SERVICE MANUAL - Service
Contents
1. output No 1 too high Sensor reference voltage output No 1 too low Ea Sensor reference voltage output No 2 too high 03 Sensor reference voltage output No 2 too low Zar controller command line short to battery Glow controller internal malfunction Glow controller command line open load short to GND Glow controller internal malfunction 02 Glow plug R side short Glow diagnosis line short to GND Glow controller internal malfunction 04 Glow plug R side open load Glow diagnosis line open load Glow controller internal malfunction Main relay relay output short to battery 03 Main relay relay output short to GND A C relay output short to battery A C relay output open load short to GND EGR control DC motor Output 1 Short to battery short to GND output 2 short to battery short to GND motor short EGR control DC motor output 1 open load output 2 open load motor open load TWV1 output open load Injector 1 coil open TWV2 output open load injector 3 coil open TWV3 output open load injector 4 coil open COM1 output short to battery TWV1 or 3 output short to battery both TWV1 and TWV3 open load COM output short to GND TWV1 or 3 output short COM2 output short to battery TWV2 or 4 output short to battery both TWV2 and TWV4 open load COM2 output short to GND TWV2 or 4 output short to GND Capacitor charge up circuit malfunction insufficient charge Capacitor charge up circuit malfunction excessive char2. P0100 Mass airflow sensor Intake air temperature sensor Coolant temperature sensor Operation Section 1 14 Symptom Failure Mode E Identification Number VIN not pro grammed Rejected reprogramming attempt of a critical 4D not programmed o Engine ECU internal engine torque supervisions Alternator L terminal duty ratio too high at Key ON test o8 Alternator L terminal duty ratio too low at Run test Alternator F terminal ratio too high at Key ON test Alternator F terminal ratio too low at Run test 01 Permanently active One or Both Brake error Brake switch sequence error Brake Lamp Switch BLS error engine identifier Maximum Vehicle Speed Vmax limitation speed 4B 34 5A 4E SQL value not programmed SQL value error Variable Nozzle Turbo VNT hose popping off Pump learning incompletion All wheel signals set to invalid by sender ABS Both non driven wheel signals set to invalid by sender ABS 71 71 Engine identifier in engine ECU calibration and engine ECU EEPROM are not matching 3B Illegal engine tuning protection 06 ass arto senor gallos Operation Section 1 15 DIC FalluePat Failure Part Symptom Failure Mode 07 Accelerator position sensor No 1 signal too high Accelerator position sensor No 1 signal too high P1120 Accelerator position sensor 1 Im Accelerator position sensor No 1 signal too low 07 Accelerator position sensor No 2 signal to
3. THExh2 GND nal Exhaust temperature sensor Exhaust temperature sensor 3 Sig 18 THExh3 GND GND 42 THExh3 na 19 oan SLD oan Cylinder recognition sensor Shield Ei pe G Cyinder recognition sensor NE SLD Crankshaft position sensor Shield Cylinder recognition sensor Variable nozzle turbo DC motor Crankshaft position sensor Variable nozzle turbo DC motor Crankshaft position sensor peque pepe Operation Section 1 24 Terminal Connections A side pins 49 96 et o e E Il 54 SPAD VCC VCC j EE nozzle turbo actuator Sexe E 55 VNT DI DIS I T DI Diesel throttle controller diagnosis i LOIL SW OIL level SW signal ACGF F ACG F terminal Alternator E PO SW SW OIL pressure SW signal pressure SW OIL pressure SW signal GC L ACG L terminal Alternator Pow sw fot pe nozzle turbo position sen 58 LVNT VCC2 82 S SW1 Spare sor VCC Variable swirl control position sensor 59 LVSS VCC2 S SW2 Spare VCC aan 3 60 LEGR VCC2 VCC2 EGR position sensor VCC position sensor EGR position sensor VCC W Spare E airflow sensor air temperature PIM VCC2 Boost pressure sensor VCC IAT ANG Anal nalog PFUEL VCC2 Rail pressure sensor VCC EGR GND EGR shield PExhD VCC2 Differential pressure sensor VCC BY PASS EGR By pass Valve G VCC2 Cylinder recognition sensor VCC S REL2 Spare 65 Eu VCC1 Crankshaft position senso
4. control valve SCV EI THF GND Fuel temperature sensor GND Fuel temperature sensor Signal 31 THw e 7 THW GND GND Coolant temperature sensor GND temperature sensor Coolant temperature sensor GND H Coolant temperature sensor Signal W UM nozzle turbo position sen I nozzle turbo position sen LVNT GND 32 LVNT sor GND sor Signal Variable swirl control position sensor Variable swirl control position sensor LVSS GND 33 LVSS GND Signal 10 LEGR GND GND EGR position sensor GND position sensor EGR position sensor GND EI LEGR EGR position sensor Signal RH Boost pressure sensor GND CES pressure sensor Signal PFUEL GND Rail pressure sensor GND PFUEL Rail pressure sensor Signal 13 PFUEL SLD SLD Rail pressure sensor Shield pressure sensor Rail pressure sensor Shield 37 PFUEL e Rail pressure sensor Signa pressure sensor Rail pressure sensor Signa BET air temperature sensor 2 14 MAF GND Mass airflow sensor GND 38 IAT Signal i 15 PEXhD GND GND Differential pressure sensor GND pressure sensor Differential pressure sensor GND EI PEXAD Differential pressure sensor Signal pressure sensor Differential pressure sensor Signal Exhaust temperature sensor NAM Prem temperature sensor 1 Sig 16 THExh1 GND 40 THExh1 GND nal Exhaust temperature sensor Exhaust temperature sensor 2 Sig 17 THExh2 GND 41
5. e The shape of the rail as well as the installation positions for the fuel pressure sensor and pressure limiter have been changed The shape and characteristics of the rail pressure sensor and pressure limiter have not changed For details refer to the service manual entitled Common Rail System for OPEL 4EE2 Type Engine Doc ID 00400028 New Model Rail Pressure Pc Sensor Q002037E Old Model Rail Pressure Pc Sensor Q002049E Operation Section 1 6 4 INJECTOR 4 1 Outline e The shape of the injector as well as the QR code ID code correction point have been changed Other specifications and operations have not changed For details refer to the service manual entitled Common Rail System for OPEL 4EE2 Type Engine Doc ID 00400029 QR Code to Fuel Tank Solenoid Valve High Pressure Fuel from Rail Nozzle Spring VR EP E L L L L L Li L Nozzle Needle il Seat Area Q002038bE Operation Section 1 7 4 2 QR Code QR code correction points are as per the figure below QR Code Correction Point 180 MPa 140 MPa P4 3 90 MPa Injection Quantity Q Actuating Pulse Width Tq QR Code 9 9 mm ID Code 22 sets of 16 alphanumeric figures Contents of Printing TE TPs 2 BCC Q002039E Operation Section 1 8 5 CONTROL SYSTEM COMPONENTS DESCRIPTION 5 1 Outline e Changes additions to control related parts are expla
6. 811 8 Cruise control off switch diagnostics IVLAN cruise U0405 Cruise switch i switch status malfunction P1610 P1614 Upper oxygen catalyst temperature sensor exhaust gas temperature 1 Upper DPF temperature sensor exhaust gas temperature 2 Deferential pressure sensor Fan relay 1 output Fan relay 2 output Fan relay 3 output CAN communication Torque control safety Immobilizer system Upper oxygen catalyst temperature sensor exhaust gas temperature 1 voltage too high Upper oxygen catalyst temperature sensor exhaust gas temperature 1 voltage too low Upper oxygen catalyst temperature sensor exhaust gas temperature 1 temperature too high EN aal perature 2 voltage too high perature 2 voltage too low perature 2 temperature too high 58 proren pressure omn 05 Hemedscemedwam _ 08 Fanconi relay opentoadshontoGND Irma 06 Fan control relay 3 open load short to GND Lost communication with ABS Traction Control Sys tem TRC Lost communication with Body Control Module BCM 9 Remeras 09 Freien val alo 00 Tue range reso VAAN RR 00 Secret key security code are not programmed yet The Immobilizer 2 Control Unit ICM2 function in engine ECU is switched off a sc coe enes 00 mau ona Lm reia cae cores meer Lum me arm rnonder reponse was ng Operation Section 1 19 Failure Part Symptom Failure Mode 00 System not programmed seed amp key not armed
7. CV P0001 SCV valve SCV stuck Rail pressure sensor performance invalid included P0094 Common rail system fuel leak ELM ME short to battery H eegen output open load short to GND SCV coil open SCV coil short SCV output open load short to GND SCV E Engine ECU internal failure P0606 CPU fault Watchdog IC fault Cylinder 1 fuel system failure Cylinder 3 fuel system failure Cylinder 2 fuel system failure Cylinder 4 fuel system failure Operation Section 1 12 DIC FalluePat Failure Part Symptom Failure Mode Ben B EGR excessive fow EGR positive deviation EGR excessive flow EGR positive deviation system P0400 e EGR insufficient flow EGR negative deviation EGR valve LS EGR valve open close stuck P0299 52 Turbo control system negative deviation Turbo system E LEN 7 Turbo control system positive deviation T Electric Vacuum Regulating Valve EVRV Im EVRV Turbo output short to battery Turbo o EVRV Turbo output open load short to GND E VSS output VSV short to battery VSS output VSV open load short to GND 01 Diesel throttle controller output signal short to bat tery P0638 Diesel throttle system Diesel throttle controller output signal open load short to GND P2620 08 Diesel throttle controller failure status 07 Upper oxygen catalyst temperature sensor exhaust gas temperature 1 voltage too high P0425 Upper Oxygen catalyst temperature sensor 03 Up
8. Diesel Injection Pump SERVICE MANUAL OPEL Z17DT TYPE ENGINE COMMON RAIL SYSTEM CRS OPERATION January 2007 DENSO CORPORATION 00400588E 2006 DENSO CORPORATION All Rights Reserved This book may not be reproduced or copied in whole or in part without the written permission of the publisher Table of Contents Table of Contents Operation Section 1 PRODUCT APPLICATION INFORMATION 1 1 Outline une Sei ce ie Dee tbt debet pe ia 1 1 1 2 AD pliGatione 2 ds a ct de Me d i Med A E E e ear ERROR ed oer e RON n 1 1 13 System Component Part Number 1 1 2 SUPPLY PUMP 2 1 Outline ento ub XM AXES EE e xps 1 2 2 2 Suction Control Valve SCV 2 20 hara een nennen nenn 1 3 3 RAIL 3 1 ET EE 1 5 4 INJECTOR CS Ol TRUE 1 6 AOS 1 A ERR 1 7 5 CONTROL SYSTEM COMPONENTS DESCRIPTION 5 1 LO TUI ye eta EDITED IE LOQUITUR 1 8 5 2 Engine ECU ci oa nia a vote e wx ARDET pep rp od ENDS ede a osi Ea dede 1 8 5 3 Boost Pressure Sensor 533 e d DE rc ene pe A TI ERE RIO RENS 1 8 6 DIAGNOSIS 6 1 Diagnostic Trouble Code DTC Table hn 1 9 7 EXTERNAL WIRING DIAGRAM 7 1 Engine ECU External Wiring Diagram 00 00 t eee 1 21 7 2 Engine ECU Connector Diagram o 1 23 Operation Section 1 PRODUCT APPLICATION INFORMATION 1 1 Outline The Common Rail System CRS used with the OPEL Z17DT engine has been redesigned Basic system configuration is identical to that of the CRS used wi
9. M failure 01 Permanently active Brake Lamp Switch BLS error Brake switch signal error o Brake switch sequence error BLS error Brake switch event error Brake Test Switch BTS P1571 04 error P1602 0B SQL value not programmed Microinjection quantity learning SQL PO62F SQL value error P0299 Popping off Variable Nozzle Turbo VNT hose popping off Operation Section 1 20 D ES Part an Be oT Mode Pumpleamng Pumpleamng 0E Pumpleamigincompete Pump learning incomplete incomplete P Pumpen mean NN identifier in engine ECU calibration and rogrammin S S gt ECU EEPROM are not matching P1602 Tuning protection Tuning protection protection 08 ilegal engine tuning protection engine tuning protection Engine identifier not programmed Programming xe reprogramming attempt of a critical ES identifier EN air temperature sensor analog signal too Intake air temperature analog sensor ENE Intake air temperature sensor analog signal too low P1600 Programming Engine ECU internal engine torque supervisions Operation Section 1 21 7 EXTERNAL WIRING DIAGRAM 7 1 Engine ECU External Wiring Diagram Powertrain Main Relay A A 49 re Injector 4 9 A 51 Injector 3 C gt AN A 25 A 1 Less 0 Aa fieneg Uej25 ung Recognito E ie Engine ECU Sensor O V SUE Accelerator P Position Sensor 19 O Cra
10. Vehicle Identification Number VIN not pro Programming 04 rimis Im Variant not programmed E memes i ration list is not programmed poro Massaron sensor 08 MasssMowsemortolw _ 0 Jeton Differential pressure sensor characteristic abnor P2452 02 mality Upper oxygen catalyst temperature sensor Upper oxygen catalyst temperature sensor mE Exhaust gas temperature 1 sensor characteristic exhaust gas temperature 1 abnormality P042A Upper DPF temperature sensor exhaust 02 Upper DPF temperature sensor exhaust gas tem gas temperature 2 perature 2 sensor characteristic abnormality 01 EGR cooler bypass output short to battery P2425 EGR cooler bypass pup 0 EGR cooler bypass output open load short to GND P0400 EGR DC motor EGR DC motor lock P1615 Incorrect Vehicle ID Body Control Module BCM received Vehicle ID P1616 Incorrect Vehicle ID Immobilizer Control Unit ICM received P0409 EGR valve 02 EGR lift sensor characteristic abnormality 1 Fuel injection quantity reduction diagnosis by exhaust temperature P0168 Fuel injection quantity reduction 0 Check engine warning light short to battery P0650 Check engine warning light 4 Check engine warning light open load short to GND Engine speed output to battery P0720 NE output PO62F DPF system 01 0 04 Engine speed output short to GND All wheel signals invalid by sender ABS Electronically Erasable and Programmable Read Only Memory EEPRO
11. ation Section 1 10 Failure Part Symptom Failure Mode 07 A C pressure sensor signal too high A C pressure sensor A C pressure sensor signal too low A C pressure sensor GND signal open Brake switch diagnostics Cruise control brake P0571 Brake switch switch no signal P0168 Fuel injection quantity reduction Fuel quantity reduction by injector leak temperature Clutch switch circuit malfunction manual transmis P0704 Clutch switch sion only P0520 Oil pressure switch Oil pressure switch stuck open Crankshaft position sensor no pulse P0335 Crankshaft position sensor 08 Crankshaft position sensor signal invalid Cylinder recognition sensor no pulse P0340 Cylinder recognition sensor Cylinder recognition sensor signal invalid P0016 Crankshaft position sensor Cylinder recog nition sensor sensor signal synchronization error P0685 02 Main relay diagnostics Main relay stuck closed Main relay Main relay diagnostics Main relay stuck open relay P1625 62 output open load Sensor reference voltage output No 1 too high Sensor reference voltage output No 1 too low Sensor reference voltage output No 2 too high Sensor reference voltage output No 2 too low Crankshaft position sensor cylinder recognition o P0641 Sensor reference voltage 1 ojo Sensor reference voltage 2 o Glow controller command line short to battery Glow controller internal malfunction Glow controller command line open load short to Glow
12. aust 55 Upper DPF temperature sensor exhaust gas tem gas temperature 2 perature 2 characteristic abnormality EGR cooler bypass output short to battery P2425 EGR cooler bypass E 0 EGR cooler bypass output open load short to GND P0400 EGR DC motor 62 EGR DC motor lock EB Immobilizer 3 Control Unit ICM3 function in ECU P1610 is not programmed or is in function reset mode be E Transmitted response was incorrect P1614 Transmitted response was distorted O Electronically Erasable and Programmable Read PO62F DPF system Only Memory EEPROM failure P0409 EGR valve EGR lift sensor characteristic abnormality MEA EOM EXE E BE o Node error Bus off E errer ABS General Frame receive is failed Body Control Module BCM General Frame KI 70 receive is failed U0418 Brake pedal initial travel achieved validity invalid Traction Control System TRC request torque Roll U2108 ing Counter RC error TRC request torque Protection value error Brake pedal position RC error U0418 Vehicle Integrated Function VIF related diagnosis Brake pedal initial travel achieved protection value error U0405 Failure Part U2101 Programming Alternator L terminal system Alternator F terminal system P0571 Brake switch signal error P1602 PO62F P0299 P1602 P0500 Microinjection quantity learning SQL Popping off Pump learning Tuning protection 2 For Meriva DTC Failure Part P0501 P1602 P1602
13. ed to the SCV in order to control the quantity of fuel that is supplied to the high pressure plunger Because only the quantity of fuel that is required for achieving the target rail pressure is drawn in the drive load of the supply pump decreases When current flows to the SCV variable electromotive force is created in accordance with the duty ratio moving the armature to the left side The armature moves the cylinder to the left side changing the opening of the fuel passage and thus regulating the fuel quantity e With the SCV OFF the return spring contracts completely opening the fuel passage and supplying fuel to the plungers Full quantity intake and full quantity discharge When the SCV is ON the force of the return spring moves the cylinder to the right closing the fuel passage normally opened By turning the SCV ON OFF fuel is supplied in an amount corresponding to the actuation duty ratio and fuel is dis charged by the plungers Valve Body Return Spring MN Needle Valve Q002045E 1 Short duty ON duration Short duty ON duration gt large valve opening gt maximum intake quantity LL Feed Pump ng Gs TD 85 Needle Valve Large Opening Q002047E Operation Section 2 Long duty ON duration Long duty ON duration gt small valve opening gt minimum intake quantity Needle Valve Small Opening Operation Section 3 RAIL 3 1 Outline
14. ge E EUH D BENE Ban TWVA output open load injector 2 coil open Operation Section 1 17 ST Li Joe SCV output short to battery SCV output short to battery SCV output Open Load short to GND SCV output Open Load short to GND SCV coil open SCV coil short gt Sek p ET P0087 Suction control valve SCV o X P0094 P0088 P0601 0 Common rail system 0A Engine ECU internal failure 0 P0606 4 4 CPU fault Watchdog IC fault Cylinder 1 fuel system failure P0303 0 Cylinder 3 fuel system failure EGR excessive flow EGR positive deviation EGR system P0400 03 EGR insufficient flow EGR negative deviation Cylinder 2 fuel system failure 04 EGR valve 0 EGR valve open close stuck P0299 02 Turbo control system negative deviation Turbo system P0234 02 Turbo control system positive deviation Electric Vacuum Regulating Valve EVRV EVRV Turbo output short to battery Turbo EVRV Turbo output open load short to GND VSS output VSV short to battery VSS output VSV open load short to GND Diesel throttle controller output signal short to bat tery Diesel throttle controller output signal open load short to GND 1 01 P0243 01 Variable swirl control VSS output VSV 01 Diesel throttle system Diesel throttle controller failure status Operation Section 1 18 Failure Part Symptom Failure Mode P042A P2452 P0480 P0481 P0482 U2108 U2107 P1
15. ined herein For details on other parts refer to the service manual entitled Common Rail System for OPEL 4EE2 Type Engine Doc ID 00400028 5 2 Engine ECU e The shape of the engine ECU has been changed As a result the shape of the connector has also been changed For details on the connector refer to 7 EXTERNAL WIRING DIAGRAM Old Model New Model Q002040E 5 3 Boost Pressure Sensor The boost pressure sensor detects intake air pressure The boost pressure sensor also includes a thermistor type tem perature sensor THA Vcc GND Vout Q002041E Operation Section 6 DIAGNOSIS 6 1 Diagnostic Trouble Code DTC Table Read symptom codes using the manufacturer s diagnostic tool 1 For Corsa Failure Part Mass airflow sensor Intake air temperature sensor Coolant temperature sensor Accelerator position sensor 1 P1122 Accelerator position sensor 2 Symptom Failure Mode Intake air temperature sensor signal too high M Accelerator position sensor signal performance P1120 Accelerator position sensor 52 invalid invali Boost pressure sensor Rail pressure sensor EGR lift position sensor Atmospheric pressure sensor Intake air temperature frequency sensor Intake air temperature analog sensor eo Fuel temperature sensor es Rail pressure sensor signal keeping the middle range too long too short high Intake air temperature analog sensor signal too low Oper
16. ke system Evaluation of vehicle deceleration brake test switch A C pressure signal too high P0530 Brake switch diagnostics Cruise control brake P0571 Brake switch i d switch no signal Brake Lamp Switch GL Su Starter switch short to battery 01 P0512 Starter switch BEE 06 Starter switch open short to GND Clutch switch circuit malfunction manual transmis P0704 Clutch switch 1 sion only P0520 Oil pressure switch Oil pressure switch stuck open Crankshaft position sensor no pulse P0335 Crankshaft position sensor Crankshaft position sensor signal invalid Cylinder recognition sensor no pulse P0340 Cylinder recognition sensor Cylinder recognition sensor signal invalid Operation Section 1 16 Dre FalluePat Failure Part ala A AA AAA Mode P0016 Crankshaft position sensor Cylinder recog Crankshaft position sensor Cylinder recognition position sensor Cylinder recognition nition sensor sensor signal synchronization error PO685 P1625 P0641 P0651 P0380 P0683 P0645 P0403 P2146 P2149 P0606 Main relay Sensor reference voltage 1 Sensor reference voltage 2 Glow system Main relay A C relay output EGR control DC motor Injector drive Main relay diagnostics Main relay stuck closed Main relay diagnostics Main relay stuck open relay output open load 07 Sensor reference voltage output No 1 too high reference Sensor reference voltage output No 1 too high
17. nkshaft fi laa Position Sensor 1 es ES Accelerator Position Sensor 2 EE ae Es ensor ei Sensor Fuel Tempareture Clutch SW N C Sensor Brake SW2 N C od Je ype Bo eg Oil Pressure SW Low Oil Level SW Jejojuo MO PE fe Ferne a A Actuator 1 JV DC Motor cc Twist Pair lt A Shield Wire Q002042E Variable Swirl Control Solenoid Turbo Solenoid A 91 Diesel Throttle A 90 Controller zo Rail Pressure Sensor o er EGR By Pass Valve VSV Differential Pressure Sensor Exhaust Temperature sensor 1 Exhaust Temperature sensor 2 Engine ECU B 21 Operation Section 1 22 Reverse Gear SW Meriva onl Vehicle Speed Sensor Check Engine Warning Light dei KWP2000 Engine Speed Output ID N IT D u D IP Cluste Ww Ww Ww r N Os CT N Q SOSO TO n 7 o 19497 WO einssald IO 14617 Buiusem Sul ug Oe Twist Pair c Shield Wire Q002043E Operation Section 1 23 7 2 Engine ECU Connector Diagram Engine ECU Connector Pin Layout A AA A 5 Ee T7Tes 29 sd 2 ss 4 s 17 54 55 56 57 56 59 o 61 e2 63 64 65 oe 7p L 70 7 3 33 34 35 36 37 se 4041 42 43 L7 FER 20 211 23 24 25 26 27 28 29 301 132 5 el eTobo e osa e e hd le AL 214144449144 Q002044E Terminal Connections A side pins 1 48 E 15 sc Suction control valve SCV Suction
18. o high P1122 Accelerator position sensor 2 03 Accelerator position sensor No 2 signal too low position sensor No 2 Accelerator position sensor No 2 signal too low too low er position sensor signal performance P1120 Accelerator position sensor Invalid 07 Boost pressure sensor signal too high pressure sensor signal too Boost pressure sensor signal too high P0235 Boost pressure sensor Boost pressure sensor signal too low Boost pressure sensor performance invalid Fuel temperature sensor signal too high P0180 Fuel temperature sensor Fuel temperature sensor signal too low Rail pressure sensor signal too high 03 Rail pressure sensor signal too low P0190 Rail pressure sensor 09 Z 9 02 Rail pressure sensor signal keeping the middle range EGR lift position sensor signal too high P0409 EGR lift position sensor EGR lift position sensor signal too low Atmospheric pressure sensor too high P2226 Atmospheric pressure sensor Atmospheric pressure sensor too low 07 Ambient temperature signal too high P0110 Intake air temperature frequency sensor 3077 06 Ambient temperature signal too low Vehicle speed sensor frequency too high P0500 Vehicle speed sensor 06 Vehicle speed sensor input open short 08 Vehicle speed sensor signal invalid A C pressure sensor A C pressure signal too low A C pressure GND signal open 01 Recognition of a permanently active brake contact brake test switch P1571 Bra
19. per oxygen catalyst temperature sensor exhaust gas temperature 1 exhaust gas temperature 1 voltage too low Upper oxygen catalyst temperature sensor exhaust gas temperature 1 temperature too high Upper DPF temperature sensor exhaust gas tem perature 2 voltage too high P042A Upper DPF temperature sensor exhaust Upper DPF temperature sensor exhaust gas tem gas temperature 2 perature 2 voltage too low Upper DPF temperature sensor exhaust gas tem perature 2 temperature too high Voltage too high 03 Voltage too low P2452 Differential pressure sensor Differential pressure too high Hose line disconnect upstream 01 Fan control relay 1 short to battery P0480 Fan relay 1 output a 06 Fan control relay 1 open load short to GND 01 Fan control relay 2 short to battery P0481 Fan relay 2 output Eo 06 Fan control relay 2 open load short to GND 01 Fan control relay 3 short to battery P0482 Fan relay 3 output CENE 06 Fan control relay 3 open load short to GND DPF over loaded n 66 DPF overloaded DPF over loaded 2 P2002 DPF system Not ended regeneration Differential pressure sensor characteristic abnor P2452 52 iit mality Operation Section 1 13 Failure Part Symptom Failure Mode Upper oxygen catalyst temperature sensor Upper Oxygen catalyst temperature sensor E P0425 52 exhaust gas temperature 1 sensor characteristic Exhaust gas temperature 1 abnormality P042A Upper DPF temperature sensor exh
20. plug R side short Glow diagnosis line short to Glow plug R side open load Glow diagnosis line A C relay output short to battery A C relay output open load short to GND EGR control DC motor output 1 short to battery short to GND output 2 short to battery short to GND motor short EGR control DC motor output 1 open load output 2 open load motor open load Glow system o A C relay output o o o o o EGR control DC motor Operation Section Failure Part Symptom Failure Mode P0201 TWV1 output open load Injector 1 coil open P0203 TWV2 output open load injector 3 coil open P0204 TWV3 output open load injector 4 coil open P0202 TWVA output open load injector 2 coil open 0 COM output short to battery TWV 1 or 3 output short to battery both TWV 1 and TWV 3 open load 1 P2146 02 COM 1 output short to GND TWV 1 or 3 output e short to GND Injector drive 01 COM output short to battery TWV 2 or 4 output short to battery both TWV 2 and TWV 4 open load P2149 02 COM 2 output short to GND TWV 2 or 4 output short to GND Capacitor charge up circuit malfunction insufficient charge P0606 m 52 Capacitor charge up circuit malfunction excessive charge P0602 QR code not programmed QR correction information is abnormal P0088 Supply pump protection Common rail system Supply pump exchange P0087 Supply pump malfunction insufficient flow SCV output short to battery SCV output Suction control valve S
21. r VCC position sensor VCC Crankshaft position sensor VCC 89 s LMP1 SAMP1 LMP1 Spare SS airflow sensor air temperature IAT FRQ INT CS Diesel throttle controller Signal frequency 67 MAF FRQ Mass airflow sensor frequency Turbo solenoid CAN H CAN High Variable swirl control solenoid mur c a NEE Sch SE GE ESTA lt NOTE gt 1 Meriva only Terminal Connections B side pin 58 io rima comodos Del maen lees ae steen E fro COMETE EJ A P GND Power GND GL DI Glow controller diagnosis ee foes ENEE Operation Section 1 25 ES Ii Accelerator position sensor 1 11 40 ACCP1 VCC1 VCC Accelerator position sensor 2 12 41 ACCP2 VCC2 VCC ple AY A PAC VCC2 AIC pressure sensor VCC Accelerator position sensor 1 14 ACCP1 GND 43 STT REL H Starter relay HSD GND Accelerator position sensor 2 15 ACCP2 GND 44 GND PAC GND A C pressure sensor GND pas LFUEL GND Fuel level return pas GMLAN H GMLAN High NEOUT Engine speed output GMLAN L GMLAN Low FUELOUT Fuel quantity output CL SW Clutch switch FH REL Fuel heater relay BK2 SW Brake 2 switch GL CS Glow controller signal BK1 SW Brake 1 switch FAN2 REL Fan 2 relay EH SW Electrical heater switch STT REL L Starter relay LSD ACCP1 M REL Accelerator position sensor 1 Sig 27 56 nal Accelerator position sensor 2 Sig 28 ACCP2 nal 57 A C pressure sensor Signal lt NOTE gt Po
22. th the OPEL 4EE2 engine This service manual only addresses changes additions from the CRS used with the 4EE2 engine For details on other parts refer to the service manual entitled Common Rail System for OPEL 4EE2 Type Engine Doc ID 00400028 1 2 Application Model ver Year Vehicle Name Engine Model Engine Model Engine Displacement Displacement Reference Reference 2007 MY Z17DT Made in Europe 1 3 System Component Part Numbers The EGR valve has been changed from a DENSO product to that of another manufacturer Vehicle Model Car Manufacturer Part Number Supply Pump ee HU294000 050 97376269 Part Name fe err Cylinder Recognition Sensor E HS NE 949979 120 97321620 Boost Pressure Sensor Ys Yes 079800 783 97381191 Operation Section 1 2 2 SUPPLY PUMP 2 1 Outline e This HP3 supply pump is equipped with a compact Suction Control Valve SCV Parts other than the SCV have not changed For details refer to the service manual entitled Common Rail System for OPEL 4EE2 Type Engine Doc ID 00400028 New Model Suction Control Valve Outlet Fuel Temperature Sensor Overflow Q002036E Old Model Suction Control Valve SCV Overflow Fuel Inlet Q002061E Operation Section 1 3 2 2 Suction Control Valve SCV A linear solenoid type valve has been adopted The ECU controls the duty ratio the length of time that the current is appli
23. wertrain main relay 1 Meriva only Published January 2007 Edited and published by DENSO CORPORATION Service Department 1 1 Showa cho Kariya Aichi Prefecture Japan
Download Pdf Manuals
Related Search