Citroen Bosch EDC16 PDF

BOSCH EDC 16 C3
HDi INJECTION
SYSTEM
(DV4TD ENGINE)
Ref No: 1 . 6 . 4 1 3 Ma y 2 0 0 3
After Sales Division

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© CITROËN U.K. LTD

Reproduction whether partial or
in full without written permission
from Citroën U.K. Ltd is forbidden
A
BROCHURE SUMMARY
BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR

DV4TD ENGINE
The aim of this brochure is to define the composition and operation of the BOSCH
EDC 16 C3 type HDI diesel engine management system for the DV4TD engine.
This device consists of an ECU which analyses the information from the various
sensors and then controls the injectors at the right moment. It is also responsible for
regulating the pressure and controlling the exhaust gas recycling electrovalve.
The following subjects will be dealt with in this document:
- General details and presentation of the system,
- Description, composition and operation of the components of the various

functions or of the functions themselves,
- Description of the various operating phases,
- Maintenance advice,
- The electrical circuit,
- The diagnostic system.
BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR DV4TD ENGINE

B
CONTENTS
SECTION 1: GENERAL DETAILS: HDI INJECTION SYSTEM .......................1

I- INTRODUCTION................................................................................................. 1
SECTION 2: FUNCTION: FUEL SUPPLY...................................................5

I- DIAGRAM ......................................................................................................... 5
II - FUEL FILTER .................................................................................................... 7
III - FUEL HEATER (ELECTRIC) (1276)...................................................................... 8
IV - FUEL HIGH PRESSURE PUMP.......................................................................... 8
V- RELIEF VALVE ............................................................................................... 10
VI - TRANSFER PUMP (PRE-SUPPLY)................................................................... 11
VII - FUEL FLOW REGULATOR............................................................................... 11
VIII - FUEL HIGH PRESSURE COMMON INJECTION RAIL ......................................... 12
IX - DIESEL INJECTORS (1131, 1132, 1133, 1134) ................................................... 13
X- FEATURE OF THE DIESEL INJECTOR CONTROL ............................................. 18
XI - FUEL COOLER................................................................................................ 20
SECTION 3: AIR SUPPLY FUNCTION..........................................................21

I- DIAGRAM ....................................................................................................... 21
II - AIR FILTER ..................................................................................................... 23
III - DV4TD TURBOCHARGER................................................................................ 23
IV - AIR FLOWMETER (1310) ................................................................................. 26
SECTION 4: EXHAUST GAS RECYCLING FUNCTION..........................29

I- DIAGRAM ....................................................................................................... 29
II - VACUUM PUMP.............................................................................................. 31
III - RECYCLING REGULATION ELECTROVALVE (EGR)(1253)................................. 32
IV - EXHAUST GAS RECYCLING VALVE (EGR) ...................................................... 33
V- CATALYTIC CONVERTER................................................................................ 34

C
CONTENTS
SECTION 5: INJECTION FUNCTION........................................................35

I- ENGINE ECU .................................................................................................. 35
II - INJECTION ECU (1320) .................................................................................... 38
III - BATTERY (BB00)............................................................................................. 44
IV - CYLINDER REFERENCE SENSOR (1115)......................................................... 44
V- COOLANT TEMPERATURE SENSOR (1220) ..................................................... 45
VI - FUEL TEMPERATURE SENSOR (1221) ............................................................ 47
VII - ENGINE SPEED SENSOR (1313) ..................................................................... 48
VIII - FUEL HIGH PRESSURE SENSOR (1321) - FEATURES ..................................... 50
IX - BRAKE SWITCH (2100) - FEATURES ............................................................... 51
X- CLUTCH SWITCH (7306) - FEATURES .............................................................. 51
XI - REDUNDANT BRAKE PEDAL SWITCH (7308) - FEATURES ............................... 51
SECTION 6: PRE-POST HEATING FUNCTION............................................53

I- DIAGRAM ....................................................................................................... 53
II - PREHEATING PLUGS (1160)............................................................................ 54
III - PRE-POST HEATING UNIT (1150)..................................................................... 55
IV - PRE-POST HEATING....................................................................................... 56
SECTION 7: ENGINE COOLING FUNCTION (FRIC)...............................57

I- DIAGRAM ....................................................................................................... 58
II - COOLANT TEMPERATURE SENSOR (1220) ..................................................... 60
III - POST-VENTILATION ........................................................................................ 60
IV - DOWNGRADED MODE.................................................................................... 61
V- COOLING CIRCUIT........................................................................................... 62

D
CONTENTS
SECTION 8: ENGINE COOLING REQUIREMENTS FOR THE AIR

CONDITIONING (BRAC) .......................................................63
I- DIAGRAM ....................................................................................................... 63
II - REFRIGERANT PRESSOSTAT (PRESSURE SENSOR) (8009) ........................... 65
III - ADDITIONAL HEATING..................................................................................... 67
SECTION 9: MAINTENANCE .....................................................................71

I- RECOMMENDED FUEL................................................................................... 71
II - SAFETY PRECAUTIONS.................................................................................. 71
III - REPLACING PARTS – OPERATIONS TO BE PERFORMED............................... 72
IV - GUARANTEE RETURN PROCEDURES............................................................. 74
SECTION 10: DIAGNOSTICS ....................................................................75

I- TOOLING ........................................................................................................ 75
II - TOOL FUNCTIONS........................................................................................... 76
III - LEXIA / PROXIA SCREENS .............................................................................. 77
IV - DOWNGRADED MODE.................................................................................... 86
V- SENSOR FAULTS ........................................................................................... 88
VI - ASSOCIATED FUNCTIONS FAULTS ................................................................. 92
SECTION 11: WIRING DIAGRAM ..............................................................95

I- LAYOUT.......................................................................................................... 95
II - WIRING DIAGRAM........................................................................................... 96
III - LOCATION ...................................................................................................... 97
IV - PARTS LIST.................................................................................................... 98

1
Section 1
GENERAL DETAILS: HDI INJECTION SYSTEM
Warning: All values given in this document are guidelines only. Refer to the
documentation corresponding to the vehicle.
I- INTRODUCTION
The development of the new range of DV4TD engines has allowed a new powerful
injection system to be incorporated.
This system satisfies the EURO 3 emissions control standard and the future EURO 4
standard and provides driving pleasure, fuel economy and reliability.
A - POLLUTION
Fuel combustion causes the following pollutants to be given off:
• carbon dioxide (CO2),
• carbon monoxide (CO),
• unburned hydrocarbons (HC),
• nitrogen oxides (NOx),
• carbon particles.
The emissions control standards are becoming stricter and the following changes
have been introduced:
• fitting of an exhaust gas recycling device (EGR) which reduces nitrogen oxide
(NOx) levels,
• reduction in the amount of sulphur used in fuel (SO2).
Improvements to fuel have allowed oxidising catalytic converters to be fitted on
diesel vehicles.
Fitting an oxidising catalytic converter reduces the following pollutants:
• unburned hydrocarbons (HC),
• carbon particles.
Note: EGR: exhaust gas recycling device.

2
Section 1
B - MAIN DESIGN OF THE DV4TD ENGINE
Feature:
• 4 cylinders, 8 valves with overhead camshaft, driven by a synchronous belt,
• an inlet manifold incorporated into the cylinder head cover,
• an exhaust manifold located in the front part of the engine,
• a catalytic converter mounted directly on the turbocharger outlet,
• a water pump driven by the timing belt,
• a duo-centric oil pump,
• direct injection turbocharged by a turbocharger without heat exchanger,
• an exhaust gas recycling device (EGR),
• an exhaust gas recycling regulation electrovalve,
• a low pressure circuit operating in a "vacuum".
C - BOSCH EDC 16 C3 INJECTION SYSTEM
Features of the Bosch EDC 16 C3 injection system:
• new 32 bit engine management ECU with "anti-tuning" strategy, larger internal
memory and a single injection bank for the 4 injectors,
• fuel injection managed as a function of engine torque,
• fuel pressure in the common rail can reach 1350 bars,
• ZP18 fuel pump integrated into the high pressure pump (low pressure circuit in
a vacuum),
• CP3.2 type high pressure pump.

3
Section 1
D - SAFETY PRECAUTIONS
Note: The safety instructions are given in a procedure in the mechanical

binder of the vehicle in question.
IMPORTANT: Due to the very high pressures in the high pressure fuel circuit
(1350 bars), it is essential to comply with the following
instructions.
Do not smoke near to the high pressure circuit whilst working on it.
Avoid working near to flames or sparks.
When the engine is running:
• do not work on the high pressure fuel circuit,
• always remain out of the range of a possible fuel jet which can cause serious
injuries,
• never place your hand near to a leak in the high pressure fuel circuit,
• after switching off the engine, wait for 30 seconds before starting any work.
Note: Allow sufficient time for the pressure in the high pressure fuel circuit to
return to atmospheric pressure.

4
Section 1

5
Section 2
FUNCTION: FUEL SUPPLY
I- DIAGRAM
1 2 3 4
14
12 13
11
A
10 9 8
B
DV4001P

6
Section 2
Key:
A - Fuel tank return circuit
B - Fuel low pressure circuit (vacuum)
C - Fuel high pressure circuit
Parts list:
PART NUMBER IN WIRING

REF DESCRIPTION
DIAGRAMS
1-4 Diesel injectors (electrohydraulic) 1131 - 1132 - 1133 - 1134
5 Fuel temperature sensor 1221
6 Manual fuel priming pump
7 Fuel cooler
8 Fuel tank
9 Fuel heater (electric) 1276
10 Water bleed screw
11 Fuel filter + water in fuel separator
12 Fuel high pressure pump (CP3.2)
13 Fuel high pressure common injection rail
14 Fuel high pressure sensor 1321

7
Section 2
II - FUEL FILTER
A - ROLE
Role of the fuel filter:
• to filter the fuel,
• to separate water,
• to heat the fuel.
B - DESCRIPTION
11
b
a
22
23
10 DV4002D
Direction of fuel flow (following arrows).

Fuel heater (23) (electric)
Water bleed screw (22).
a - Fuel inlet (click fit connector)
b - Fuel outlet (to fuel high pressure pump) (click fit connector)
Fuel filter (11):
• replacement frequency: every 37,500 miles (60,000 km),
• bleed: every 12,000 miles (20,000 km).
Note: The fuel filter must be replaced as a whole unit.
The filter element can be fitted on the following injection systems:
• vacuum injection system: SIEMENS SID 802
• vacuum injection system: BOSCH EDC 16 C3
Note: The filtration bowl is fitted with a water in fuel detector (4050) (grand
export countries).
Translucent pipe between the fuel filter and the fuel high pressure pump:
• presence of small bubbles: normal operation,
• presence of large bubbles: abnormal operation.

8
Section 2
III - FUEL HEATER (ELECTRIC) (1276)
A - ROLE
The fuel heater raises the fuel to its usage temperature.
B - DESCRIPTION
The fuel heater heats up the fuel from the fuel tank.
The fuel heater (23) consists of resistors incorporated into the fuel filter.
The fuel flows around the resistor.
This route provides optimum heat distribution.
The temperature is regulated by a thermostat.
C - LOCATION
Location: integrated into the fuel filter.
IV - FUEL HIGH PRESSURE PUMP
A - ROLE OF THE FUEL HIGH PRESSURE PUMP

• To provide the fuel high pressure.
• To supply the injectors through the high pressure common injection rail.
• The fuel high pressure pump is driven by the timing belt.
Note: The fuel high pressure pump is not a distributor-type pump and
therefore does not require setting.
The high pressure part of the pump is a single unit and comprises
three components at 120°
B - DESCRIPTION
17 20
24
17 20
25
24 19
25
26 26
DV4003D

9
Section 2
15
21 16
6
17
13 11
18
19
20
12
8 DV4004D
Parts list:

REF DESCRIPTION
DIAGRAMS
6 Manual fuel priming pump
8 Fuel tank
15 Diesel injector fuel return to fuel tank
16 Relief nozzle
17 Relief valve
18 Flow nozzle
19 Transfer pump
20 Fuel flow regulator 1277 or 1208
21 Pressure limiter (integrated into the fuel high
pressure common injection rail)
24 Fuel inlet (low pressure)
25 Fuel return to fuel tank
26 Fuel high pressure outlet
Features:
• the relief nozzle is used to discharge the fuel high pressure common injection
rail quickly when the accelerator pedal is released suddenly,
• the flow nozzle limits the fuel inlet to the supply pump at high engine speeds,
• fuel circuit in a vacuum: suction by the transfer pump integrated into the fuel
high pressure pump.

10
Section 2
C - OPERATING PHASE
The engine ECU controls the fuel flow regulator in a closed loop, via the fuel high
pressure sensor.
The engine ECU controls the flow regulator by sending an OCR type adjustable
current (open cycle ratio).
The engine ECU uses the fuel flow regulator to control the fuel pressure in the fuel
high pressure common injection rail
If the OCR signal is small, the fuel flow regulator allows a larger amount of fuel to
pass through to the fuel high pressure pump.
If the OCR signal is large, the fuel flow regulator allows a small amount of fuel to
pass through to the fuel high pressure pump.
Note: The fuel flow regulator is open when it is not controlled by the engine
ECU.
V- RELIEF VALVE
A - ROLE
The relief valve (17) is used to:
• degas the fuel high pressure pump,
• provide internal lubrication for the fuel high pressure pump,
• regulate the pressure at the flow regulator inlet.
Warning: Repairs to the relief valve are forbidden.

11
Section 2
VI - TRANSFER PUMP (PRE-SUPPLY)
A - ROLE
Role of the transfer pump:
• to pump the fuel from the fuel tank,
• to supply the fuel high pressure pump,
• to lubricate and cool the fuel high pressure pump.
B - DESCRIPTION
The transfer pump (pre-supply) is a gear displacement pump.
The vacuum is between 0.5 and 1 bar when the fuel enters the transfer pump.
The fuel pressure at the outlet of the transfer pump to the fuel high pressure pump
varies as a function of engine speed (between 4.5 and 6 bars).
Warning: Repairs to the high pressure fuel pump are forbidden.
VII - FUEL FLOW REGULATOR
A - ROLE
The fuel flow regulator (20) adjusts the fuel flow going from the transfer pump to
the fuel high pressure pump.
The fuel high pressure pump compresses the required amount of fuel as
requested by the engine ECU.
The fuel flow regulator reduces:
• the amount the fuel heats up,
• the power consumed by the fuel high pressure pump.

12
Section 2
VIII - FUEL HIGH PRESSURE COMMON INJECTION RAIL
A - ROLE
Role of the fuel high pressure common injection rail:
• to store the amount of fuel required by the engine regardless of operating
phase,
• to damp the pulses created during injection,
• to connect the components of the high pressure circuit.
Components connected to the fuel high pressure common injection rail:
• fuel high pressure supply pipe,
• diesel injector supply pipes,
• fuel return to tank pipe,
• fuel high pressure sensor.
B - DESCRIPTION
DV4005D
14 28 27
14 - Fuel high pressure sensor

27 - Fuel return to fuel tank
28 - High pressure fuel inlet
Note: The pressure limiter in the fuel high pressure common injection rail is
used to limit the maximum pressure in the fuel high pressure common
injection rail to between 1400 and 1500 bars.
C - LOCATION
The common injection rail located between the high pressure pump and the petrol
injectors is mounted on the rear of the engine block.

13
Section 2
IX - DIESEL INJECTORS (1131, 1132, 1133, 1134)
A - ROLE
The diesel injectors inject the fuel required for the engine to operate.
Injecting the fuel directly into the top of the pistons improves engine efficiency.
The fuel can be injected in the following cases:
• preinjection,
• main injection.
• post injection (for stricter emission control standards, currently not used).
B - DESCRIPTION
f
29
43 30
31
42
32
29
33
41 40 38 37 36 35 34
DV4006D
39
f - Fuel tank return
29 - Electrical connector
30 - Control electrovalve coil
31 - Control electrovalve spring
32 - Nut
33 - Control electrovalve needle
34 - Diesel injector tip
35 - Diesel injector needle
36 - Pressure chamber
37 - Diesel injector spring
38 - Control piston
39 - Control chamber
40 - Supply nozzle
41 - Fuel return circuit nozzle
42 - Fuel high pressure inlet connector
43 - Laminar filter incorporated into the connector (43)
Note: The laminar filter does not require any maintenance.

14
Section 2
The amount of fuel injected depends on the following parameters:

• duration of the electrical control (injection ECU),
• diesel injector opening speed,
• diesel injector hydraulic flow (number of holes and diameter),
• fuel pressure in the fuel high pressure common injection rail.
The fuel pressures used in the HDI system prevent the diesel injectors being
directly controlled electrically.
The diesel injectors are opened by means of the pressure difference between the
control chamber (39) and the pressure chamber (36).
The diesel injector needle (35) is held against its seat by the spring (37).
The control piston (38) is fitted on top of the diesel injector needle (35) (the
control piston is free to move in its bore).
The top of the control piston opens into the control chamber (39).
The control chamber is connected to the following circuits:
• the fuel high pressure circuit through the nozzle (40),
• the return to tank circuit through the nozzle (41).
The control chamber (39) is isolated from the fuel return circuit by the electrovalve
needle (33).
The diesel injector needle (35) is held against its seat by the spring (31).
The fuel is distributed in the same way between (39) and (36).
The nozzle (41) is larger than the nozzle (40).
The electrovalve needle lifts when the electrovalve coil is supplied (magnetic
field).
Note: The injector class has to be configured in the diesel injection ECU as a
hexadecimal code.

15
Section 2
C - LIFTING PRINCIPLE OF A DIESEL INJECTOR
J K
33
41
39
40
38
37
36
35
DV4007D
J - Diesel injector closed

K - Opening of a diesel injector
33 - Control electrovalve needle
35 - Diesel injector needle
36 - Pressure chamber
37 - Diesel injector spring
38 - Control piston
39 - Control chamber
40 - Supply nozzle
41 - Fuel return circuit nozzle

16
Section 2
1 - Diesel injector closed

The force exerted by the high pressure is the same between the control
chamber (39) and the pressure chamber (36).
The control piston does not move (held against the diesel injector needle).
The pressure increase in the fuel high pressure common injection rail causes
the diesel injector to close.
2 - Opening principle of a diesel injector

The injection ECU supplies the control electrovalve.
Operating phase when the electrovalve needle (33) lifts under the action of
the control electrovalve (magnetic field):
• a fuel leakage is created through the nozzle (41),
• the fuel let in by the nozzle (40) does not compensate for the leakage
through the other nozzle (41),
• the pressure balance between chambers (39) is (36) is broken,
• the pressure in the pressure chamber (36) lifts the diesel injector needle,
• the control piston rises back up,
• the fuel is sent to the top of the piston.

Note: Fuel injection lasts for as long as the diesel injector electrovalve is
supplied.
Note: Maximum lift of the control electrovalve needle: 0.06 mm.

17
Section 2
3 - Features as a function of electrovalve control duration

Short duration control:
• the control piston has a certain amount of inertia,
• the needle of the diesel injector is lifted slightly,
• a small amount of fuel is injected,
• the injection pressure is less than the pressure in the fuel high pressure
injection rail.
Long duration control:
• the control piston and the diesel injector needle are fully lifted,
• a large amount of fuel is injected,
• the injection pressure is equal to the pressure in the fuel high pressure
injection rail.
4 - Closing principle of a diesel injector

Operating phase when the injection ECU cuts off the supply to the diesel
injector electrovalve:
• the electrovalve spring (32) holds the electrovalve needle (34) against its
seat,
• the nozzle (41) is blocked,
• the fuel leakage to the return circuit ceases,
• the rise in pressure in the control chamber (32) causes the diesel injector
to close,
• the pressure balance between chambers (39) and (36) is restored,
• the diesel injector is ready for a new cycle.

18
Section 2
X- FEATURE OF THE DIESEL INJECTOR CONTROL
A - GENERAL DETAILS
The diesel injectors are controlled by the control stage of the injection ECU:
The diesel injector control stage is used to obtain the following voltages:
• a peak voltage of 80 volts required to start the diesel injector moving,
• a voltage of 50 volts required to keep the diesel injectors open.
The control stage integrated into the injection ECU contains a capacitor which
stores the power required to control the diesel injectors.
Between each injection, the injection ECU sends pulses on the coil of the injector
which is not being controlled.
The pulses create an induced voltage to charge the control stage (capacitor).
Warning: The control stage cannot charge up when there is a fault on the
supply line of a diesel injector.
A safety system inside the ECU is used to disconnect the control stage when the
engine is switched off.
IMPORTANT: Given the presence of the high voltage at the terminals of the
ECU and the diesel injectors, all voltage measurements must
be performed using the recommended equipment.

19
Section 2
B - DIESEL INJECTOR ELECTROVALVE CONTROL

Y
44
45
46 47 48
DV4008C
Diesel injector control current:

Y - Amps
X - Duration
44 - In-rush current
45 - Holding current
46 - In-rush phase
47 - Holding phase
48 - End of control
The electrical supply of an electrovalve consists of 2 phases:
• in-rush phase (in-rush voltage and current),
• holding phase (holding voltage and current).
1 - In-rush phase
The aim of the in-rush phase is to cause the electrovalve needle to rise
rapidly.
The diesel injector electrovalve is supplied as follows:
• a voltage of approximately 80 V,
• a current of approximately 20 A.
Note: The in-rush phase lasts less than a millisecond (0.3 ms).
2 - Holding phase
The holding phase is used to continue to supply the electrovalve whilst
limiting the electrical power absorbed.
The diesel injector electrovalve is supplied as follows:
• a voltage of approximately 50 V,
• a current of approximately 12 A.
Warning: A diesel injector must not be supplied with 12 volts (electrovalve
will be destroyed).

20
Section 2
XI - FUEL COOLER
A - ROLE
The high pressure pump pressurises the fuel which raises the temperature of the
fuel.
The fuel cooler cools the fuel as it returns to the fuel tank.
B - DESCRIPTION
The fuel cooler consists of a metal coil which promotes heat exchange between
the fuel and the air.
C - LOCATION
The fuel cooler is located under the body.

21
Section 3
AIR SUPPLY FUNCTION
I- DIAGRAM
1 2
15 4
7 8
A
B DV4009P
C
14 13 12 11 10 9
Warning: The diagram is a symbolic representation of the air supply function.

22
Section 3
Air circulation (in direction of arrows):

A - Air
B - Exhaust gas + air
C - Exhaust gas
Parts list:

REF DESCRIPTION
DIAGRAMS
1 Injection ECU 1320
2 Exhaust gas recycling regulation electrovalve (EGR) 1253
3 Vacuum pump
4 Exhaust gas recycling valve (EGR)
5 Air inlet manifold
6 Exhaust gas manifold
7 Turbocharging pressure regulating valve: pressure-
controlled
8 Regulating valve control pneumatic capsule (on the
turbocharger): pressure-controlled
9 Catalytic converter
10 Exhaust turbine
11 Turbocharger
12 Air inlet turbine
13 Air flowmeter + air temperature sensor 1310
14 Air filter
15 Atmospheric pressure sensor (incorporated into the 1320
injection ECU)

23
Section 3
II - AIR FILTER
Replacement frequency: every 37,500 miles (60,000 km).
III - DV4TD TURBOCHARGER
10
16
7
DV4010D
17
8
7 - Turbo pressure regulating valve

8 - Regulating valve control pneumatic capsule
10 - Exhaust turbine
16 - Pressurised oil inlet (cooler)
17 - Oil return
A - ROLE
The turbocharger is used to turbocharge the air entering the engine.
There is only one assembly: turbocharging pressure regulated by the regulating
valve only.

24
Section 3
B - DESCRIPTION
a b 7 8
DV4011C
12 10
Warning: The turbocharger is shown symbolically but its operation is the same.
7 - Turbo pressure regulating valve
8 - Regulating valve control pneumatic capsule: pressure controlled
10 - Exhaust turbine
12 - Air inlet turbine
a - To inlet manifold
b - Gas from exhaust manifold
The turbocharger has two separate chambers.
The turbocharger comprises the following components:
• a chamber linked to the engine exhaust function,
• a chamber linked to the inlet function,
• a turbine and a compressor, connected by means of a shaft.

25
Section 3
The turbine, which is operated by the exhaust gases, drives the compressor
which then compresses the inlet air.
Note: Turbocharger lubrication: the very high speeds of the moving parts and
the high temperatures to be dissipated require careful lubrication.
The pressurised oil required for this purpose is taken from the engine's oil circuit.
IMPORTANT: Before switching off the engine, it is essential to let the engine
return to idle speed. Failure to comply with this will eventually
destroy the turbocharger (lack of lubrication).
The turbocharging pressure is regulated by the regulating valve only.

The regulating valve is closed at rest.
The turbo pressure is regulated from the air pressure in the inlet manifold.
Operating phases when the rating value of the pneumatic capsule is exceeded
(8):
• the turbo pressure regulating valve opens,
• the speed of the exhaust turbine decreases,
• the turbo air pressure decreases,
The reduction in the turbo pressure causes the turbo pressure regulating valve to
close.

26
Section 3
IV - AIR FLOWMETER (1310)
A - ROLE
The air flowmeter measures the air flow let into the engine.
Role of the injection ECU depending on the information received:
• to determine the exhaust gas recycling rate,
• to limit the formation of smoke during transitory phases (acceleration,
deceleration) by correcting the fuel flow.
B - DESCRIPTION
DV4012D
e d c 16
c - Protective grille
d - Metal plate (hot film)
e - Air temperature sensor
The air flowmeter consists of the following components:
• metal plate (hot film),
• air temperature sensor.
The metal plate is very thin and is used to determine the amount of air entering
the air circuit.

27
Section 3
The metal plate comprises the following components:

• heating resistor,
• measuring resistor (NTC).
The injection ECU provides the current to the heating resistor so as to keep the
metal plate at a fixed temperature.
The air passing through the flowmeter cools the metal plate: the measuring
resistor (NTC) varies.
The ECU associates the value of the measuring resistor to an air flow.
IMPORTANT: Do not touch the metal plate. The use of an air blower is
forbidden.
C - ELECTRICAL FEATURES
Allocation of connector pins:
• pin 1: air temperature information
• pin 2: flowmeter mass,
• pin 3:
• pin 4: flowmeter supply (5 Volts)
• pin 5: air flow information
• pin 6: earth
D - LOCATION
The air flowmeter is located between the air filter and the turbocharger.

28
Section 3

29
Section 4
EXHAUST GAS RECYCLING FUNCTION
I- DIAGRAM
1 2
15 4
7 8
A
B DV4009P
C
14 13 12 11 10 9
Warning: The diagram is a symbolic representation of the exhaust gas recycling

function.

30
Section 4
Air circulation (in direction of arrows):

A - Air
B - Exhaust gas + air
C - Exhaust gas
Parts list:

REF DESCRIPTION
DIAGRAMS
1 Injection ECU 1320
2 Exhaust gas recycling regulation electrovalve 1253
(EGR)
3 Vacuum pump
4 Exhaust gas recycling valve (EGR)
5 Air inlet manifold
6 Exhaust gas manifold
7 Turbocharging pressure regulating valve: pressure-
controlled
8 Regulating valve control pneumatic capsule (on the
turbocharger): pressure-controlled
9 Catalytic converter
10 Exhaust turbine
11 Turbocharger
12 Air inlet turbine
13 Air flowmeter + air temperature sensor 1310
14 Air filter
15 Atmospheric pressure sensor (incorporated into 1320
the injection ECU)

31
Section 4
II - VACUUM PUMP
A - ROLE
The vacuum pump provides the vacuum required to control the following
components:
• exhaust gas recycling valve (EGR) (depending on version),
• pneumatic control capsule of the exhaust gas recycling valve,
• brake servo.
B - DESCRIPTION
The vane vacuum pump is driven by the camshaft.
16
3
DV4013C
3 - Vacuum pump
16 - Safety valve (the valve is integrated into the outlet connector)
A safety valve incorporated into the pump isolates the brake vacuum circuit when
the engine is off.
The safety valve:
• maintains a vacuum reserve in the brake servo,
• regulates the exhaust gas recycling function.
C - LOCATION
Location: on the cylinder head, on the end of the camshaft on the gearbox side.

32
Section 4
III - RECYCLING REGULATION ELECTROVALVE (EGR) (1253)
A - ROLE
To control the opening of the exhaust gas recycling valve (EGR)
B - DESCRIPTION
The electrovalve connects the vacuum pump and the exhaust gas recycling valve
capsule.
a
b 17 c
DV4014C
d a b
a - "Usage" outlet
b - Vacuum pump vacuum inlet
c - White mark
d - Atmospheric pressure inlet
The electrovalve is controlled with an OCR (open cycle ratio).
The proportional electrovalve controlled with an OCR voltage is connected to the
following components:
• atmospheric pressure,
• the vacuum supplied by the vacuum pump.
The pressure supplied by the electrovalve is between atmospheric pressure and
the vacuum from the vacuum pump.
Control: injection ECU (earth).
Open Cycle Ratio control (OCR):
• full supply (maximum OCR) = maximum vacuum,
• no supply (minimum OCR) = no vacuum (atmospheric pressure).
Note: OCR: Open Cycle Ratio.

33
Section 4
IV - EXHAUST GAS RECYCLING VALVE (EGR)
A - ROLE
The exhaust gas recycling valve controls the amount of exhaust gases recycled.
The EGR device is used to reduce the amount of nitrogen oxide (NOx) emitted by
the exhaust.
Nitrogen oxide levels are reduced by injecting part of the exhaust gas into the
cylinders.
The recycling phases are memorised in cartographic maps in the injection ECU.
B - DESCRIPTION
4 - Exhaust gas recycling valve (EGR)

e - Vacuum inlet (gas recycling regulation electrovalve)
f - Pneumatic control capsule of the exhaust gas recycling valve
Warning: The recycling valve is closed when it is not controlled pneumatically
(vacuum).
Operating phases when the pneumatic control capsule is supplied with a vacuum:
• the gas recycling valve opens,
• part of the exhaust gas is absorbed by the engine (air inlet manifold).
C - LOCATION
The recycling valve is located on the exhaust manifold.

34
Section 4
V- CATALYTIC CONVERTER
The catalytic converter has a 2-way converter.
The catalytic converter (located in the exhaust system) reduces the amount of the
following pollutant emissions released into the atmosphere:
• unburned hydrocarbons (HC).

35
Section 5
INJECTION FUNCTION
I- ENGINE ECU
A - DIAGRAM
1115
2
1220
3 14 15
1221 1150 1160

4 16
1261 1277
5 17
1310 1253
6 18
1313 1276
7 19
1320
1321
24
8
1620 1331 1332 1333 1334

9
2101
10
4050 1211
11
20
7306
12 23 21
7308 BSI 0004

13 22 DV4016P
8009 2100

36
Section 5
COMPONENTS
BSI Built-in Systems Interface
0004 Control panel
1115 Cylinder reference sensor or camshaft sensor
1150 Preheating unit
1160 Preheating plugs
1211 Fuel sender
1220 Coolant temperature sensor
1221 Diesel thermistor
1253 EGR electrovalve
1261 Accelerator pedal position sensor
1276 Electric diesel heater
1277 Flow regulator (IMV - inlet metering valve)
1310 Air temperature sensor and flowmeter
1313 Engine speed sensor
1320 Engine management ECU
1321 Diesel high pressure sensor
1331 Injector, cylinder N°1
1620 Vehicle speed sensor (vehicles without ABS or ESP)
2100 Main brake switch
2101 Redundant brake switch (vehicles with ESP)
4050 Water in diesel sensor
7306 Clutch pedal switch
7308 Secondary brake switch
8009 Pressostat

37
Section 5
CONNECTIONS
CONNEC-
SIGNAL SIGNAL NATURE
TION N°
1 Camshaft position information (Hall effect sensor) SQUARE WAVE SIGNAL
2 Coolant temperature information ANALOGUE
3 Diesel temperature information ANALOGUE
4 Accelerator pedal position information ANALOGUE
5 Inlet air amount information ANALOGUE
Inlet air temperature information ANALOGUE
6 Engine speed information (Hall effect sensor) SQUARE WAVE SIGNAL
7 Fuel pressure information ANALOGUE
8 Vehicle speed information (active Hall effect sensor) SQUARE WAVE SIGNAL
(vehicles without ABS or ESP)
9 Redundant brake pedal information (vehicles with ESP) ALL OR NOTHING
10 Water in diesel information ALL OR NOTHING
11 Clutch pedal information ALL OR NOTHING
12 Secondary brake switch information (only available with ALL OR NOTHING
cruise control option)
13 Air conditioning circuit pressure information ANALOGUE
14 Preheating unit control ALL OR NOTHING
15 Preheating plug control ALL OR NOTHING
16 Flow actuator control OPEN CYCLE RATIO
(OCR)
17 Control of the exhaust gas recycling electrovalve at the OPEN CYCLE RATIO
inlet (EGR) (OCR)
18 Control of the ECU earth to supply the fuel heater ALL OR NOTHING
19 Control of the 4 diesel injectors (PULSE) OPEN CYCLE RATIO
(OCR)
20 Fuel level information ANALOGUE
21 Fuel level information MULTIPLEXED SIGNAL
(COMFORT VAN)
22 Brake information ALL OR NOTHING
23 Request to illuminate LEDs on the control panel MULTIPLEXED SIGNAL
(CAN)
24 Fuel sender information MULTIPLEXED SIGNAL
(CAN)

38
Section 5
II - INJECTION ECU (1320)
A - DESCRIPTION
26
25 27
29 28
DV4017C
25 - Name of the injection system (BOSCH EDC 16 C3)

26 - Atmospheric pressure sensor
27 - Coded date of manufacture
28 - PSA hardware reference
29 - PSA software reference
B - ROLE
The ECU controls the whole injection system.
The ECU software performs the following functions:
• the injection control and emissions control functions,
• the driving pleasure strategies,
• the engine immobiliser function (ADC2),
• the emergency strategies,
• management of the engine cooling fans and warning LEDs (*),
• diagnostics and storage of faults,
• the cruise control function (*).
(*) depending on version.

39
Section 5
The ECU checks the electrical operation of the following components:

• diesel injectors,
• fuel high pressure regulator,
• fuel flow regulator actuator (1208),
• recycling regulation electrovalve (EGR) (1253),
• preheating and postheating unit (postheating cut-off),
The ECU supplies the following information:
• current consumption: to the BSI,
• air conditioning cut-off.
The atmospheric pressure sensor cannot be removed from the injection ECU.
The ECU contains a power stage which provides the very high control current
required for the diesel injectors to operate.
The software of the injection ECU is updated by downloading (ECU with a flash
EPROM).
C - INJECTION
On the EDC 16 C3 system, the engine ECU determines the injection time in
relation to the engine torque requested and/or required.
The engine ECU calculates the engine torque requirements from:
• the driver's demand,
• the traction control (ESP),
• the cruise control,
• the operating mode (idling, full load, etc),
• the additional torque (air conditioning compressor, power steering, electrical
consumer).
The engine ECU performs all the engine torque calculations and only converts the
torque into an injection time at the instant at which the injectors are controlled.

40
Section 5
D - ATMOSPHERIC PRESSURE SENSOR (1320)

This sensor measures the atmospheric pressure.
• to determine the density of the air,
• to prevent recycling when driving at altitude.
Note: Air density decreases with altitude.
The atmospheric pressure sensor (24) is incorporated into the injection ECU.
Warning: The atmospheric pressure sensor cannot be removed from the

injection ECU.
E - DESCRIPTION
H G F E DC B A A BC D E F G H J K L M ABC D E F G H
4 1 1
3 2 2
2 3 3
1 4 4
CME CMI CH
DV4018D
CME connector (grey 32-way).

CMI connector (brown 48-way).
CH connector (black 32 way).
The injection ECU is connected to the injection harness by 3 modular connectors.
Connector assembly order:
• grey connector,
• brown connector,
• black connector.

41
Section 5
1 - Allocation of connector pins
a - CME connector (grey 32-way).
CONNECTION AND PINS SIGNAL

A1
A2
A3
A4 Pre-post heating relay diagnostic
B1
B2 +ignition on
B3
B4
C1
C2
C3
C4
D1
D2
D3
D4
E1
E2 Pre-post heating relay control output
E3
E4
F1 Sensor earth
F2
F3
F4
G1 Injector, cylinder 4
H1 Injector, cylinder 1

42
Section 5
b - CMI connector (brown 48-way).

A1 Cylinder reference sensor earth
A2
A3
A4
B1 Engine speed sensor signal input
B2
B3 Vehicle speed information input
B4 Diesel pressure sensor supply
C1 Engine speed sensor earth
C2
C3
C4 Diesel pressure sensor earth
D1 Cylinder reference sensor signal input
D2
D3
D4
E1 Main relay control output
E2 Flowmeter earth (Vs-)
E3
E4
F1
F2 Coolant temperature sensor signal input
F3 Engine speed sensor supply
F4 Cylinder reference sensor supply
G1 Flowmeter signal input (Vs+)
G2 Inlet air temperature sensor signal input
G3 Diesel pressure sensor signal input
G4
H1 Coolant temperature sensor earth
H2 Diesel temperature sensor signal input
H3
H4
J1
J2
J3
J4
K1
K2
K3
K4
L1
L2 EGR electrovalve control output
L3
L4
M1
M2 Power relay control output
M3
M4 Flow regulator control output (on high pressure
pump)

43
Section 5
c - CH connector (black 32 way).

A1
A2
A3 Dialogue line: CAN H
A4 Dialogue line: CAN L
B1 Additional heating control output
B2 Low speed fan unit control (terminal earthed)
B3
B4 Diagnostic line (line K)
C1 Additional heating control output
C2 Accelerator pedal sensor input (track n°2)
C3 +ignition on
C4 Fan unit diagnostic
D1
D2
D3
D4 High speed fan unit control output (terminal earthed)
E1
E2
E3 Clutch switch signal input
E4 Secondary brake pedal information input
F1
F2 Air conditioning pressure supply
F3
F4 Air conditioning pressure sensor earth
G1
G2 Accelerator pedal sensor supply
G3 Accelerator pedal sensor input (track n°1)
G4 Earth
H1 Earth
H2 Air conditioning sensor signal input
H3 Accelerator pedal sensor earth
H4 Power earth

44
Section 5
III - BATTERY (BB00)

The battery charge level is important for the operation of the HDi direct injection
system.
Warning: A battery voltage of less than 7 volts disrupts the operation of the HDi
direct injection system.
The ECU stores a fault in the following cases:
• battery voltage greater than 18 volts,
• battery voltage below 6.5 volts.
IV - CYLINDER REFERENCE SENSOR (1115)
A - ROLE
The cylinder reference sensor informs the injection ECU of the TDC point during
compression of each cylinder.
The injection ECU needs this information to control the diesel injectors in
sequential mode (cylinder by cylinder in the order 1 - 3 - 4 - 2).
B - DESCRIPTION
A B
31
30
D C
a
DV4019C
REF DESCRIPTION
30 Cylinder reference sensor
A Top dead centre, cylinder N°2 (compression)
B Top dead centre, cylinder N°1 (compression)
C Top dead centre, cylinder N°3 (compression)
D Top dead centre, cylinder N°4 (compression)
A Target
31 Timing gear
C - LOCATION
The Hall effect reference sensor is mounted opposite a target incorporated into
the camshaft timing gear.

45
Section 5
V- COOLANT TEMPERATURE SENSOR (1220)
A - ROLE
The coolant temperature sensor informs the ECU of the temperature of the
coolant.
• to adjust the preheating time,
• to adjust the postheating time,
• to adjust the starting flow,
• to adjust the idle speed,
• to authorise exhaust gas recycling (EGR),
• to adjust the fuel flow,
• to limit the flow injected if the coolant temperature is critical (anti-boiling
function),
• to switch on the cooling fans,
• to control the logometer on the control panel (*),
• to control the warning and pre-warning LEDs (*).
Note: (*) depending on version.

46
Section 5
B - DESCRIPTION
The coolant temperature sensor consists of a Negative Temperature Coefficient
resistor (NTC).
The more the temperature rises, the more the resistance falls.
NOMINAL
COOLANT MIN RESISTANCE IN MAX RESISTANCE
RESISTANCE IN
TEMPERATURE IN °C OHMS IN OHMS
OHMS
60 1266 1244 1288
80 642 632 652
100 345 338 352
120 198 194 202
C - LOCATION
32
DV4020C
32 - Coolant temperature sensor

47
Section 5
VI - FUEL TEMPERATURE SENSOR (1221)
A - ROLE
• to adjust the fuel flow,
• to calculate the density of the fuel.
B - DESCRIPTION
The temperature sensor (33) consists of a Negative Temperature Coefficient
resistor (NTC).
The more the temperature rises, the more the resistance falls.
MAX RESISTANCE IN
FUEL TEMPERATURE MIN RESISTANCE IN OHMS
OHMS
- 40 79 000 109 535
- 30 41 255 55 557
- 20 22 394 29 426
0 7 351 9 248
20 2 743 3 323
40 1 141 1 339
60 522 595
80 259 287
100 138 150
120 78 84
130 0.60 0.64
C - LOCATION
33
DV4021C

48
Section 5
VII - ENGINE SPEED SENSOR (1313)
The engine speed information on DV engines is supplied by a new active sensor.
Features of the engine speed sensor:
• located on the timing side,
• Hall effect operating principle,
• no adjustments or maintenance required.
A - ROLE
The sensor is used to determine:
• engine speed,
• position of the reciprocating gear.
B - DESCRIPTION
34
N S
N
S
N
S
N
S
N
S
N
S
N DV4022D
E
b - Magnetic target
E - Air gap
34 - Engine speed sensor

49
Section 5
C - OPERATION
The target has 60 (58 + 2) pairs of magnetic poles located around its periphery,
with two missing poles in order to locate TDC of pistons 1 and 4.
Note: By combining the two cylinder reference sensor and engine speed
sensor signals, the engine ECU determines the exact position of each
cylinder over time.
The sensor output voltage varies as the north and south poles pass in front of the
target (high state - low state).
The frequency of the square signals created as the poles pass in front of the
target represents the engine's rotational speed.
Note the following points:
• wash your hands before working on the gear,
• avoid hitting or damaging the magnetic strip,
• sharp tools must not be used,
• do not place magnetic tooling near to the gear,
• do not exert any force on the target armature.
D - LOCATION
DV4023C
34
The Hall effect sensor (34) is mounted opposite a target on the oil pump body.
The ferromagnetic target is mounted on the crankshaft gear.

50
Section 5
VIII - FUEL HIGH PRESSURE SENSOR (1321) - FEATURES
35
DV4024D
35 - Diesel high pressure sensor.
A - ROLE
The sensor supplies a voltage proportional to the fuel pressure in the high
pressure common injection rail (50 - 1500 bars).
B - ELECTRICAL FEATURES
• pin 1: earth
• pin 2: pressure information (0 - 5 V)
• pin 3: 5 V supply

51
Section 5
IX - BRAKE SWITCH (2100) - FEATURES
A - ROLE
The switch allows the injection ECU to provide good driving pleasure.
The electrical information provided by the brake switch is sent by wire to the BSI
and sent to the injection ECU via the multiplex network (*).
B - LOCATION
The brake switch is located on the pedal set.
X- CLUTCH SWITCH (7306) - FEATURES
A - ROLE
The clutch switch allows the injection ECU to perform the driven idle function.
B - LOCATION
The clutch switch is located on the pedal set.
XI - REDUNDANT BRAKE PEDAL SWITCH (7308) - FEATURES
A - ROLE
The switch allows the injection ECU to provide good driving pleasure.
The signals from the brake switches are constantly compared with each other to
detect any faults.
B - LOCATION
The brake switch is located on the pedal set.

52
Section 5

53
Section 6
PRE-POST HEATING FUNCTION
I- DIAGRAM
1150
8 9 1 3 4 5
1320
A4
E2
1160 1
BSI 0004
DV4025C
Pin no. A4 of the grey 32-way connector (CME) (preheating unit diagnostics).
Pin no. E2 of the grey 32-way connector (CME) (pre-post heating unit relay control).
COMPONENTS
BSI Built-in Systems Interface
0004 Control panel
1150 Preheating unit
1160 Preheating plugs
CONNECTIONS
CONNEC-
TION N°
1 Request to illuminate the preheating LED CAN
2 Request to illuminate the preheating LED COMFORT VAN

54
Section 6
II - PREHEATING PLUGS (1160)
A - ROLE
The preheating plugs are used to increase the temperature in the combustion
chambers quickly during the cranking phase.
B - DESCRIPTION
DV4026C
11 V preheating plugs.
Total length: 118.5 mm.
Composition of the preheating plugs:
• a heating resistor,
• a metal protective casing.

55
Section 6
III - PRE-POST HEATING UNIT (1150)
A - ROLE
The unit provides the electrical supply to the preheating plugs as a function of
orders from the injection ECU.
B - DESCRIPTION
The pre-post heating times are determined by the injection ECU.
The ECU stores a fault if an error occurs on the preheating unit.
• pin 1: earth,
• pin 3: +12 V after ignition,
• pin 4: pre-post heating unit relay control,
• pin 5: preheating unit diagnostic,
• pin 8: permanent +12 V,
• pin 9: preheating plug supply.
D - LOCATION
DV4027C
6
REF DESCRIPTION
3 Heater plug
4 Wiring harness
5 Preheating unit
6 Cylinder head

56
Section 6
IV - PRE-POST HEATING
The preheating and post heating times are determined by the engine ECU as a
function of coolant temperature, idle speed and altitude.
A - PREHEATING OPERATION
Preheating Preheating
Preheating Preheating in
Coolant Idle speed in secs, in secs,
time (in secs, Altitude
temp. in rpm Altitude of Altitude of
seconds) of 1000m
1500m 2000m
80°C 0 750 0 0 0
20°C 0 800 0.5 2 3
0°C 0.5 890 1 5 5
-10°C 5 950 5.5 9.5 9.5
-20°C 5 1050 5.5 9.5 9.5
-25 °C 10 1075 10.5 12.5 12.5
-30 °C 15 1100 15 15 15
B - POSTHEATING OPERATION
Postheating is used to extend the operation of the preheating plugs after the
cranking phase.
Postheating is used to reduce pollutant emissions during the first few minutes
after starting the engine.
Postheating reduces blue smoke emissions when cold and at altitude.
PREHEATING TIME POSTHEATING IN
COOLANT TEMP. IDLE SPEED IN RPM
(IN SECONDS) SECONDS
80°C 0 750 0
20°C 0 800 0
0°C 0.5 890 180
-10°C 5 950 180
-20°C 5 1050 180
-25 °C 10 1075 180
-30 °C 15 1100 180
Parameters which can interrupt postheating:

• coolant temperature greater than 65°C,
• engine speed greater than 3500 rpm,
• inlet air temperature greater than 40°C,
• injected fuel flow greater than 35 mg/st (between 0 and 2500 rpm),
• injected fuel flow greater than 25 mg/st (engine speed above 3000 rpm),
• battery voltage less than 7.5 V.

57
Section 7
ENGINE COOLING FUNCTION (FRIC)
Functions of the injection ECU:
• to switch the fan(s) on or off (engine cooling),
• to control post-ventilation (for 6 minutes maximum),
• to control the illumination of the coolant temperature warning LED on the control panel,
• to control the coolant temperature gauge on the control panel,
• to perform diagnostics on the operation of the fan(s),
• to acquire the coolant temperature,
• to control downgraded modes.

58
Section 7
I- DIAGRAM
1 3
1220 8009 1508

4
2
16 5
1320 1509 1510

14
15 6
11
7
8080 10 BSI 1514

9
8
0004 8020 DV4028D
Key:
Single arrow - wire connection
Triple arrow - multiplex connection
Note: This diagram shows the configuration fitted on the Xsara 2.

DESCRIPTION
DIAGRAMS
Built-in Systems Interface BSI
Control panel 0004
Coolant temperature sensor 1220
Injection ECU 1320
Low speed supply relay 1508
High speed supply relay 1509
Fan unit 1510
Mid speed supply relay 1514
Pressostat 8009
Air conditioning compressor 8020
Air conditioning ECU 8080

59
Section 7
CONNECTIONS
CONNEC-TION
N°

2 Refrigerant pressure information ANALOGUE
3 Low speed relay control ALL OR NOTHING
4 Low speed fan supply ALL OR NOTHING
5 High speed fan supply ALL OR NOTHING
6 Mid speed fan supply ALL OR NOTHING
7 Mid speed relay control ALL OR NOTHING
8 Air conditioning compressor control ALL OR NOTHING
9 Coolant temperature warning LED illumination control COMFORT VAN
Air conditioning management status COMFORT VAN
Air conditioning compressor status COMFORT VAN
10
AC/ON control COMFORT VAN
Coolant temperature information COMFORT VAN
11 Air conditioning request COMFORT VAN
Authorisation to engage air conditioning compressor
CAN
(AC/OUT)
14
Request to flash coolant temperature warning LED CAN
Coolant temperature information CAN
Request to authorisate engaging of air conditioning
15 CAN
compressor (AC/TH)
16 High speed relay control ALL OR NOTHING

60
Section 7
II - COOLANT TEMPERATURE SENSOR (1220)
The coolant temperature sensor informs the ECU of the temperature of the coolant.
The coolant temperature sensor is located on the coolant housing.
10
DV4029C
12
10 - Coolant outlet housing

12 - Coolant temperature sensor (1220).
COOLANT NOMINAL RESISTANCE MIN RESISTANCE IN MAX RESISTANCE

TEMPERATURE IN °C IN OHMS OHMS IN OHMS
60 1266 1244 1288
80 642 632 652
100 345 338 352
120 198 194 202
III - POST-VENTILATION
When the engine is switched off, the ECU operates post-ventilation if the coolant
temperature exceeds a certain limit (105°C) (*).
(*) depending on vehicle.
Post-ventilation occurs at low speed and lasts for a maximum of 6 minutes after the
engine is switched off.

61
Section 7
IV - DOWNGRADED MODE
CHARACTERISATION OF THE INFORMATION - EMERGENCY

COOLANT TEMPERATURE DETECTION LEVEL STRATEGY - REPLACEMENT
SENSOR FAULT VALUE
Sensor voltage less than 2.2 Illumination of engine diagnostic
Short circuit to earth
V LED
Open circuit or short circuit to Sensor voltage greater than Illumination of coolant temperature
+BAT 4.9 V warning LED
Reduced flow mode (3000 rpm)
Exhaust gas recycling cut off (EGR)
Air conditioning compressor
prohibited from engaging or cut off
Consistency of temperature rise (AC/OUT)
Fan at high speed
Fuel temperature replacement value
for 1 minute after engine started
then 100°C
DV ENGINE
Coolant temperature warning 118°C
Post-ventilation duration 6 min
Post-ventilation triggering temperature limit (low speed) 105°C
Fan low speed triggering temperature 96°C
Fan high speed triggering temperature 105°C

62
Section 7
V- COOLING CIRCUIT
8
7
10
DV4030P
11
7 - Expansion bottle.
8 - Coolant inlet housing.
9 - Heater matrix.
10 - Coolant outlet housing
11 - Cooling radiator.

63
Section 8
ENGINE COOLING REQUIREMENTS FOR THE AIR

CONDITIONING (BRAC)
I- DIAGRAM
1 3
1220 8009 1508

4
2
16 5
1320 1509 1510

14
15 6
11
7
8080 10 BSI 1514

9
8
0004 8020 DV4028D
Key:
Note: This diagram shows the configuration fitted on the Xsara 2.
DESCRIPTION
DIAGRAMS
Built-in Systems Interface BSI
Control panel 0004
Coolant temperature sensor 1220
Injection ECU 1320
Low speed supply relay 1508
High speed supply relay 1509
Fan unit 1510
Mid speed supply relay 1514
Pressostat 8009
Air conditioning compressor 8020
Air conditioning ECU 8080

64
Section 8
CONNECTIONS
CONNEC-
TION N°
2 Refrigerant pressure information ANALOGUE
3 Low speed relay control ALL OR NOTHING
4 Low speed fan supply ALL OR NOTHING
5 High speed fan supply ALL OR NOTHING
6 Mid speed fan supply ALL OR NOTHING
7 Mid speed relay control ALL OR NOTHING
8 Air conditioning compressor control ALL OR NOTHING
9 Coolant temperature warning LED illumination control COMFORT VAN
Air conditioning management status COMFORT VAN
Air conditioning compressor status COMFORT VAN
10
AC/ON control COMFORT VAN
Coolant temperature information COMFORT VAN
11 Air conditioning request COMFORT VAN
Authorisation to engage air conditioning compressor (AC/OUT) CAN
14 Request to flash coolant temperature warning LED CAN
Coolant temperature information CAN
Request to authorise engaging of air conditioning compressor
15 CAN
(AC/TH)
16 High speed relay control ALL OR NOTHING

65
Section 8
II - REFRIGERANT PRESSOSTAT (PRESSURE SENSOR) (8009)
A - ROLE
The sensor measures the value of the pressure in the air conditioning circuit.
• to authorise the operation of the fan (air conditioning condenser cooling),
• to authorise the engaging of the air conditioning compressor.
B - DESCRIPTION
DV4031C
The sensor is of piezo-electric type.

The sensor consists of strain gauges.
The pressostat supplies a voltage proportional to the pressure in the air
conditioning circuit.
Identification: black connector.
Note: The electrical information provided by the sensor is transmitted by wire
to the injection ECU and sent to the BSI via the multiplexed network.
Pressure value
FAN SWITCHED ON FAN SWITCHED OFF
Low speed Mid speed High speed Low speed Mid speed High speed
Pressure
10 16 22 7 13 19
(bar)

66
Section 8
• pin 1: 5 V supply
• pin 2: pressure information (0 - 5 V)
• pin 3: earth.
Voltage supplied for a pressure of 1 bar: + 0.5 volt.
Voltage supplied for a pressure of 31 bars: + 4.5 volts.
D - LOCATION
The sensor is located on the air conditioning condenser.
E - DOWNGRADED MODE
Role of the injection ECU when the pressure switch is faulty:
• to prevent the air conditioning compressor from being engaged (AC/OUT),
• to record a fault in the engine management ECU.
The fan unit is no longer operational for the cooling requirements linked to the air
conditioning.

67
Section 8
III - ADDITIONAL HEATING
A - GENERAL DETAILS
As the engine is very efficient, assistance is required to help the passenger
compartment warm up in low temperatures.
The passenger compartment temperature rise assistance function is controlled
by the BSI and operated by the engine ECU.
Two devices are used depending on marketing country:
− Several thermoplungers (electrical resistors) located in the heater matrix
coolant circuit
− An additional fuel-operated boiler (or burner) located in the front LH wheel
arch (for vehicles in very cold countries).
Note: The boiler system has been discontinued on the Xsara 2 with BOSCH
EDC 16 C3 injection.
B - DIAGRAM
4
1320 BCP3
5
1190 DV4032D
BSI
Key:
COMPONENTS
BCP3 Protection switching unit
1190 Coolant circuit heater

68
Section 8
CONNECTIONS
CONNEC- SIGNAL
SIGNAL
TION N° NATURE
1 Control of relay R1A (in the BCP3) by earthing the engine ECU 0 or 5 V
output (black 32-way B1)
2 Power circuit for two additional heating resistors 12 V
3 Power circuit for two additional heating resistors 12 V
4 Control of relay R2B (in the BCP3) by earthing the engine ECU 0 or 5 V
output (black 32-way C1)
5 Additional heating request CAN
C - OPERATING CONDITION
Te
B
80 a
70
65
b
40
Ta
-20 -10 10 DV4033D
Ta - Exterior air temperature

Te - Coolant temperature
a - Example 1
b - Example 2
A - Heating authorisation zone
B - Heating prohibition zone
The BSI determines the additional heating requirement when the engine is
started as a function of exterior air temperature and coolant temperature.
Example 1:
• Coolant temperature = 70°C,
• Exterior temperature = 10 °C,
• The temperature conditions are outside the operating zone: there is no
additional heating.

69
Section 8
Example 2:
• Coolant temperature = 40°C,
• Exterior temperature = - 10°C,
• The temperature conditions are within the additional heating operating zone.
The BSI determines the additional heating requirement of the passenger
compartment when the engine is started as a function of exterior air temperature
and coolant temperature.
The BSI controls the thermoplungers under the following conditions:
• engine has been operating for 60 seconds,
• engine speed greater than 700 rpm,
• battery voltage greater than 12 V (positive electrical balance),
• coolant temperature above 40°C.
The BSI controls the heating stages progressively:
• first stage,
• second stage.
Additional heating ceases when the temperature conditions are satisfied (curve).

70
Section 8

71
Section 9
MAINTENANCE
I- RECOMMENDED FUEL
Warning: The use of additives such as fuel circuit cleaners/remetallisers is
forbidden.
II - SAFETY PRECAUTIONS
A - INTRODUCTION
All operations on the injection system must be performed in accordance with the
provisions and regulations of the following:
• professional health and safety organisations,
• accident prevention,
• protection of the environment.
Do not smoke near to the high pressure circuit whilst working on it.
Avoid working near to flames or sparks.
When the engine is running:
• do not work on the high pressure fuel circuit,
• always remain out of the range of a possible fuel jet which can cause serious
injuries,
• never place your hand near to a leak in the high pressure fuel circuit.
after switching off the engine, wait for 30 seconds before starting any work.
Note: Allow sufficient time for the pressure in the high pressure fuel circuit to
return to atmospheric pressure.
Warning: Operations must only be performed by personnel who have been
specially trained in the safety measures and instructions to be
implemented.
Warning: It is forbidden to work on the high pressure fuel circuit when the
engine is running.
Warning: Before removing the injection ECU: wait for 30 seconds after
switching off the ignition and disconnect the negative terminal from
the battery.
Warning: It is forbidden to disconnect a diesel injector when the engine is
running (risk of damaging the engine).
Warning: Do not control a diesel injector when not in the cylinder head if its
body is not earthed (risk of electrostatic discharge).
Warning: Do not force the lugs on the connectors when removing the injection
ECU.

72
Section 9
III - REPLACING PARTS – OPERATIONS TO BE PERFORMED
A - PRELIMINARY OPERATIONS
Before working on the injection circuit, the connectors of the following
components may have to be cleaned (see corresponding operations):
• fuel filter,
• fuel high pressure pump,
• fuel high pressure common injection rail,
• fuel high pressure pipes,
• diesel injector holders.
IMPORTANT: After removal, the connectors of the sensitive components must
be blanked, to prevent the ingress of dirt.
IMPORTANT: Use the correct tightening torques for the fuel high pressure
components, using a regularly checked torque wrench.
B - EXCHANGING PARTS
Warning: Before adding or replacing parts, ensure that the customer is in
possession of their confidential card.
C - FORBIDDEN OPERATIONS
Removal - refitting:
• fuel high pressure sensor on the fuel high pressure common injection rail,
• flow regulator (1208) on the fuel high pressure pump,
• fuel temperature sensor on the 4-way connector.
COMMENT /
REPLACED
OPERATIONS TO BE PERFORMED INFORMATION
COMPONENTS
REQUIRED
Match with the BSI Customer code
Configure the engine ECU Description of vehicle
Engine
equipment
management ECU
Configure the hexadecimal numbers for each VIN
diesel injection in the corresponding cylinder
Diesel injector When replacing a diesel injector, configure the 8
hexadecimal numbers of each diesel injector with
the corresponding cylinder
Built-in Systems Match with engine ECU Customer code
Interface VIN
All keys
Engine Relay Unit Nothing Specific engine relay
unit, depending on
version

73
Section 9
D - PROGRAMMING THE INJECTION ECU

Warning: Swapping an injection ECU between two vehicles makes it
impossible to start the vehicles.
When replacing an injection ECU, the engine immobiliser system must be
programmed.
To program the engine immobiliser system it is essential to:
• have the access code to the Built-in Systems Interface (written on the customer
confidential card),
• have a new injection ECU,
• use the diagnostic tool,
• program the engine management ECU: "ENGINE ECU PROGRAMMING",
• download the injection ECU (if necessary).
1 - Configuring the injection ECU

This procedure is used to reduce the number of ECU references.
Parameters which can be configured:
• engine cooling (fan),
• air conditioning pressostat,
• vehicle speed,
• additional heating,
• ECUs.
2 - Downloading to the injection ECU

The software of the injection ECU is updated by downloading (ECU with a
flash EPROM).
Note: This operation is performed using diagnostic tools.

74
Section 9
IV - GUARANTEE RETURN PROCEDURES
A - INJECTION SYSTEM COMPONENTS

Before returning them to the guarantee department, the following components
must be blanked, placed in a plastic bag and packaged in their original
packaging:
• diesel injectors,
• fuel high pressure pump,
• fuel high pressure common injection rail,
• fuel high pressure sensor,
• fuel filter.
B - INJECTION ECU
Disconnecting the injection ECU will lead to it being automatically locked.
IMPORTANT: If returning the injection ECU under guarantee, it must be

returned along with its access code.

75
Section 10
DIAGNOSTICS
I- TOOLING
PROXIA: 4165 -T
4HP141C
LEXIA: 4171 -T
4HP142C

76
Section 10
II - TOOL FUNCTIONS
A - PROXIA: 4165T
The tool is used for:
• ECU identification,
• log (history),
• reading fault codes,
• erasing faults,
• measuring parameters and associated variables,
• testing actuators,
• updating ECUs by downloading,
• viewing wiring diagrams.
B - LEXIA: 4171T
The tool is used for:
• ECU identification,
• log (history),
• reading fault codes,
• erasing faults,
• measuring parameters and associated variables,
• testing actuators,
• updating ECUs by downloading,
• viewing wiring diagrams.

77
Section 10
III - LEXIA / PROXIA SCREENS
A - READING FAULTS
FAULT DESCRIPTION
Title Type p-code Characterisation
P0533 Short circuit to positive or open
Air conditioning pressure signal fault Local circuit
P0532 Short circuit to earth
P1507 No communication on CAN
Air conditioning control authorisation
Local P1508 Value received on CAN
not received fault
incorrect
Accelerator pedal signal fault Local P1628 Consistency with brake switch
P0104 Measurement variation too
large
Flowmeter signal fault Local P0102 Short circuit to earth
circuit
P0402 Air flow higher than setting
P0401 Air flow lower than setting
Air inlet circuit fault Local
P0194 Consistency with air flow
P0404
Additional heating circuit 1 fault Local P1403 Short circuit to earth, short
circuit to positive, open circuit
or actuator fault
Additional heating circuit 2 fault Local P1404 Short circuit to earth, short
or actuator fault
circuit
Accelerator pedal signal 1 fault Local P0222 Short circuit to earth
P0221 Consistency with accelerator
pedal signal 2
circuit
Accelerator pedal signal 2 fault Local P0227 Short circuit to earth
P0226 Consistency with accelerator
pedal signal 1
P1118 Atmospheric pressure sensor
in short circuit to positive or
ECU internal fault Local open circuit
P1117 Atmospheric pressure sensor
in short circuit to earth
P0563 Battery voltage too high
Battery voltage signal fault Local
P0562 Battery voltage too low
Brake switch signal fault Local P0571 Faulty pedal information
received on the CAN

78
Section 10
FAULT DESCRIPTION
P0116 Consistency of temperature
rise
Coolant temperature signal fault Local P0118 Short circuit to positive or open
circuit
Clutch switch signal fault Local P0704 No signal or signal incoherent
Air temperature signal fault Local P0111 Exterior air and inlet air
temperatures faulty
Configuration fault Local P1613 Configuration incorrect or not
done
P1410 Short circuit to positive
EGR electrovalve control fault Local
P0403 Open circuit or actuator
malfunction
P0342 No signal
P0343 Incorrect signal
Camshaft signal fault Local
P0341 Temporary absence of signal
P0344 Signal temporarily incorrect
P0337 No signal
Engine speed signal fault Local
P0336 Temporary absence of signal
P0339 Signal temporarily incorrect
Cooling function incorporated into Local P0483 Consistency between fan
ECU fault speed and setting
High speed fan control fault Local P0480 Short circuit to earth, short
or actuator fault
Low speed fan control fault Local P0481 Short circuit to earth, short
or actuator fault
Diesel temperature signal fault Local
P1300 Short circuit to earth, short
Preheating relay circuit fault Local or actuator fault
P0382 Plugs permanently supplied
P0380 Plugs never supplied
ECU fault Local P0611 Internal fault
P0620
P0656
P0657
P1700

79
Section 10
FAULT DESCRIPTION
P1632
P0606
P1631
P1634
P1633
P1636
P1635
P1621
EEPROM fault Local P0603 ECU internal fault
Analogue - digital converter fault Local P0610 ECU internal fault
Inlet air temperature signal fault Local circuit
Engine immobiliser fault Local P1612 Error reading or writing ADC2
code
P0200 Control in short circuit to
P0211 positive or short circuit to earth
Injector control fault Local
P0210
Control in open circuit
P0212
Cylinder 1 injector circuit fault Local P0201 Short circuit between 2 injector
pins
P0263 Open circuit
pins
P0266 Open circuit
pins
P0269 Open circuit
pins
P0272 Open circuit
Diesel high pressure pump filling P1209 Regulation electrovalve short
Local
actuator fault circuited to positive

80
Section 10
FAULT DESCRIPTION
P1210 Regulation electrovalve in open
circuit or actuator malfunction
P1208 Regulation electrovalve short
circuited to earth
P0230 Pressure lower than setting
P0231 Pressure lower than setting
and pump filling flow setting
too high
Diesel high pressure regulation
circuit fault P0232 Rail pressure limitation
impossible by lowering pump
filling flow setting
P0233 Rail pressure less than
minimum pressure
P1200 Maximum rail pressure
exceeded
P1201 Rail pressure inconsistency

Diesel high pressure regulation upon releasing pedal
Local
circuit fault
P1203 Filling flow setting inconsistent
when idling
P1202 Filling flow setting inconsistent
when pedal released
Injection system supply relay circuit Local P0215 Opened too quickly or relay
fault still closed
PD118 No communication with the
BSI
CAN communication fault Remote
PD003 No communication
PD000 Engine ECU mute
circuit
Diesel pressure signal fault Local P0192 Short circuit to earth
P0191 Measurement variation too
large
Accelerator pedal sensor supply Local P0608 Supply outside tolerances
fault
Engine speed, air conditioning Local P0609 Supply outside tolerances
pressure and camshaft sensor
supply fault
Rail pressure sensor supply fault Local P1614 Supply outside tolerances
ECU + ignition on supply fault Local P1511 No + ignition on
Vehicle speed signal fault P0503 Maximum speed exceeded
P0501 Consistency with engine flow
Local
and speed

81
Section 10
FAULT DESCRIPTION
P1504 Speed received on CAN
incorrect
P1504 Speeds received by the CAN
Remote and by wire incorrect
P1799 Speed received by the CAN
incorrect, no ABS
communications
Engine torque fault Local P1604 Engine torque uncertain
P1666 ECU functional but
Temperature fault inside ECU Local downloading temporarily
impossible
P1505 Triggering of airbag impact
Engine stopped fault Local
detector

82
Section 10
B - READING PARAMETERS
These values are guidelines.
Engine idling, coolant temperature = 80°C, no electrical consumers.
REFERENCE
PARAMETERS UNITS PARAMETER DEFINITION
VALUE
Engine speed rpm 750 Engine rotational speed in
number of revolutions per minute
Camshaft/crankshaft Yes Detection of signal from cylinder
synchronisation reference sensor authorising
starting of the engine
Measured fuel pressure bars 310-320 Fuel pressure measured in the
high pressure rail
Fuel pressure setting bars 310-320 Fuel pressure to be reached in
the high pressure rail
Fuel flow regulator OCR % Opening rate of the fuel pressure
regulating electrovalve in the fuel
high pressure pump.
Injected flow Mg/ stroke 4 Fuel flow in the injector
Cylinder X injector flow Mg/ stroke Correction of the flow injected into
correction cylinder X by the engine ECU
Diesel flow setting Mm3/stroke Fuel flow to be reached in the
high pressure rail
Measured air flow Mg/ stroke 200-220 Air flow measured for controlling
the EGR valve
Air flow setting Mg/ stroke 200-220 Air flow to be reached in the inlet
manifold to control the EGR valve
EGR valve OCR % 0 Opening ratio of the exhaust gas
recycling electrovalve
Preinjection advance ° 10 Pilot injection instant (1st
injection) in relation to TDC
Main injection advance ° -2 Main injection instant (2nd
injection) in relation to TDC
Coolant temperature °C 80 Coolant temperature allowed by
the engine ECU using the
information from the sensor
Fuel temperature °C 70 Diesel return circuit fuel
temperature
Inlet air temperature °C 25 Inlet air temperature taken in the
air flowmeter
Atmospheric pressure Mbars 1013 Ambient air pressure measured
by the sensor inside the ECU
Battery voltage Volt 12 - 14.7 Battery voltage measured by the
engine ECU
+ ignition on voltage Volt 12 - 14.7 + ignition off voltage measured by
the engine ECU
Pre-post heating relay Inactive Status of the pre-post heating
plug supply relay control

83
Section 10
REFERENCE
VALUE
Air conditioning cut-off No Air conditioning compressor
request activation prohibition from
injection ECU
Air conditioning pressure Bars 5 Refrigerant pressure acquired by
the engine ECU
Fan relay No
Fan speed 0 Fan rotational speed (varies from
0 - 100%)
Fan speed setting 0 Fan rotational speed requested
by the ECU as a function of
coolant temperature and air
conditioning
Measured injected flow Mg/ stroke 4 Fuel flow in each injector during
an engine cycle
Vehicle speed kph 0 Speed acquired by the sensor
mounted on the gearbox or by the
CAN
Accelerator pedal % 0 Position measured by the
position accelerator pedal sensor
Gear engaged 0 Gear ratio calculated as a
function of vehicle speed and
engine speed
Main brake pedal Released Information from the brake pedal
sensor (info from the BSI)
Measured injected flow Mg/ stroke 4 Fuel flow determined by the
injection time and the fuel
pressure
ECU temperature °C Temperature acquired by the
sensor inside the ECU.
Downloading is prohibited above a
temperature of 70°C
Clutch pedal Released Information provided by the clutch
pedal position sensor (driving
comfort)
ECU unlocked Engine is authorised to start
Impossible to start engine
Possibility of performing the
following diagnostic operations:
• Identification
ECU state -
ECU locked • Read faults
• Parameter measurements
• Configuration
Engine immobiliser - Design state The ECU cannot be locked

programming state

84
Section 10
REFERENCE
VALUE
programming state After sales state The ECU is supplied locked.
Program the ECU code then
match
Programmed The ECU is locked. Reprogram
once the ECU code then match.
Programmed The ECU is locked. Reprogram
twice the ECU code then match.
Programmed 3 The ECU is locked. Program the
times BSI access code.
ECU matched The engine immobiliser function is
operational.

85
Section 10
C - LIST OF CONFIGURATION OPERATIONS
TITLE CONFIGURATION OPTION

Single speed fan
Engine cooling
Two or three speed fan
Air conditioning pressure No air conditioning

sensor. Pressostat
Gearbox Long manual gearbox
Alternator class Class 15
No additional heating
Additional heating
Plugs controlled by the BSI
Without cruise control, without traction control (ESP)
Without cruise control, with traction control (ESP)
ECU configuration
With cruise control, without traction control (ESP)
With cruise control, with traction control (ESP)
LH drive
Bodywork configuration
RH drive
D - INJECTOR CLASSIF ICATIONS
DV4034C
When replacing a diesel injector (1) or replacing the engine ECU, the eight
hexadecimal numbers (2) of each diesel injector must be programmed with the
corresponding cylinder, using the diagnostic tool.

86
Section 10
IV - DOWNGRADED MODE
A - VISUALISING FAULTS
The LED will illuminate on the control panel following the appearance of certain
faults in the injection system.
2 3
DV4035C
Illumination of engine diagnostic LED (2):

• flow regulator fault on the fuel high pressure pump,
• accelerator pedal supply fault (5 V),
• fuel high pressure sensor supply fault (5 V),
• accelerator pedal sensor fault,
• fuel high pressure sensor fault,
• coolant temperature sensor fault,
• exhaust gas recycling fault,
• fuel high pressure common injection rail pressure regulation fault,
• diesel injector fault,
• pre-postheating relay fault,
• engine ECU configuration fault.
Coolant temperature LED (3):
• the LED illuminates if the coolant temperature reaches 118°C,
• the LED extinguishes if the coolant temperature falls below 117°C,
• the LED flashes if the electrical line of the coolant temperature sensor is faulty,
• fan fault.

87
Section 10
B - EMERGENCY STRATEGY
When one or more faults appear, the engine ECU switches to downgraded mode
and implements emergency strategies to overcome the fault.
If the fault is a major one, the engine ECU limits the engine speed to 3000 rpm or
1200 rpm (limp home).
Reduced fuel flow:
• this downgraded operating mode limits fuel flow,
• the engine speed cannot exceed 3000 rpm.
Limp home:
• this downgraded operating mode limits fuel flow in the event of a serious
problem,
• the engine speed cannot exceed 1200 rpm,
• this mode allows the driver to reach the nearest repair garage.
Note: Some faults lead to the engine being stopped or prevent the engine
from being started.
Note: When the diesel temperature is greater than 90°/95°C, the engine ECU
limits the amount of fuel injected.

88
Section 10
V- SENSOR FAULTS
A - CAMSHAFT SENSOR (1115)
INFORMATION - EMERGENCY
FAULT
DETECTION LEVEL STRATEGY - REPLACEMENT
CHARACTERISATION
VALUE
No signal If the signal is incorrect before
synchronisation with the engine
speed sensor, the engine cannot
be started.
If the signal is incorrect during
Incorrect signal use, the engine ECU orders the
engine to be stopped.
B - AIR FLOWMETER SENSOR (1310)
FAULT
CHARACTERISATION
VALUE
Large measurement variation Measurement not on
cartographic map
Short circuit to earth Air flow less than 9 kg/h
Exhaust gas recycling cut off as
and engine speed greater a function of engine speed and
than 150 rpm. load
Short circuit to + or open Air flow more than 500 kg/h
circuit
C - INLET AIR TEMPERATURE SENSOR (1310)
FAULT
CHARACTERISATION
VALUE
Short circuit to earth Sensor voltage less than 0.1 Replacement value 50°C
V
Short circuit to +BAT Sensor voltage greater than Replacement value 50°C
4.75 V

89
Section 10
D - ACCELERATOR PEDAL SENSOR (1261)
CHARACTERISATION DETECTION LEVEL STRATEGY - REPLACEMENT
VALUE
Acceleration pedal blocked Engine speed greater than Limp home (1200 rpm)
detection (consistency with 1100 rpm.
brake pedal) Vehicle speed above 1 mph
(2.5 kph)
Acceleration greater than
20%
Brake pressed for more than
1 second
Consistency of tracks no. 1 Outside cartographic range Lowest track
and 2 of sensor Reduced flow (3000 rpm)
Track no. 1 short circuited to Sensor voltage less than 0.9 The engine ECU uses the
earth V second pedal sensor track
Reduced flow mode of 3000 rpm
Track no. 1 short circuited to Sensor voltage greater than The engine ECU uses the
+BAT or open circuit 4.75 V second pedal sensor track
Track no. 2 short circuited to Sensor voltage less than 0.9 The engine ECU uses the
earth V second pedal sensor track
Track no. 1 short circuited to Sensor voltage greater than The engine ECU uses the
+BAT or open circuit 4.75 V second pedal sensor track
Tracks no. 1 and 2 faulty Limp home (1200 rpm)
E - AIR CONDITIONING PRESSURE SENSOR (8009)

FAULT
CHARACTERISATION
VALUE
Open circuit or short circuit to Sensor voltage less than 0.2 Air conditioning compressor cut
earth V off
Replacement value 100 Kpa
Short circuit to +BAT Sensor voltage greater than Air conditioning compressor cut
4.95 V off
Replacement value 100 Kpa

90
Section 10
F - FUEL HIGH PRESSURE COMMON INJECTION RAIL PRESSURE SENSOR

(1321)
FAULT
CHARACTERISATION
VALUE
Open circuit or short circuit to Sensor voltage less than 0.25 Illumination of engine diagnostic
earth V LED
Short circuit to +BAT Sensor voltage greater than Reduced flow mode (3000 rpm)
4.95 V
Engine cut off
G - ENGINE SPEED SENSOR (1313)

FAULT
CHARACTERISATION
VALUE
No signal In order:
• Engine cut off
• If injection resynchronised
Incorrect signal • If resynchronisation fails,
engine stopped
Temporary absence of signal
Signal temporarily incorrect
H - TEMPERATURE SENSOR INSIDE ENGINE ECU (1320)

FAULT
CHARACTERISATION
VALUE
V
Short circuit to +BAT Sensor voltage greater than Replacement value 20°C
4.75 V
I - ATMOSPHERIC PRESSURE SENSOR (1320)

FAULT
CHARACTERISATION
VALUE
Open circuit or short circuit to Sensor voltage less than 2.2 Replacement value 900 mbars
earth V
Short circuit to +BAT Sensor voltage greater than Replacement value 900 mbars
4.75 V

91
Section 10
J - FUEL TEMPERATURE SENSOR (1221)

FAULT
CHARACTERISATION
VALUE
V
Open circuit or short circuit to Sensor voltage greater than Replacement value 70°C
+BAT 4.75 V
K - COOLANT TEMPERATURE SENSOR (1220)

FAULT
CHARACTERISATION
VALUE
Short circuit to earth Sensor voltage less than 2.2 Illumination of engine diagnostic
V LED
Open circuit or short circuit to Sensor voltage greater than Illumination of coolant
+BAT 4.9 V temperature warning LED
Consistency of temperature Reduced flow mode (3000 rpm)
rise Exhaust gas recycling cut off
(EGR)
Air conditioning compressor
prohibited from engaging or cut
off (AC/OUT)
Fan at high speed
Fuel temperature replacement
value for 1 minute after engine
started then 100°C
L - SENSOR SUPPLY
FAULT
CHARACTERISATION
VALUE
Accelerator pedal sensor Voltage more than 5.3 V or Illumination of engine diagnostic
supply voltage no. 1 too low voltage less than 4.7 V LED
or too high Limp home
Air conditioning pressure Voltage more than 5.3 V or Emergency strategy applied to
sensor, engine speed sensor, voltage less than 4.7 V faulty sensors
camshaft sensor supply
voltage no. 2
Fuel high pressure common Voltage more than 5.3 V or Illumination of engine diagnostic
injection rail pressure sensor voltage less than 4.7 V LED
supply voltage no. 3 Reduced flow mode (3000 rpm)
Engine cut off
Emergency strategy applied to
faulty sensors

92
Section 10
VI - ASSOCIATED FUNCTIONS FAULTS

A - FUEL FLOW REGULATOR (1208)
FAULT
CHARACTERISATION
VALUE
Short circuit to earth Reduced flow mode (3000 rpm)
Short circuit to +BAT Illumination of engine diagnostic
LED
Open circuit
Engine cut off
Switch to open loop regulation
Consistency with power Switch to open loop regulation
consumption
B - ADDITIONAL HEATING
FAULT
CHARACTERISATION
VALUE
Short circuit to earth, short
circuit to +BAT, open circuit
C - COMMUNICATION FAULT ON CAN

FAULT
CHARACTERISATION
VALUE
Engine ECU mute
Replacement value for affected
No communication with the CAN parameters
BSI
D - CLUTCH PEDAL SWITCH (7306)

FAULT
CHARACTERISATION
VALUE
No signal or signal incoherent 8 gear changes with no
modification to the clutch
pedal signal
E - SECONDARY OR REDUNDANT BRAKE PEDAL SWITCH (7308)

FAULT
CHARACTERISATION
VALUE
Consistency between main BSI strategy Brake not pressed
and secondary brake
switches

93
Section 10
F - EXHAUST GAS RECYCLING ELECTROVALVE (EGR) (1253)

FAULT
CHARACTERISATION
VALUE
Short circuit to earth
Exhaust gas recycling cut off
Short circuit to +BAT
(EGR)
Open circuit
G - EXHAUST GAS RECYCLING FUNCTION (EGR)

FAULT
CHARACTERISATION
VALUE
Air flow lower than setting Illumination of diagnostic LED
Reduced flow mode (3000 rpm)
Exhaust gas recycling cut off
(EGR)
Air flow greater than setting Exhaust gas recycling cut off
(EGR)
H - FUEL HIGH PRESSURE COMMON INJ. RAIL PRESSURE REGULATION

FAULT
CHARACTERISATION
VALUE
Pressure lower than setting Variation of more than 350 Illumination of engine diagnostic
bars when the engine speed LED
is less than 800 rpm Reduced flow mode (3000 rpm)
Variation of more than 200 Reduction in setting to 200 bars
bars when the engine speed
is more than 800 rpm
Fuel high pressure pump Variation in fuel high pressure Illumination of engine diagnostic
filling flow setting too high common injection rail LED
pressure greater than 150 Reduced flow mode (3000 rpm)
bars and fuel high pressure Injection cut-off
filling flow setting greater than
a limit set as a function of
engine speed.
Fuel high pressure pump Variation in fuel high pressure Illumination of engine diagnostic
filling flow setting too low common injection rail LED
pressure less than a limit set Reduced flow mode (3000 rpm)
as a function of engine speed
Fuel high pressure common Variation in fuel high pressure Illumination of engine diagnostic
injection rail pressure less common injection rail LED
than nominal pressure pressure less than a limit set Reduced flow mode (3000 rpm)
as a function of engine speed Injection cut-off
(between 0 and 220 bars)
Maximum fuel high pressure Fuel high pressure common Illumination of engine diagnostic
common injection rail injection rail pressure greater LED
pressure exceeded than 1450 bars Reduced flow mode (3000 rpm)
Injection cut-off

94
Section 10
I - FAN UNIT
FAULT
CHARACTERISATION
VALUE
Consistency between fan Illumination of coolant
speed and setting temperature warning LED
Air conditioning compressor cut
off
Short circuit to earth or to +
of the low or high speed
control relays
Low or high speed relays in
open circuit

95
Section 11
WIRING DIAGRAM
I- LAYOUT

96
Section 11
II - WIRING DIAGRAM

97
Section 11
III - LOCATION

98
Section 11
IV - PARTS LIST
BH28 - Passenger compartment fuse box

BB00 - Battery
BSI1 - Built-in Systems Interface
PSF1 - Engine relay unit
C001 - Diagnostic connector
CA00 - Ignition switch
M000 -
MC11 -
MC13 -
MC14 - Earths
MC30 -
MC31 -
MC32 -
MM01 -
0004 - Control panel
1115 - Cylinder reference sensor
1208 - Flow regulator
1220 - Coolant temperature sensor
1221 - Diesel thermistor
1253 - EGR all or nothing electrovalve
1261 - Accelerator pedal position sensor
1276 - Diesel heater
1310 - Air flowmeter
1313 - Engine speed sensor
1320 - Engine management ECU
1321 - Fuel high pressure sensor
1331 - Injector, cylinder N°1
1620 - Vehicle speed sensor (*)
7306 - Cruise control safety switch (clutch)
11 -- - Preheating ignition function
15 -- - Engine cooling function
43 -- - Fuel information function
65 -- - Airbag function
72 -- - Trip computer function
73 -- - Cruise control function
80 -- - Air conditioning function

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BOSCH EDC 16 C3

After Sales Division

© CITROËN U.K. LTD

BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR

The following subjects will be dealt with in this document:

- General details and presentation of the system,

- Description, composition and operation of the components of the various

- Description of the various operating phases,

- The electrical circuit,

- The diagnostic system.

BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR DV4TD ENGINE

SECTION 1: GENERAL DETAILS: HDI INJECTION SYSTEM .......................1

SECTION 2: FUNCTION: FUEL SUPPLY...................................................5

II - FUEL FILTER .................................................................................................... 7

III - FUEL HEATER (ELECTRIC) (1276)...................................................................... 8

IV - FUEL HIGH PRESSURE PUMP.......................................................................... 8

V- RELIEF VALVE ............................................................................................... 10

VI - TRANSFER PUMP (PRE-SUPPLY)................................................................... 11

VII - FUEL FLOW REGULATOR............................................................................... 11

VIII - FUEL HIGH PRESSURE COMMON INJECTION RAIL ......................................... 12

IX - DIESEL INJECTORS (1131, 1132, 1133, 1134) ................................................... 13

X- FEATURE OF THE DIESEL INJECTOR CONTROL ............................................. 18

SECTION 3: AIR SUPPLY FUNCTION..........................................................21

II - AIR FILTER ..................................................................................................... 23

III - DV4TD TURBOCHARGER................................................................................ 23

IV - AIR FLOWMETER (1310) ................................................................................. 26

SECTION 4: EXHAUST GAS RECYCLING FUNCTION..........................29

III - RECYCLING REGULATION ELECTROVALVE (EGR)(1253)................................. 32

IV - EXHAUST GAS RECYCLING VALVE (EGR) ...................................................... 33

BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR DV4TD ENGINE

SECTION 5: INJECTION FUNCTION........................................................35

II - INJECTION ECU (1320) .................................................................................... 38

III - BATTERY (BB00)............................................................................................. 44

IV - CYLINDER REFERENCE SENSOR (1115)......................................................... 44

V- COOLANT TEMPERATURE SENSOR (1220) ..................................................... 45

VI - FUEL TEMPERATURE SENSOR (1221) ............................................................ 47

VII - ENGINE SPEED SENSOR (1313) ..................................................................... 48

VIII - FUEL HIGH PRESSURE SENSOR (1321) - FEATURES ..................................... 50

IX - BRAKE SWITCH (2100) - FEATURES ............................................................... 51

X- CLUTCH SWITCH (7306) - FEATURES .............................................................. 51

XI - REDUNDANT BRAKE PEDAL SWITCH (7308) - FEATURES ............................... 51

SECTION 6: PRE-POST HEATING FUNCTION............................................53

II - PREHEATING PLUGS (1160)............................................................................ 54

III - PRE-POST HEATING UNIT (1150)..................................................................... 55

SECTION 7: ENGINE COOLING FUNCTION (FRIC)...............................57

II - COOLANT TEMPERATURE SENSOR (1220) ..................................................... 60

III - POST-VENTILATION ........................................................................................ 60

BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR DV4TD ENGINE

SECTION 8: ENGINE COOLING REQUIREMENTS FOR THE AIR

II - REFRIGERANT PRESSOSTAT (PRESSURE SENSOR) (8009) ........................... 65

III - ADDITIONAL HEATING..................................................................................... 67

SECTION 9: MAINTENANCE .....................................................................71

III - REPLACING PARTS – OPERATIONS TO BE PERFORMED............................... 72

IV - GUARANTEE RETURN PROCEDURES............................................................. 74

SECTION 10: DIAGNOSTICS ....................................................................75

III - LEXIA / PROXIA SCREENS .............................................................................. 77

V- SENSOR FAULTS ........................................................................................... 88

VI - ASSOCIATED FUNCTIONS FAULTS ................................................................. 92

SECTION 11: WIRING DIAGRAM ..............................................................95

III - LOCATION ...................................................................................................... 97

BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR DV4TD ENGINE

GENERAL DETAILS: HDI INJECTION SYSTEM

BOSCH EDC 16 C3 HDI INJECTION SYSTEM FOR DV4TD ENGINE