High Airflow Detected P2173 Throttle actuator control system high airflow detected Description The mass air flow is compared with the throttle position to determine whether an incorrect correlation exists Enable Criteria e None Disable Criteria e MAF fault s present Potential failure modes e Throttle plate damage Air leak in intake system Notes A mechanically sprung 7 throttle opening may be imposed or the injectors may be shut off to stop the engine mmm A AIC Refrigerant Distribution Valve P2612 A C Refrigerant Distribution Valv
38. drive end of the camshaft Each VVT oil control valve modulates a spool valve position in accordance with the drive signal duty cycle this in turns controls the oil pressure applied to the vanes A50 duty cycle applied to the valve will hold the valve current timing by preventing oil flow from the VVT controller housing a duty cycle less than 50 will retard the valve timing a duty cycle greater then 50 will advance the valve timing The ECM regulates this duty cycle based on the feedback signal from the respective camshaft position sensor to optimise the camshaft timing Component connections Sensor Connector _ Description ECU Pin ECU Connector 1 Battery Voltage 2 VVT Control Valve Inlet Bank 1 B2 48 Way Centre 1 Battery Voltage 2 VVT Control Valve Exhaust Bank 1 A2 48 Way Centre 1 Battery Voltage 7 2 VVT Control Valve Inlet Bank 2 A3 48 Way Centre 1 Battery Voltage 7 2 VVT Control Valve Exhaust Bank 2 A4 48 Way Centre Monitor e Continuous Enable Criteria e Engine running gt 30 secs e Coolant temperature gt 60 C 140 F Disable Criteria e P0116 P0117 P0118 Coolant temperature fault codes Malfunction Criteria e VVT error gt 5 degrees for time gt 2 5 secs Potential failure modes e Static valve timing is incorrect e VVT camshaft actuator failure e VVT control valve stuck open closed e VVT control valve filter Diagnostic Mask e The MIL will be illuminated if the faults ar
39. e Control Circuit Low P2613 A C Refrigerant Distribution Valve Control Circuit High Description The A C refrigerant flow is regulated by the ECM using the distribution valve to control the evaporator to the required temperature and prevent freezing Component connections Connector Description ECM Pin ECM Connector 1 Control valve driver K3 48 Way Centre 2 Ignition via rear ign relay z Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e P2612 valve wiring open circuit or shorted to ground e P2612 loss of power from rear ignition relay e P2613 valve circuit ECM side shorted to battery voltage e Valve failure e ECM output circuit failure Diagnostic Mask e The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips SEEMA Page 77 aay A C Compressor Lock Sensor Circuit B1422 A C Compressor Lock Sensor Circuit Description The ECM monitors the A C compressor speed If this speed is lower than the engine speed the ECM will turn off the A C compressor clutch This is to prevent belt damage due to slippage Component connections Connector Description ECM Pin ECM Connector 1 Lock sensor ve C1 32 Way Left 2 Lock sensor ve B1 32 Way Left Monitor e Continuous Enable Criteria Engine running Disable Criteria e P0646 P0647 A C compressor clutch f
40. e present for 2 consecutive trips OSE Page 11 Crankshaft Position Camshaft Position Correlation Error P0016 Crankshaft position camshaft position correlation bank 1 sensor A Inlet P0017 Crankshaft position camshaft position correlation bank 1 sensor B Exhaust P0018 Crankshaft position camshaft position correlation bank 2 sensor A Inlet P0019 Crankshaft position camshaft position correlation bank 2 sensor B Exhaust Description The crankshaft position sensor is used to identify engine position and speed via a pole wheel mounted on the front end of the crankshaft The camshaft position sensor is used to determine camshaft position from a three vane reluctor on the rear end of the inlet and exhaust camshaft Fault codes P0016 P0017 P0018 P0019 indicate a mechanical timing error such as incorrectly set or jumped cam timing Monitor e Continuous Enable Criteria Engine running from cranking up to 4 seconds Disable Criteria e None Malfunction Criteria Camshaft out of phase with crankshaft gt 16 degrees Potential failure modes e Static valve timing is incorrect e VVT camshaft actuator failure e VVT control valve stuck open closed e VVT control valve filter Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips mmm Page 12 EEE aa Camshaft Timing Control VVT P0076 Intake Valve Control Solenoid Circuit Low
41. e the ECM may take action to either shut down the engine bank containing the misfiring cylinder and limit the engine speed to 4000rpm or limit the throttle opening if there is more than one cylinder misfiring See misfire faults P0300 P0301 P0302 P0303 P0304 P0305 P0306 Monitor e Continuous Enable Criteria e Battery voltage between 10 16 V e Coolant temperature between 10 120 C 14 248 F e Engine speed between 480 8010rpm e Engine speed transient gt 15rpm e Altitude lt 8000 ft 2438 m Baro gt 756mbar e Fuel level gt 5 litres 1 3 US gallons e Engine load greater than 14 25 depending on engine speed Disable Criteria e DFCO enabled Deceleration Fuel Cut Off e Rough road e MAF faults Malfunction Criteria e P1301 Emissions Failure Misfire percentage gt 7 measured over 1000 engine revolutions e P1302 Catalyst Damage Failure Misfire percentage gt 16 6 40 depending on engine speed and load measured over 200 engine revolutions Potential failure modes e Injector related codes as these can cause misfire codes to be set e VVT codes set e Sensor connector and wiring for signs of corrosion or loose connections e Spark plug cylinder compression Cam timing damage to rocker arm assembly e Fuel pressure Diagnostic Masks e Fora P1301 fault code the MIL will be illuminated immediately e For a P1302 fault code the MIL will be illuminated immediately and
42. elated codes e MAF meter or related codes e Connectors and wiring for signs of corrosion or loose connections e Spark plug coil cylinder compression e PCV system hoses e Fuel pressure e Coolant temperature sensor e Vacuum hoses e ECU Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips mmm Page 36 Knock Control System P0327 Knock Sensor Circuit Low Bank 1 P0328 Knock Sensor Circuit High Bank 1 P0332 Knock Sensor Circuit Low Bank 2 P0333 Knock Sensor Circuit High Bank 2 Description The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed The piezoelectric element sends continuously sends a signal to the ECU when the cylinder block vibrates due to engine knocking this signal increases The ECU is able to identify each cylinder If knock is detected then the ECU will retard the ignition of the relevant cylinder to suppress it The knock control sensor cannot differentiate between spark knock and other similar sounding noises Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Sensor input D1 48 Way Centre 2 Bank 1 Ground C1 48 Way Centre 3 Bank 2 Sensor input D2 48 Way Centre 4 Bank 2 Ground C2 48 Way Centre Monitor e Continuous Enable Criteria Engine running Malfunction Criteria e P0327 This code is set when the bank 1 knock sensor signal is lt 0 586 V e P0328
43. elled by the application of either the brake pedal or the clutch pedal see also P0806 P0807 and P0808 Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Cruise control switch input E3 48 Way Right 2 Cruise control ground K3 48 Way Right 1 Brake Switch Ground 2 Brake Switch Input C4 48 Way Right P0564 P0578 Monitor e Continuous Enable Criteria e None Disable Criteria e None Malfunction Criteria e P0564 Cruise control multifunction switch open circuit or short circuit e P0578 Input other than OFF received for more than 100 seconds Potential failure modes e Cruise switch wiring open circuit or shorted e Cruise switch fault e ECU input circuit fault Notes The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips P0571 Monitor e Continuous Enable Criteria 1 e KMH gt 10 kmh e PPS gt 0 488 Enable Criteria 2 e ABS communications working Disable Criteria e None E OGC OS poss Malfunction Criteria 1 Brake switch on for greater than 25 5 seconds Malfunction Criteria 2 ABS indicating brakes are on but brake switch off for greater than 0 5 seconds Potential failure modes e Brake switch wiring open circuit or shorted e Brake switch fault Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the
44. gt 1 5 secs Potential failure modes e MAF sensor circuit short to ECU supply voltage Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips EEE eee Page 15 EE Barometric Pressure P0106 Manifold Absolute Pressure Barometric Pressure Circuit Range Performance P0107 Manifold Absolute Pressure Barometric Pressure Circuit Low Input P0108 Manifold Absolute Pressure Barometric Pressure Circuit High Input Description The barometric pressure sensor is located internally within the ECU and measures atmospheric pressure This parameter is required to compensate the mass air flow when the vehicle is operated at higher altitudes P0106 Monitor e Continuous Enable Criteria e Engine running Engine speed 2010 5490rpm e TPS gt 80 Disable Criteria e P0101 P0102 P0103 MAF Sensor fault codes e P0121 P0122 P0123 P0222 P0223 P2135 Throttle Pedal position fault codes Malfunction Criteria e Measured Baro is compared to a predicted Baro based on current engine conditions e Error gt 150kPa for time gt 4 5 seconds Potential failure modes e Sensor failure Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips P0107 P0108 Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Malfunction Criteria e P0107 Voltage at ECU lt 1 08V for time gt 1 5 secs e P0108 Voltage at ECU
45. gt 4 98V for time gt 1 5 secs Potential failure modes e Sensor failure Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips i Page 16 D aes S22 eS eee Intake Air Temperature P0111 Intake Air Temperature Sensor 1 Circuit Range Performance P0112Intake Air Temperature Sensor 1 Circuit Low P0113Intake Air Temperature Sensor 1 Circuit High Description The combined sensor which measures both Mass Air Flow MAF and Intake Air Temperature IAT is incorpo rated into the air box The IAT sensor is a thermistor device which changes resistance with temperature As air intake temperature decreases the thermistor resistance value increases and conversely as air temperature increases so the thermistor resistance value decreases Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 IAT Signal J3 48 Way Centre 2 IAT Ground E3 48 Way Centre 3 Battery Voltage 4 MAF Ground J4 48 Way Centre 5 MAF Signal G1 48 Way Centre Sensor characteristics IAT 20 C 4 F 13 6 18 4 KQ IAT 20 C 68 F 2 21 2 69 KQ IAT 60 C 140 F 0 50 0 67 KQ P0111 Monitor e Continuous Disable Criteria e P0116 P0117 P0118 Coolant temperature fault codes Enable Criteria 1 e Engine running lt 30 secs e Coolant temperature lt 30 C 86 F Malfunction Criteria 1 Inlet air temperature gt 38 C 100 F for time gt 1 5 secs Enable Crite
46. he clutch engaged The ECM continuously monitors the clutch position sensor input for malfunctions Component connections Connector Description ECU Pin ECU Connector A Ground K3 48 Way Right B Clutch position sensor signal B1 48 Way Right C Reference voltage F4 48 Way Right P0806 Monitor e Continuous Enable Criteria e Maximum and minimum clutch position measured over 15 gear changes Disable Criteria e None Malfunction Criteria e Voltage difference between maximum and minimum of less than 2 101V Potential failure modes e Clutch sensor failure e Clutch pedal failure Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips P0807 P0808 Monitor e Continuous Enable Criteria e None Disable Criteria e None Malfunction Criteria e P0807 Sensor voltage lt 0 098V e P0808 Sensor voltage gt 4 790V ems OGC OS soy Potential failure modes e P0807 Clutch sensor wiring open circuit or shorted to ground e P0808 Clutch sensor ECU input circuit shorted to 5V or 12V e Clutch sensor failure e Clutch pedal failure e ECU input circuit failure Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips mmm Page 66 Air intake control valve circuit P1113 Air intake control valve circuit De
47. ibly from fuel improper use of RTV engine oil or coolant Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0134 Bank1 or P0154 Bank2 Monitor e Until either passed or failed Enable Criteria Engine run time gt 30 seconds e Engine is not at idle e Engine is in closed loop fuel control e 02 sensor ready Malfunction Criteria e Set when the sensor fails to switch above 673mV and below 400mV within a 60 second period Potential failure modes e Sensor connector and wiring should be checked for corrosion and loose connections e Gas leak in exhaust system Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0135 P0155 Monitor e Continuous Enable Criteria Engine run time gt 20 seconds Malfunction Criteria e Set when the heater output is greater than 1900mA or less than 250mA for 1 5 seconds for 40 consecutive checks Potential failure modes e Sensor connector and wiring should be checked for corrosion and loose connections Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips G MM AA Page 27 EE O2 Sensor Post Catalyst P0137 O2 Sensor Circuit Low Voltage Bank 1 P0138 O2 Sensor Circuit High Voltage Bank 1 P0139 O2 Sensor Circuit Slow Response Bank 1 P0140 O2 Sensor Circuit No Activity Detected Bank 1 P0141 O2 Sensor Heater Circuit Ban
48. is rich the oxygen sensor output will be high If the air fuel mixture is lean the oxygen sensor output will be low Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal G3 48 Way Centre 2 Bank 1 Ground J2 48 Way Centre 3 Bank 1 Heater H3 48 Way Centre 4 Bank 1 Battery Voltage 1 Bank 2 Signal G4 48 Way Centre 2 Bank 2 Ground J2 48 Way Centre 3 Bank 2 Heater H4 48 Way Centre 4 Bank 2 Battery Voltage a Sensor characteristics Normal operating range is 0 1000mV P0131 Bank1 or P0151 Bank2 Monitor e Continuous Disable Criteria e DFCO Deceleration Fuel Cut Off e AE DE Acceleration Enrichment Deceleration Enleanment e Misfire Enable Criteria Engine running Failure Criteria e Sensor voltage lt 15mV for more than 1 5 seconds consecutively for a specified number of times O Page 25 aay Potential failure modes e Low fuel pressure Lean mixture e Malfunctioning sensor e External water on sensor e Sensor wire shorted to ground Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0132 Bank1 or P0152 Bank2 Monitor e Continuous Disable Criteria e None Enable Criteria e Engine running Malfunction Criteria e Sensor voltage gt 1200V for more than 1 5 seconds consecutively for a specified number of times Potential failure modes e High fuel pressure Rich mixture e Leaking o
49. k 1 P0157 O2 Sensor Circuit Low Voltage Bank 2 P0158 O2 Sensor Circuit High Voltage Bank 2 P0159 O2 Sensor Circuit Slow Response Bank 2 P0160 O02 Sensor Circuit No Activity Detected Bank 2 P0161 O2 Sensor Heater Circuit Bank 2 Description The oxygen sensors separately monitor the oxygen content in the exhaust gases of each bank of the engine Each sensor is electrically heated to improve response from start The sensor consists of a zirconia electrode between two platinum plates When zirconia comes into contact with oxygen it becomes an electrical conductor The exhaust gases passes through louvers in the sensor One plate is in contact with the outside air and the other plate is in contact with the exhaust gases The platinum plate in contact with the air is electrically negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically positive This will cause a difference in electrical potential to develop between the two plates Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts depending on the oxygen content of the exhaust gases Thus when the air fuel mixture is rich the oxygen sensor output will be high If the air fuel mixture is lean the oxygen sensor output will be low The post catalyst oxygen sensor performance is a good indicator of catalyst efficiency Sensor connections Sensor Connector Description ECU Pin ECU Connector 1
50. llow connector lead VCD to Vehicle USB lead VCD to PC USB extension lead VCD to PC not illustrated Stand alone laptop PC Yellow connector lead Vehicle Communication Device VCD Data Link Connector DLC USB connector lead Use of TechCentre Instructions for using the TechCentre are available in the Technical Information section displayed on programme start up eS Page 82 ay
51. n Relay 3 F1 48 Way Right Fan Relay 2 E2 48 Way Right Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e Wiring harness problem e Relay e ECU Diagnostic Mask e The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips mm Page 50 Vehicle Speed Sensor P0500 Vehicle Speed Sensor A Description This input to the ECU is from the ABS module via CAN Monitor e Continuous Enable Criteria e Following conditions must occur for 5 seconds e Engine speed gt 1800rpm and lt 5010rpm e Baro gt 756 mbar e Engine in a mode that indicates that the vehicle must be moving Malfunction Criteria e KMH lt 5 kmh Potential failure modes e ABS module failure e CAN bus communication error to ABS controller Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips EEE eee Page 51 i Idle Speed Control P0506 Idle Air Control System RPM Lower Than Expected P0507 Idle Air Control System RPM Higher Than Expected Description The ECM controls the engine idle speed using a combination of spark advance and throttle blade adjustment If this control cannot attain the desired idle speed a fault is diagnosed Monitor e Continuous Enable Criteria Engine at idle speed e Battery voltage between 10 V and 16 V Malfunction C
52. nds Disable Criteria e None Malfunction Criteria e Set when the heater output is greater than 1900mA or less than 250mA for 1 5 seconds for 40 consecutive checks Potential failure modes e Sensor connector and wiring should be checked for corrosion and loose connections Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips EEE eee Page 31 ee Fuel Control System Too Lean Or Rich P0171 System Too Lean Bank 1 P0172 System Too Rich Bank 1 P0174 System Too Lean Bank 2 P0175 System Too Rich Bank 2 Description The oxygen sensor sends a signal to the ECU corresponding to the exhaust gas oxygen content enabling the ECU to maintain a 14 7 1 air fuel ratio under normal driving conditions The ECU can make fuel corrections of 30 to the calculated fuel demand This value is then learned by the ECU over time If the ECU determines a rich condition exists oxygen sensor above 450mV it will decrease the calculated fuel demand to maintain a 14 7 1 ratio If the ECU determines a lean condition exists oxygen sensor below 450mV it will increase the calculated fuel demand to maintain a 14 7 1 ratio Monitor e Continuous Enable Criteria e Fuel Trim condition enabled e Closed loop fuelling enabled e MAF lt 28 g sec e Altitude lt 8000 ft 2438 m Baro gt 756 mbar Disable Criteria P0171 amp P0172 e P0106 P0107 P0108 Baro sensor faults e P0131 P0135
53. ngaged ECM diagnosis is only carried out on the crank relay Component connections Relay Connector Description ECU Pin ECU Connector 2 Main relay via fuse R1 4 Crank relay control G1 48 Way Right Monitor e Continuous Enable Criteria Engine running Disable Criteria e None Potential failure modes e P0616 Crank relay wiring open circuit or shorted to ground e P0616 Fuse R1 e P0617 Crank relay wiring shorted to 12V e Crank relay failure Immobiliser failure e ECU output circuit failure Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips o CU eee Page 59 ay Fuel Pump Relay P0628 Fuel Pump A Control Circuit Low Voltage P0629 Fuel Pump A Control Circuit High Voltage Description The fuel system is of the non return type The fuel pump is incorporated into the fuel tank module which also contains the level sensor fuel pressure regulator and vapour pressure sensor The ECM controls the fuel pump operation via a relay because of this the only fault diagnosis is of the fuel pump relay Component connections Relay connector Description ECU Pin ECU Connector 1 Rear ignition relay fuse R7 2 Fuel pump relay control H2 48 Way Right Monitor e Continuous Enable Criteria e Ignition on Disable Criteria e None Potential failure modes e P0628 fuel pump relay wi
54. noid Circuit Low Bank 1 13 P0077 Intake Valve Control Solenoid Circuit High Bank 1 13 P0079 Exhaust Valve Control Solenoid Circuit Low Bank 1 13 P0080 Exhaust Valve Control Solenoid Circuit High Bank 1 13 P0082 Intake Valve Control Solenoid Circuit Low Bank 2 13 P0083 Intake Valve Control Solenoid Circuit High Bank 2 13 P0085 Exhaust Valve Control Solenoid Circuit Low Bank 2 13 P0086 Exhaust Valve Control Solenoid Circuit High Bank 2 13 P0101 Mass or Volume Air Flow Circuit Range Performance 14 P0102 Mass or Volume Air Flow Circuit Low Input 14 P0103 Mass or Volume Air Flow Circuit High Input 14 P0106 Manifold Absolute Pressure Barometric Pressure Circuit Range Performance 16 P0107 Manifold Absolute Pressure Barometric Pressure Circuit Low Input 16 P0108 Manifold Absolute Pressure Barometric Pressure Circuit High Input 16 P0111 Intake Air Temperature Sensor 1 Circuit Range Performance 17 P0112 Intake Air Temperature Sensor 1 Circuit Low 17 P0113 Intake Air Temperature Sensor 1 Circuit High 17 P0116 Engine Coolant Temperature Circuit Range Performance 19 P0117 Engine Coolant Temperature Circuit Low 19 P0118 Engine Coolant Temperature Circuit High 19 P0122 Throttle Position Sensor A Circuit Low 21 P0123 Throttle Position Sensor A Circuit High 21 P0128 Coolant Thermostat Coolant Temperature Below Thermostat Regulating Temperature 24 P0131 O2 Sensor Circuit Low Voltage Pre Catalyst Bank1 25 P0132 O2 Sensor Circuit High Voltage
55. nsor E circuit low Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU Note that the potentiometers operate on 5 volts Enable Criteria e None Disable Criteria e None Potential failure modes e Signal short circuit lt 0 283 V e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied ee Sw Pedal Position Sensor E Circuit High P2128 Pedal position sensor E circuit high Enable Criteria e None Disable Criteria e None Potential failure modes e Signal open circuit gt 4 487 V e Reference voltage open circuit e Reference voltage short to ground e Sensor failure Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied Throttle Position Sensor A B Voltage Correlation P2135 Throttle position sensor A B voltage correlation Description Two potentiometers are built into the throttle actuator unit in order to provide a throttle position signal to the ECU Two processors within the ECU compare the two output signals which should match within a defined tolerance Note that the potentiometers operate on 5 volts Ena
56. o determine if there is any difference a big difference indicates as a fault The ECU also monitors the signal on gear changes to see if there is any pressure rise as a result of the fuel sloshing around These codes are likely to indicate a pressure sensor fault Disable Criteria e P0500 Wheel speed sensor fault Monitor e Until leak check is completed Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips EEE eee Page 47 ae Fuel Level Sensor P0461 Fuel Level Sensor A Circuit Range Performance P0462 Fuel Level Sensor A Circuit Low P0463 Fuel Level Sensor A Circuit High Description When the engine is running the ECU continuously monitors the fuel level sensor feedback signals The feedback signal should be low when turned ON and high when turned OFF The following codes will be set if the above conditions are not meet Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 2 Fuel level sensor A2 48 Way Right 3 Fuel level sensor ground K3 48 Way Right P0462 P0463 Monitor e Continuous Enable Criteria Engine Running Disable Criteria e None Malfunction Criteria e P0462 Voltage lt 0 020V P0463 Voltage gt 0 684V for 1 5 secs Potential failure modes e Sensor open or short circuit e Fuel level sensor Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips
57. on on Disable Criteria 2 e Electronic throttle fault P2135 P0122 P0122 P0222 or P0223 present Malfunction Criteria 2 e Throttle not able to find closed position during boot Potential failure modes e Blocked throttle body Damage to throttle actuator Diagnostic Mask e The MIL will be illuminated if fault is present Notes A mechanically sprung 7 throttle opening may be imposed mmm Page 62 Air Conditioning System P0646 A C Clutch Relay Control Circuit Low P0647 A C Clutch Relay Control Circuit High Description The ECM controls the A C clutch relay in response to the A C driver request and ECM control logic Component connections Relay Connector Description ECU Pin ECU Connector 1 Ignition supply fuse R11 2 AC clutch relay control F2 48 Way Right Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e P0646 A C compressor relay wiring open circuit or shorted to ground e P0646 Fuse R11 e P0647 A C compressor relay circuit shorted to 12V A C compressor relay failure e ECU output circuit failure Diagnostic Mask e The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips EEE eee Page 63 Variable intake manifold circuit P0661 Variable intake manifold circuit voltage low P0662 Variable intake manifold circuit voltage high Descrip
58. previous two trips mmm Page 56 ECU Integrit P0601 Checksum P0606 Watchdog Description These codes are used by the ECU to check the integrity of the software and calibration data P0601 checks that on power up the checksum for calibration data is the same as checksum saved on the previous power down P0606 checks the watchdog timer after a defined period to see if it has reset If the watchdog timer has not reset then the code has entered an unplanned loop or condition stopping it resetting the timer Monitor e P0601 at ECU power up e P0606 continuously while the engine running Diagnostic Mask e The MIL will be illuminated if a fault is present EEE eee Page 57 a Variant Code Not Programmed P0610 Variant code not programmed Description The ECM programming process includes the Vehicle Variant Code If anew ECM has been fitted the relevant variant code needs to be programmed using the Lotus TechCentre tool Monitor During start up Disable criteria e None Potential failure modes e Variant code not programmed Diagnostic mask e The MIL will be illuminated if fault is present mmm Page 58 SS Crank Rela P0616 Starter relay voltage low P0617 Starter relay voltage high Description When the ignition key is in the crank position battery voltage is applied to the start request input of the ECM The ECM will then energise the crank relay via the immobiliser to allow the starter motor to be e
59. r shorted injector e Purge valve fault e Oxygen sensor contamination Engine oil contamination e Sensor wire shorted to heater voltage Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0133 Bank1 or P0153 Bank2 Monitor e Continuous Disable Criteria e P0116 P0117 P0118 Coolant temperature sensor faults e P0101 P0102 P0103 MAF sensor faults e P0335 P0500 Crank or vehicle speed faults e P0131 P0132 P0134 P0135 Pre catalyst oxygen sensor faults for Bank1 checks e P0151 P0152 P0154 P0155 Pre catalyst oxygen sensor faults for Bank2 checks Enable Criteria e Vehicle speed between 0 255 km h 158 5 mph e MAF per stroke between 15 48 mg e Engine speed between 1285 1818rpm Engine run time gt 200 seconds e Coolant temperature gt 60 C 140 F Closed loop fuelling enabled Monitor e Monitored until the required amount of switches 30 in both directions has been achieved or 130 seconds has elapsed Page 26 Malfunction Criteria e Set when the sensor fails to switch from a Lean to a Rich condition or switch from a Rich to a Lean condition in a sufficiently timely manner A selection of switches is used to determine the average times highlighted section removed Potential failure modes e Sensor connector and wiring should be checked for corrosion and loose connections e Sensor contaminated poss
60. re faults P0451 P0452 P0453 Tank Pressure sensor faults P0461 P0462 P0463 Fuel level sensor faults e P0500 Vehicle speed faults G MM AA Page 43 aaa Malfunction Criteria P0441 This code can be caused by the purge value being either stuck closed or open This test is also completed upon vehicle start up Purge valve stuck open A purge valve that is unable to seal correctly will result in a tank evacuation during the sealing phase of the leak check sequence In this phase a pressure rise would normally be expected but when the purge valve is not sealing this causes depression in the tank When the pressure is below 4mbar a purge valve fault is detected Upon vehicle start up the tank pressure should not drop below 25mbar as the CCV and purge valve are closed Is this does occur a fault is detected Purge valve stuck closed Apurge valve that is unable to open will not be able to achieve the required depression during the evacuation phase A positive pressure rise during the leak check evacuation phase will be detected Additional purge checks will set a purge valve fault code these require normal driving to complete Monitor e Until leak check is completed Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0442 This code is set during the evaporative leak check process if the system calculates the measure of leak is above a specified value 3 1 5 7 mb
61. revious trip Lost Communications with TPMS U0127 Lost Communications with TPMS Description The ECM communicates with the Tyre Pressure Monitor System TPMS via the CAN bus If these CAN bus communications have been interrupted the ECM will register a diagnostic code Potential failure modes e CAN wiring e TPMS control module failure CAN bus corruption by another module on bus Diagnostic Mask e The service light will be illuminated for 30 seconds after engine start if the fault was present on the previous trip mms FAC 79 ps Software Incompatible with VDCM U0316 Software Incompatible with VDCM Description The ECM checks that the Vehicle Dynamic Control Module VDCM matches the vehicle variant code If not the above code will be set and the ECM will not respond to torque requests from the VDCM Potential failure modes e The ECM has been programmed with an incorrect variant code which does not match vehicle VDCM level e VDCM error Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault was present on the previous trip EEE eee Page 80 aay EMR 5 CAN BUS DIAGNOSTICS LOTUS TECHCENTRE Controller Area Network CAN is an electronic standard to allow high speed communication between mod ules and controllers via a serial data bus The bus is a circuit linking the modules to the controller consisting of a pair of cables twisted together to
62. ria 2 Engine running Malfunction Criteria 2 e Inlet air temperature erratic by more than 40 C 72 F for time gt 1 5 secs Enable Criteria 3 e Accumulated mass air flow gt 10000g gt 60secs e Mass air flow gt 15g s for 20secs e Mass airflow change from 15g s to 6g s lt 20secs e Mass airflow lt 6g s for 20secs Malfunction Criteria 3 e Failure to change temperature by 1 2 C after the enable criteria tests have been completed eS Page 17 i Potential failure modes e P0112 signal short circuit e P0113 signal open circuit e Sensor failure Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips P0112 Monitor e Continuous Disable Criteria e None Enable Criteria Engine running Malfunction Criteria Inlet air temperature gt 119 C 246 F for time gt 1 5 secs Potential failure modes e Signal short circuit e Sensor failure Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips P0113 Monitor e Continuous Disable Criteria e None Enable Criteria e Engine running Malfunction Criteria Inlet air temperature lt 40 C 104 F for time gt 1 5 secs Potential failure modes e Signal open circuit e Sensor failure Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips mm Page 18 Engine Coolant Temperature P011
63. ring open circuit or shorted to ground e P0628 fuse R7 e P0629 fuel pump relay wiring shorted to 12V e Fuel pump relay failure e ECU output circuit failure Diagnostic Mask The MIL will be illuminated immediately if a fault is present m Page 60 EO EE VIN Not Programmed or Incompatible ECU PCM P0630 Vin not programmed or incompatible Description The ECM programming process includes the Vehicle Identification Number VIN If anew ECM has been fitted this operation is performed using the Lotus TechCentre tool Monitor e During start up Enable Criteria e Engine running for up to 4 seconds Disable Criteria e None Potential failure modes VIN not programmed Diagnostic Mask e The MIL will be illuminated if fault is present MlA Page 61 EE Throttle Actuator Control Range Performance P0638 Throttle actuator control range performance Description The single throttle butterfly valve mounted at the inlet to the intake plenum is operated by a stepper motor under the command of the engine ECU The valve moves through a range of nearly 90 and should display 100 at full throttle and around 2 at idle Monitor e Continuous Enable Criteria 1 Engine running Disable Criteria 1 e Electronic throttle fault P2135 P0122 P0122 P0222 or P0223 present Throttle demand transient condition Malfunction Criteria 1 TPS error gt 3 for 7 5 secs Enable Criteria 2 e Igniti
64. riteria 1 e Idle air learn value on upper limit of 1 8g s e Idle speed more than 200 rpm above desired idle speed for more than 5 seconds Malfunction Criteria 2 e Idle air learn value on lower limit of 1 8g s e Idle speed more than 100 rpm below desired idle speed for more than 5 seconds Potential failure modes e Induction system air leak e Excessive engine load from front end accessory drive system water pump power steering alternator e Electronic Throttle Control Diagnostic Mask e The MIL will be illuminated if a fault is present for 2 consecutive trips Notes There will be a different learn value for AC on and AC off Either could trigger fault mmm Page 52 AIC Evaporator temperature sensor P0537 A C Evaporator temperature sensor circuit low P0538 A C Evaporator temperature sensor circuit high Description The A C system incorporates an evaporator temperature sensor for system control This is a thermistor device that changes resistance with temperature As the evaporator temperature decreases the thermistor resistance value increases and conversely as the evaporator temperature increases so the thermistor resistance value decreases Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor signal A3 48 Way Right 1 Sensor ground K3 48 Way Right Monitor e Continuous Enable Criteria e Vehicle Running Disable Criteria e None Malfunction Criteria e P0537 Signal volt
65. round C3 32 Way Left 3 Supply voltage 5V D1 32 Way Left 1 Inlet Bank 2 Signal A2 32 Way Left 2 Inlet Bank 2 Ground C2 32 Way Left 3 Supply voltage 5V D1 32 Way Left 1 Exhaust Bank 2 Signal D3 32 Way Left 2 Exhaust Bank 2 Ground C4 32 Way Left 3 Supply voltage 5V D1 32 Way Left Monitor e Continuous Enable Criteria e Engine running e Engine speed gt 600rpm Engine runtime gt 4 secs Disable Criteria e None Malfunction Criteria e 15 revolutions of crankshaft without receiving camshaft signal Potential failure modes Sensor signal open circuit or short to ground e Sensor ground open circuit e Sensor failure e Cam failure e Camshaft position plate e ECU Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips Notes Fault code P0341 will also be generated if the vehicle fails security checks on start up mms PAGE SI oy Ignition System P0351 Ignition Coil A Primary Secondary Circuit P0352 Ignition Coil B Primary Secondary Circuit P0353 Ignition Coil C Primary Secondary Circuit P0354 Ignition Coil D Primary Secondary Circuit P0355 Ignition Coil E Primary Secondary Circuit P0356 Ignition Coil F Primary Secondary Circuit Description A Direct Ignition System DIS is used on the engine The DIS improves the ignition accuracy reduces high voltage loss and enhances the reliability of the ignition system The
66. s Sensor Connector Description ECU Pin ECU Connector 1 IAT Signal J3 48 Way Centre 2 IAT Ground E3 48 Way Centre 3 Battery Voltage 4 MAF Ground J4 48 Way Centre 5 MAF Signal G1 48 Way Centre Sensor characteristics 0 330 g sec Typical values 1 5 5 0 g sec idle 5 0 15 0 g sec 2500rpm elevated idle no load P0101 Monitor e Continuous Enable Criteria e Engine running Engine speed gt 1500rpm e Engine speed lt 3510rpm e Fuel Learns enabled Disable Criteria e P0122 P0123 P0222 P0223 Throttle Pedal position fault codes Malfunction Criteria e Measured MAF is compared to a predicted MAF based on current engine conditions e Error gt 40 for time gt 1 5 secs Potential failure modes MAF meter e Air induction system e Air intake hose connections Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips P0102 Monitor e Continuous Enable Criteria e Engine running Page 14 n Disable Criteria e None Malfunction Criteria Voltage at ECU lt 0 52V for time gt 1 5 secs Potential failure modes e MAF sensor circuit open e MAF sensor circuit short to ground Diagnostic Mask e The MIL will be illuminated if the faults are present for 2 consecutive trips P0103 Monitor e Continuous Enable Criteria Engine running Disable Criteria e None Malfunction Criteria Voltage at ECU gt 4 86V for time
67. s expired Monitor e Until leak check is completed Potential failure modes e Leak from pipes or connections e Leaking or damaged seal on filler cap not fitted correctly e Canister Closure valve not fully closing Diagnostic Mask e The MIL will be illuminated if these faults are present for 2 consecutive trips EEE eee Page 45 eri Evaporative Emission Control Purge Open Closed Circuit P0444 Evaporative Emission System Purge Control Valve Circuit Open P0445 Evaporative Emission System Purge Control Valve Circuit Closed P0446 Evaporative Emission System Vent Control Circuit P0447 Evaporative Emission System Vent Control Circuit Open P0448 Evaporative Emission System Vent Control Circuit Closed P0451 Evaporative Emission System Pressure Sensor Switch Range Performance P0452 Evaporative Emission System Pressure Sensor Switch Low P0453 Evaporative Emission System Pressure Sensor Switch High Description When the engine is running the ECU continuously monitors the status of the evaporative emission components for open circuit or short The feedback signal should be low when turned ON and high when turned OFF The following codes will be set if the above conditions are not met P0444 P0445 P0447 P0448 P0452 P0453 Sensor component connections Vapour Pressure sensor Connector Pins Description ECU Pin ECU Connector 1 Ground K3 48 Way Right 2 Signal B3 48 Way Right 3 5V V Ref F4 48 Way Right Purge C
68. scription The air cleaner is equipped with 2 inlets one of which is opened or closed by the Air Intake Control Valve AICV This system reduces intake noise and increases engine power When the engine is operating in the low to mid speed range the ECM deactivates the Vacuum Solenoid Valve VSV and allows the AICV to close one of the air cleaner inlets When the engine speed is greater than a specified value the ECM activates the VSV and the applied vacuum activates the AICV to open both of the air cleaner inlets Component connections Connector Description ECU Pin ECU Connector 1 Ignition supply fuse R8 2 VSV control B1 48 Way Central Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e VSV open circuit or short to ground e VSV circuit short to ECU Diagnostic Mask e The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips EEE eee Page 67 aay Misfire P1301 Misfire level causing emissions increase P1302 Misfire level causing catalyst system damage Description When the engine misfire reaches a high enough percentage the engine emission output levels can exceed the allowed limits this will produce the fault code P1301 If the misfire percentage is high enough and there is a possibility that the catalyst may be damaged then code P1302 will be set To prevent catalyst damag
69. the ECM will take action to prevent catalyst damage Notes e Misfire learns are calculated during DFCO Deceleration Fuel Cut Off i Page 68 D eee Coolant Recirculation Pum P2602 Coolant Pump Control Circuit Low P2603 Coolant Pump Control Circuit High Description During a hot shutdown of the engine the recirculation pump can continue to pump coolant around the engine The recirculation pump will run after the engine has been turned off if the enable criteria are matched The recirculation pump will also run after a short period of idle to aid heater performance Component connections Connector Description ECU Pin ECU Connector 1 Recirc pump driver M1 48 Way Right 2 Main relay via fuse R4 Monitor e Continuous Enable Criteria e P2602 continuous e P2603 engine running Disable Criteria e None Potential failure modes e P2602 pump wiring open circuit or shorted to ground e P2602 fuse R4 e P2603 pump circuit ECM side shorted to battery voltage e Pump failure e ECU output circuit failure Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips ECUwooeeE CO eee Page 69 aa Throttle Actuator Control Motor Circuit Open P2100 Throttle actuator control motor circuit open Description The throttle actuator stepper motor operates on 12 volts Monitor e Continuous En
70. tion This circuit opens and closes the variable intake manifold VIM in response to changes in the engine speed and load in order to increase the intake efficiency When the engine speed is less than 4200 rpm and the engine load is greater than 52 the ECM turns on the VIM control valve to close the VIM Under all other conditions the VIM control valve is usually off and the VIM is open Component connections Connector Description ECU Pin ECU Connector 1 Ignition supply fuse R8 2 VIM control valve control L4 48 Way Central Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e P0661 VIM wiring open circuit or shorted to ground e P0661 Fuse R8 e P0662 VIM circuit ECM side shorted to battery voltage VIM control valve failure e ECU output circuit failure Diagnostic Mask e The MIL will be illuminated if a fault is present for two consecutive trips mm Page 64 Clutch position sensor circuit P0806 Clutch position sensor circuit range performance P0807 Clutch position sensor circuit low P0808 Clutch position sensor circuit high Description The clutch position sensor is used to identify the position of the clutch engaged disengaged or slipping This information is used to control features such as fuel cut during gear changes cruise control deactivation and ensuring any torque increase requests from the ESP system only occur with t
71. ure value and opening the purge solenoid with the appropriate duty cycle This allows the engine to draw a vacuum on the entire evaporative emission system After a calibrated vacuum level is achieved the purge solenoid is closed sealing the system A leak is detected by monitoring any decrease in vacuum level over a calibrated period of time Sensor component connections Vapour Pressure sensor Connector Pins Description ECU Pin ECU Connector 1 Ground K3 48 Way Right 2 Signal B3 48 Way Right 3 5V V Ref F4 48 Way Right Purge Canister Closure Valve Connector Pins Description ECU Pin ECU Connector A Battery Voltage B CCV Output B4 48 Way Centre Purge Solenoid Connector Pins Description ECU Pin ECU Connector 1 Battery Voltage 2 Solenoid Output B3 48 Way Centre Enable Criteria e Altitude lt 8000 ft 2438 m Baro gt 756 mbar e SUTair Start up air temperature gt 10 C 14 F Coolant gt 45 C 113 F e Air temp lt 80 C 176 F e Fuel level between 10 51 litres 2 64 13 5 US gallons e Vehicle must be stationary for leak check e Subsequent checks are made with purge levels gt 75 and vehicle moving with part throttle e Closed loop fuelling control enabled e Closed loop idle speed control enabled e Ignition on Disable Criteria e P0171 P0172 P0174 P0175 Fuel trim too rich or lean soft code P0441 P0444 P0445 Purge faults P0446 P0447 P0448 Canister closu
72. utdown Description If a problem is detected which could result in engine speed runaway or if sufficient control of engine speed is lost the ECU switches off the fuel injectors in order to stop the engine Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e Electronic throttle fault Note This code indicates action taken by the ECU and will always be accompanied by another code which has caused this action aaa es Page 71 aa Throttle Actuator Control System Forced Limited Power P2106 Throttle actuator control system forced limited power Description If a problem is detected which could result in engine speed control difficulties the ECU will limit throttle opening to a maximum of 15 Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes e Electronic throttle fault Note This code indicates action taken by the ECU and will always be accompanied by another code which has caused this action Throttle Actuator Control Module Processor P2107 Throttle actuator control module processor Description The ECU contains two processors dedicated to the throttle pedal and throttle valve potentiometers Monitor e Continuous Enable Criteria e Engine running Disable Criteria e None Potential failure modes ECU internal fault Incorrect ECU programming i Page 72 eee eee
73. y Catalyst Bank 1 Primary Catalyst Bank 2 Secondary Catalyst Evaporative Emission Control System Purge Control Valve Fuel Pump Relay Starter Relay Function Engine load detection Air temperature detection Engine coolant temperature detection Determines engine throttle position Determines pedal position requested by driver Barometric pressure detection Measures oxygen content in exhaust before bank 1 primary catalyst Measures oxygen content in exhaust before bank 1 primary catalyst Measures oxygen content in exhaust after bank 1 primary catalyst Measures oxygen content in exhaust after bank 2 primary catalyst Determines crankshaft position Determines bank inlet camshaft position Determines bank 2 inlet camshaft position Determines bank 1 exhaust camshaft position Determines bank 2 exhaust camshaft position Determines bank 1 engine detonation Determines bank 2 engine detonation Determines fuel tank level Evaporator temperature detection Determines clutch pedal position Determines brake pedal position Determines driver request for cruise control Actuates engine throttle Regulates fuel injected into cylinder 1 Regulates fuel injected into cylinder 2 Regulates fuel injected into cylinder 3 Regulates fuel injected into cylinder 4 Regulates fuel injected into cylinder 5 Regulates fuel injected into cylinder 6 Actuates spark plug in cylinder 1 Actuates spark plug in cylinder 2 Actuates spark plug in cylinder 3

Lotus Service Notes Section EMR

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