ÓÑ ¡ÔCommon Rail Diesel Systems - PCR 2.0 DW10 TD

Common Rail Diesel Systems
PCR 2.0 DW10 TD
www.siemensvdo.com
Validity
This manual is applicable to:
System: Siemens VDO PCR 2.0 DW10 TD
Engine: PSA DW10 TD
Vehicle: PSA T5 Peugeot 307
PSA X4 Citroën C5
PSA N7 Citroën Xsara
PSA D9 Peugeot 406

(Facelift)
PSA M49 Peugeot Partner

Citroën Berlingo
Suzuki Vitara Suzuki Vitara

Safety instructions
The following safety instructions and warning notices are

used in this manual:
Danger! Notice
When this notice appears, comply with the regulations These hints offer you advice on how to save work or
on accident prevention in their general form. give you additional information.
You could suffer severe or deadly injury.
Danger! Important!
When this notice appears, comply with the regulations This notice draws your attention to possible damage
on accident prevention on dealing with inflammable to the system, the engine or other components.
substances.
Danger!
When this notice appears, comply with the regulations

on accident prevention on dealing with energized
parts and components.

Table of contents
Table of contents
System
Piezo Common Rail (PCR) total system ............................................................................A - 1

General information about the PCR system ....................................................A - 1
System limits Fuel supply..................................................................................................A - 5

Fuel supply ......................................................................................................A - 6
System components...........................................................................................................A - 9
Injector .............................................................................................................A - 9
Injector functioning ................................................................................A - 11
Piezo actuators ......................................................................................A - 13
Piezo stack .............................................................................................A - 13
Injector nozzles ......................................................................................A - 16
Pinning injector ......................................................................................A - 19
Injector characteristics ...........................................................................A - 19
Diesel Common Rail Pump ..............................................................................A - 21
DCP function chart ................................................................................A - 22
Fuel flow in DCP ....................................................................................A - 23
DCP high pressure elements .................................................................A - 24
DCP characteristics ...............................................................................A - 25
Volumetric control valve ..................................................................................A - 27
VCV function ..........................................................................................A - 28
VCV characteristics ................................................................................A - 29
VCV pinning ...........................................................................................A - 29
VCV marking (in preparation) .................................................................A - 30
Pressure control valve .....................................................................................A - 31
PCV function ..........................................................................................A - 32
PCV characteristics ................................................................................A - 33
PCV pinning ...........................................................................................A - 33
PCV marking (in preparation) .................................................................A - 34
High-pressure lines ..........................................................................................A - 35
Configuration .........................................................................................A - 35
Identification ..........................................................................................A - 35
Rail (High pressure storage) .............................................................................A - 37
Connections ...........................................................................................A - 37
Identification ..........................................................................................A - 38
High pressure sensor .......................................................................................A - 39
HPS functioning .....................................................................................A - 40
HPS characteristics ................................................................................A - 41
HPS pinning ...........................................................................................A - 41
HPS Identification ..................................................................................A - 42
Engine control unit ...........................................................................................A - 43
Input and output signals ECU ................................................................A - 44
Injector control (ECU) ............................................................................A - 45
ECU pin assignments ............................................................................A - 48
ECU marking ..........................................................................................A - 51
PCR 2.0 DW10 TD 12/2005 1

Table of contents
Diagnosis
System set points and operating conditions ...................................................................B - 1

Typical values for various operating conditions ................................................B - 1
Conditions: .............................................................................................B - 1
Typical start behavior .......................................................................................B - 9
Error bands ............................................................................................B - 9
Troubleshooting plan .........................................................................................................B - 13

MIL control lamp does not illuminate at Kl. 15 .................................................B - 13
MIL control lamp is illuminated while motor is running ...................................B - 13
Engine does not start .......................................................................................B - 14
Poor engine starting .........................................................................................B - 16
Poor cold start behavior ...................................................................................B - 18
Motor cannot be switched off .........................................................................B - 19
Engine stops ....................................................................................................B - 19
Engine idle too high .........................................................................................B - 21
Engine idle rough / too low ..............................................................................B - 22
Engine speed does not increase / too low .......................................................B - 26
Vehicle jerks at constant speed .......................................................................B - 30
Vehicle accelerates without actuation of the accelerator pedal .......................B - 33
Vehicle does not decelerate (no coastdown) ...................................................B - 34
Vehicle jerks during travel (without load) .........................................................B - 34
Not enough power ...........................................................................................B - 35
Too much power ..............................................................................................B - 39
Bouncing while accelerating or decelerating ....................................................B - 40
Vehicle accelerates quickly while coasting after releasing the brakes .............B - 40
Engine smokes during starting ........................................................................B - 40
Engine smokes / blue smoke ...........................................................................B - 41
Engine smokes while passing ..........................................................................B - 43
Engine smokes white (especially during starting) ............................................B - 43
High fuel consumption .....................................................................................B - 44
Engine knocks ..................................................................................................B - 45
Engine gets too hot ..........................................................................................B - 45
Engine does not fulfill the AU requirements ....................................................B - 46
List of fault codes................................................................................................................B - 49
2 PCR 2.0 DW10 TD 12/2005

Table of contents
Test specifications ..............................................................................................................B - 65
Conditions for working on the system .............................................................B - 65
Recommendations ................................................................................B - 65
Safety instructions .................................................................................B - 65
Instructions on replacing parts ..............................................................B - 67
Test conditions ......................................................................................B - 69
Check low pressure system ............................................................................B - 71
Check internal fuel transfer system .......................................................B - 71
Check internal transfer pump ................................................................B - 72
Check high pressure system ...........................................................................B - 73
Check high pressure control valve .........................................................B - 73
Check high pressure pump and VCV .....................................................B - 77
Check rail pressure control circuit .........................................................B - 82
Check injectors ................................................................................................B - 89
High injector leakage / injectors remain open ........................................B - 89
Injection amount incorrect. ....................................................................B - 93
Check the engine control unit ..........................................................................B - 97
Diagnostics tools ................................................................................................................B - 99

Freeze Frames .................................................................................................B - 99
Online data using diagnostics tool ...................................................................B - 101
Actuator tests using diagnostics tool ...............................................................B - 103
Test pressure control valve ...................................................................B - 103
Test volumetric control valve .................................................................B - 103
Test glow relay ......................................................................................B - 104
Test main and power relay ....................................................................B - 104
Test EGR valve and throttle ...................................................................B - 104
Test GMV (radiator fan) .........................................................................B - 105
Repairs
Conditions for working on the system .............................................................................C - 1

Recommendations ...........................................................................................C - 1
Safety instructions ...........................................................................................C - 1
Instructions on replacing parts .........................................................................C - 3
Cleaning the high pressure connections ..........................................................................C - 7

Special tools .....................................................................................................C - 7
Preparatory work .............................................................................................C - 7
Work process ...................................................................................................C - 7
Installing and removing the high pressure lines. ............................................................C - 9

Special tools .....................................................................................................C - 10
Removing high-pressure lines .........................................................................C - 11
Installing high-pressure lines ...........................................................................C - 14
PCR 2.0 DW10 TD 12/2005 3

Table of contents
Installing and removing the rail.........................................................................................C - 15

Special tools .....................................................................................................C - 16
Removing rail ...................................................................................................C - 17
Installing the rail ...............................................................................................C - 18
Installing and removing the injectors. ..............................................................................C - 23

Special tools .....................................................................................................C - 24
Injector installation ...........................................................................................C - 25
Install injectors .................................................................................................C - 27
Installing and removing the high pressure pump. ..........................................................C - 29

Special tools .....................................................................................................C - 29
Remove high pressure pump ...........................................................................C - 30
High pressure pump installation. .....................................................................C - 33
Installing and removing the high pressure sensor ..........................................................C - 35
Installing and removing the pressure control valve........................................................C - 39

Special tools .....................................................................................................C - 40
Removing the pressure control valve ..............................................................C - 42
Installing high-pressure lines ............................................................................C - 44
Installing and removing the volumetric control valve ....................................................C - 45

Special tools .....................................................................................................C - 46
Removing the volumetric control valve ............................................................C - 48
Volumetric control valve installation .................................................................C - 50
Installing and removing the engine control unit .............................................................C - 51

Removing the engine control unit ....................................................................C - 51
Installing the engine control unit: .....................................................................C - 51
Injector system startup ......................................................................................................C - 53

Initial start in vehicle .........................................................................................C - 53
Initial start after a repair / Start after an empty tank .........................................C - 54
Special tools / Repair kits...................................................................................................C - 55

Special tools .....................................................................................................C - 55
Repair kits ........................................................................................................C - 58
Other accessories ............................................................................................C - 60
4 PCR 2.0 DW10 TD 12/2005

Table of contents
DCP inspection / repair
Conditions for inspection / repair......................................................................................D - 1

Recommendations ...........................................................................................D - 1
Safety instructions ...........................................................................................D - 1
Cleaning before inspection / repair ...................................................................................D - 3

Recommendations ...........................................................................................D - 3
Special tools .....................................................................................................D - 3
Preparatory work .............................................................................................D - 3
Work process ...................................................................................................D - 3
Disassembling the high-pressure pump...........................................................................D - 5

Special tools .....................................................................................................D - 6
Clamping the high-pressure pump. ..................................................................D - 8
Removing the Pressure Control Valve (PCV) ...................................................D - 9
Removal Volumetric Control Valve (VCV) .........................................................D - 9
Removing the fuel connections .......................................................................D - 10
Remove displacement units ............................................................................D - 11
Remove high pressure pump flange ................................................................D - 12
Remove the Internal Transfer Pump (ITP) ........................................................D - 13
Remove pump shaft / cam disk / eccentric .....................................................D - 13
Component testing .............................................................................................................D - 15

Measure the pump shaft bearing ....................................................................D - 15
Measure eccentric ...........................................................................................D - 16
Measure cam disk ...........................................................................................D - 16
Measure pump shaft .......................................................................................D - 17
Check / measure the high-pressure pump-flange ............................................D - 18
Assembling the high-pressure pump ...............................................................................D - 19

Installation eccentric / pump shaft / cam disk ..................................................D - 20
Install the internal transfer pump .....................................................................D - 21
Installing the displacement units .....................................................................D - 23
Installing the fuel connections .........................................................................D - 24
Installing the Volumetric Control Valve (VCV) ..................................................D - 25
Installing the Pressure Control Valve (PCV) .....................................................D - 26
PCR 2.0 DW10 TD 12/2005 5

Table of contents
Replace / exchange the identification place .....................................................D - 26

Check the high pressure pump on the Hartrigde AVM2-PC ............................D - 27
Check the high pressure pump ..............................................................D - 27
Close all pump connections ...................................................................D - 27
Special tools / spare parts/ repair parts ............................................................................D - 29

Special tools .....................................................................................................D - 29
Spare parts .......................................................................................................D - 32
Repair parts ......................................................................................................D - 34
Other accessories ............................................................................................D - 37
6 PCR 2.0 DW10 TD 12/2005

Table of contents
PCR 2.0 DW10 TD 12/2005 7

Table of contents
8 PCR 2.0 DW10 TD 12/2005

A System
1 Piezo Common Rail (PCR) total system
1.1 General information about the PCR system
The diesel fuel injection technology currently available is The diesel fuel is drawn out of the fuel tank by the
classified into helical groove controlled, time controlled internal transfer pump and supplied to the volumetric
and decoupled systems. The only decoupled system by control valve.
which there is no direct angle between the crankshaft
angle and the high pressure generation is the Common The volumetric control valve governs the amount of fuel
Rail-System. supplied to the high pressure pump. The internal transfer
pump and high pressure pump are directly driven by the
The Piezo Common Rail (PCR) diesel injection system engine. The high pressure pump delivers the fuel to the
A System
supplied by SIEMENS VDO is a 2nd generation common rail at a pressure of up to 1500 bar.
rail injection system for which piezo controlled injectors
are utilized. The rail and the injectors are connected together through
the high pressure pipes. The piezo injectors facilitate
It consists of the Diesel Common Rail Pump (DCP), the extremely short response times and make it possible to
Rail (storage line), the high pressure pipes and the Piezo freely select the start of injection and the fuel quantity
controlled injectors. according to the demands of the engine control unit
(ECU).
These are integrated into the Diesel Common Rail
pumps: Independent of the engine speed, the system pressure
generated with the aid of the DCP is optimally adjusted
• the high pressure pump (HPP) for every operating condition. Due to the storage volume
of the rail, the injection pressure remains practically
• the internal transfer pump (ITP)
constant over the complete duration of the injection
• the volumetric control valve (VCV) process.
• and the pressure control valve (PCV)
The diesel injection system is operated with pre and
main injection. This reduces the combustion noise,
The structure of the DCP allows the exact supply of fuel
reduces the mechanical load and in many cases, the
based on the requirements, thus providing an increase in
exhaust emissions.
the efficiency of the diesel motor. The Diesel Common
Rail pump is driven with a transmission ratio of 2:3 to the
crankshaft.
PCR 2.0 DW10 TD 12/2005 A-1

A System
Fig. A - 1 Schematic representation Total system
A-2 PCR 2.0 DW10 TD 12/2005

Key Total system:
1. Air filters 17. Pre-glow relay

2. Mass air flow meter with 18. Fuel temperature sensor
manifold air temperature sensor 19. Rail
3. Turbocharger 20. Injector
4. Catalytic converter 21. Camshaft sensor
5. Pressure regulating valve (wastegate) 22. Vacuum pump
6. Accelerator pedal 23. Exhaust return valve
7. Accelerator pedal sensor 24. Pressure control valve (EPW) for exhaust
8. Coolant temperature sensor recirculation
A System
9. Crankshaft sensor 25. Throttle valve
10. High pressure sensor 26. Pressure control valve (EPW) for throttle valve
11. Engine control unit (ECU)
12. Tank transducer Cylinders Code
13. Fuel tank
C1 Cylinder 1 cyl 0
14. Hand pump
C2 Cylinder 2 cyl 3
15. Fuel filter
16. Diesel Common Rail Pump (DCP) C3 Cylinder 3 cyl 1
a High Pressure Pump (HPP) C4 Cylinder 4 cyl 2

b Pressure Control Valve (PCV)
c Internal Transfer Pump (ITP)
d Volumetric Control Valve (VCV) Ignition sequence: C1 - C3 - C4 - C2
PCR 2.0 DW10 TD 12/2005 A-3

A System
A-4 PCR 2.0 DW10 TD 12/2005

2 System limits Fuel supply
Diesel Common Rail Pump (DCP) • Volumetric Control Valve (VCV)

V Volumetric
D Diesel
C Control
C Common Rail
V Valve
P Pump
The volumetric control valve controls the flow rate
The diesel common rail pump consists of the following
of the fuel to the high pressure pump, facilitating
components:
an exact supply to the high pressure pump as
required.
A System
• High Pressure Pump (HPP)
H High
P Pressure
P Pump Scope High pressure section
The high pressure pump is constructed as a • Rail

3 cylinder cam-plate driven plunger type pump and • High pressure sensor
supplies the rail with the necessary system
pressure. • High pressure pipes to rail
• 4 high pressure pipes to the injectors
• Pressure Control Valve (PCV)
P Pressure
C Control
V Valve
Piezo injectors
The pressure control valve governs the exit
pressure of the high pressure pump. The Piezo injectors allow an extremely quick and exact
dosage of the fuel amount.
• Internal Transfer Pump (ITP)
I Internal • The response time of the Piezo injectors, which is
4 times quicker than the previous systems, allow
T Transfer shorter and variable distances between injections.
P Pump
• The required triggering energy is reduced
considerably through this energy recovery facility.
The internal transfer pump, which is constructed
as a vane-type pump, has the task to draw the fuel • In addition, through the simplified electrical control
from the tank through the fuel filter and to supply a greater electromagnetic tolerance and therewith
the high pressure pump with diesel fuel. a considerable reduction in the susceptibility to
In addition to this, it supplies the high pressure failure is achieved.
pump with fuel for lubrication purposes.
PCR 2.0 DW10 TD 12/2005 A-5

2.1 Fuel supply
A System
Fig. A - 2 Fuel supply
A-6 PCR 2.0 DW10 TD 12/2005

Fuel supply key:
1. Diesel Common Rail Pump (DCP):

a High Pressure Pump (HPP)
b Internal Transfer Pump (ITP)
c Volumetric Control Valve (VCV)
d Pressure Control Valve (PCV)
2. Rail with high pressure sensor
3. Injectors
A Fuel feed
A System
B Fuel return
PCR 2.0 DW10 TD 12/2005 A-7

A System
A-8 PCR 2.0 DW10 TD 12/2005

3 System components
3.1 Injector
The Piezo injectors, which are connected to the rail, inject

the necessary amount of fuel into the combustion
chamber for all engine operating conditions. The injected
amount per stroke consists of a pre-injection amount and
a main-injection amount. This separation effects a "soft"
combustion operation.
Using the piezo actuators makes extremely short
A System
response times feasible. That means the injected fuel
amount and the dosage can be extremely accurately
controlled. Furthermore, excellent repeatability is
ensured.
The injectors are controlled by the engine control unit

(ECU). Through the energy recovery facility with Piezo
injectors, a substantially smaller triggering energy is
required in comparison to previous systems.
Danger!
The Engine Control Unit (ECU), injectors and

energized parts of the pump carry high voltages!
Danger of death if touched!
When working on these parts comply with the

regulations on accident prevention for high-voltage
devices!
Important!
Do not remove connection lead plugs from the engine

control unit when the motor is running.
Danger of causing engine damage! Fig. A - 3 Injector
Do not dismantle the injectors when making repairs. 1. Piezo actuator

Do not remove or unscrew any injector parts; doing so 2. Electrical connection
can lead to destruction of the injectors. 3. High pressure connection
4. Fuel return
5. Injector head
6. Nozzle retaining nut
7. Injector nozzle
PCR 2.0 DW10 TD 12/2005 A-9

Cutaway view key:
1. High pressure connection

2. Fuel return
3. Plug connector to
Engine control unit (ECU)
4. Piezo actuator
5. Lever
6. Valve piston
7. Valve mushroom
8. Control piston
A System
9. Nozzle needle
10. High pressure chamber nozzle
11. Spray hole (5 each)
Fig. A - 4 Cutaway view of injector
A - 10 PCR 2.0 DW10 TD 12/2005

3.1.1 Injector functioning
Injector not triggered: Injector triggered:
The fuel, which comes from the rail under high pressure, The piezo actuator (7) presses on the valve piston (8) and
reaches the control chamber (2) and the high pressure the valve mushroom (4) opens a hole that connects the
chamber (3) of the jet via the high pressure fuel feed (1). control chamber (2) with the fuel return line.
The bore to the fuel return line (5) is closed via the valve
mushroom (4), which is actuated by a spring.. That causes a pressure drop on the control chamber and
the hydraulic force (F2x), affecting the nozzle needle is
The hydraulic force (F1), which will be exerted through larger than the force (F1x) on the control piston in the
the high pressure of the fuel on the nozzle needle (6) in control chamber.
the control chamber (2), is greater than hydraulic force The nozzle needle (6) moves upwards and the fuel
A System
(F2) which is effected on the tip of the nozzle, since the reaches the combustion chamber via the 5 spray holes.
surface of the control piston in the control chamber is
greater than the surface of the tip of the nozzle. When the engine is no longer running, the valve, which
connects the control chamber with the fuel return line
The nozzle of the injector is closed. and the injector nozzle is closed through the spring force.
A small amount of fuel will be directed for lubrication
purposes between the nozzle needle and the guide from
the high pressure side directly into the return line.
Fig. A - 6 Injector, triggered
Fig. A - 5 Injector not triggered
PCR 2.0 DW10 TD 12/2005 A - 11

Injector triggering characteristics
A System
Fig. A - 7 Injector triggering characteristics
A - 12 PCR 2.0 DW10 TD 12/2005

3.1.2 Piezo actuators 3.1.3 Piezo stack
The piezo actuator is that part of the injector which An actuator consists of a stack of ca. 350 ceramic sheets
operates the injector nozzle, which opens or closes the (piezo stack), in which each sheet is 80 µm thick. After
nozzle spray holes. The amount of fuel to be injected is applying the control voltage, the actuator expands by up
regulated through the piezo actuator control period. to 40 µm.
The actuator loading time is 0.15 ms. The actual injection Due to the very narrow dimensions, all surfaces have to
period during which the valve is opened lies between be ground to 1 µm precision. This is achieved by using
0.15 ms and 4.50 ms. After injection, the valve is re- the most modern manufacturing technology.
closed through the discharge of the piezo actuator within
0.15 ms. The piezo stack is provided with contacts and, to protect
the ceramic elements from mechanical damage, cast in a
A System
During the injection period, between 1 mm3 (during pre- plastic element.
injection) and 80 mm3 (during main injection during full
load) of fuel is injected into the combustion chamber.
Fig. A - 8 Structure of piezo stack
1. Untreated ceramic sheet 3. Stacked ceramic sheets

2. Silver printed ceramic sheets 4. Sintered ceramic sheets
PCR 2.0 DW10 TD 12/2005 A - 13

Drive unit
The injector drive receives the electrical signals from the Both cover plates act as abutments.
controller and correspondingly converts them to control
the hydraulics. In operation, acceleration forces of up to In addition, the piezo forces triggering the hydraulic valve
1000 G occur during this. are diverted through these plates.
To avoid tensile stress in the ceramic elements during

these loads, the actuator is mounted on a tube spring,
which ensures a constant pre loading.
A System
Fig. A - 9 Drive unit structure
1 Piezo stack, with contacts

2 Piezo stack, mounted
3. Piezo stack, mounted — lined with silicon
4. Piezo stack, mounted — head plate
5. Piezo stack, mounted — base plate
A - 14 PCR 2.0 DW10 TD 12/2005

The actuator unit (1) is hermetically sealed from the fuel In this manner, a temperature compensated drive
through a steel membrane. module that is simultaneously protected from
mechanical influences is formed together with the
The tube spring with the integrated piezo stack creates enclosure.
the injector drive unit together with the external housing
(2), the contacts (3) and the plug (4).
A System
Fig. A - 10 Injector head
1 Actuator unit 5 Coupling nut

2 Housing 6 O-ring
3 Electrical contact 7 Membrane
4 Plug
PCR 2.0 DW10 TD 12/2005 A - 15

3.1.4 Injector nozzles
The injector nozzle is that part of the injector which is

responsible for atomization of the fuel in the combustion
chamber.
The micro-blind hole nozzles used in this system are an

improvement on the orifice nozzles. Contrary to the
customary orifice nozzles, a more uniform spray behavior
of the individual nozzle bores is ensured here at slight
residual volumes.
This is an especially decisive advantage at low injection

A System
quantities such as necessary during pre- and re-

injections.
Fig. A - 11 Micro-blind hole nozzles

Fig. A - 12 Cutaway view of an injection nozzle
1. Nozzle body
2. High pressure sealing surface
3. Needle guide
4. High pressure bore
5. High pressure chamber
6. Nozzle shoulder
7. Nozzle shaft
8. Nozzle needle
9. Spray hole
10. Needle seat
11. Nozzle needle
A - 16 PCR 2.0 DW10 TD 12/2005

Spray holes
The following ancillary conditions have to be taken into When manufacturing the spray holes, a sharp-edged
account when designing the nozzles and the position, opening is created on the nozzle interior, which greatly
form and number of nozzle holes: influences the flow-through behavior. For that reason,
the nozzles are subsequently hydroerosively rounded off.
• Piston form
This procedure achieves the following improvements:
• Combustion chamber volume
• Required injection rate • Restriction of the HD tolerance
• Required injection amount • Increasing the through-flow coefficients
• Reducing the spray-hole surfaceroughness
A System
In current car engines, the nozzles have up to seven
spray holes, in which the diameter is approx. 120 µm. • Anticipation of the edge rounding in operation
The spray holes are manufactured using an

electroerosive process with which conical holes can be
implemented.
Fig. A - 13 Conicity of the spray holes
Figure A shows a cylindrical spray hole with slight

rounding off.
Figure B shows a conical spray hole with the same

rounding off as in figure A. Here, a higher efficiency is
already implemented through the greater conicity.
Figure C shows a conical spray hole with a larger

rounding than in figure B. Once again here, greater
efficiency is implemented through the larger rounding
off.
PCR 2.0 DW10 TD 12/2005 A - 17

Chronological development of the jet image during one injection
A System
Fig. A - 14 Jet image development during injection
A - 18 PCR 2.0 DW10 TD 12/2005

3.1.5 Pinning injector 3.1.6 Injector characteristics
A System
Fig. A - 15 Pinning injector Fig. A - 16 Injector characteristics (example)
1. Injector activation (supply) a Manufacturer number

2. Injector activation (ground) b PSA part number
c Year of manufacture:
X = 2000 ...
A = 2001 ...
B = 2002 ...
C = 2003 ...
d Month:
A = January
B = February
C = March
....
L = December
e Day:
1 - 31
f Part number:
00001 - 99999
PCR 2.0 DW10 TD 12/2005 A - 19

A System
A - 20 PCR 2.0 DW10 TD 12/2005

3.2 Diesel Common Rail Pump
The Diesel Common Rail Pump (DCP) is a demand

controlled radial piston pump with three displacement
units each staggered at 120 °. Important!
The Diesel Common Rail Pump (DCP) supplies the When installing or removing the Diesel Common Rail
volume flow for the generation of the high pressure of Pump, do not carry the pump by the connectors, pipe
the fuel in the rail, providing the necessary fuel quantity connections or on the volumetric Control Valve (VCV)
to the injectors for all operating conditions of the engine. or Pressure Control Valve (PCV) housings.
Danger of damaging these components!
A System
Fig. A - 17 Cutaway view of DCP
1. Internal Transfer Pump (ITP) 4. Pressure Control Valve (PCV)

2. Volumetric Control Valve (VCV)
a Fuel feed
3. High pressure pump element
b High-pressure connection
(Displacement unit)
c Fuel return
PCR 2.0 DW10 TD 12/2005 A - 21

3.2.1 DCP function chart
A System
Fig. A - 18 DCP function chart
A - 22 PCR 2.0 DW10 TD 12/2005

DCP function chart key: 3.2.2 Fuel flow in DCP
1. Internal Transfer Pump (ITP) The diesel fuel is drawn from the tank through a fuel filter
2. Volumetric Control Valve (VCV) by means of an integrated internal transfer pump ITP (1).
The fuel is then conveyed to the flush valve (6) and to the
3. High pressure pump element
volumetric control valve VCV (2).
4. Pressure Control Valve (PCV)
5. Admission pressure control valve The pre-pressure control valve (5), which lies parallel to
6. Flush valve the fuel delivery pump, opens when the volumetric
control valve (2) is closed and thus directs the fuel to the
7. Edge filter
suction side of the fuel pump (1).
The fuel reaches the inside of the pump via the flush
a Fuel feed
valve (6) and from there to the fuel return (c).
A System
b High-pressure connection
c Fuel return
The volumetric controlled valve governed by the engine
control unit (ECU) determines the amount of fuel which
will be delivered to the high pressure pump element (3)
and therewith to the high pressure pump. The high
pressure outlets of the three pump elements are
combined and routed to the high pressure outlet (b) of
the Diesel Common Rail Pump.
The high pressure control valve (4), which governs the

fuel amount to the high pressure outlet and therewith the
fuel pressure in the rail, is placed between the high
pressure channel and the return line.
PCR 2.0 DW10 TD 12/2005 A - 23

3.2.3 DCP high pressure elements
A System
Fig. A - 19 Cutaway view of the high pressure elements
Fuel suction Fuel delivery
During the downwards motion of the piston (1) a vacuum The cam (4) presses the piston (1) upwards. The intake
in the pump cylinder is generated which opens the inlet valve (2) is then closed through the force exerted by the
valve (2) against the force exerted by the valve spring. valve spring and the pressure being built up in the pump
cylinder.
The fuel (a), which is flowing from the volumetric control
valve is sucked in. At the same time, the outlet valve (3) The outlet valve (3) opens if the pressure in the pump
will be closed due to the pressure difference between cylinder is greater than the fuel pressure in the ring line
the pump cylinder and the fuel pressure in the ring line. (b).
A - 24 PCR 2.0 DW10 TD 12/2005

3.2.4 DCP characteristics
A System
Fig. A - 20 DCP characteristics (example)
a Manufacturer number d Calendar week

b PSA part number e Number of the manufactured pumps in
c Year of manufacture that calendar week.
T: 2000 f Number of the final series control status
U: 2001
V: 2002
W: 2003
X: 2004
Y: 2005
Z: 2006
PCR 2.0 DW10 TD 12/2005 A - 25

A System
A - 26 PCR 2.0 DW10 TD 12/2005

3.3 Volumetric control valve
The volumetric control valve (VCV) regulates the delivery The power consumption of the high pressure pump is
of fuel from the internal transfer pump (ITP), which is reduced, improving the efficiency of the engine.
integrated into the diesel common rail pump (DCP), to
the high pressure pump elements. The volumetric control valve is directly screwed to the
diesel common rail pump (DCP).
The amount of fuel delivered by the high pressure pump
can thereby already be adjusted to the requirements of
the engine on the low pressure side of the system.
A System
Fig. A - 21 Cutaway view of VCV
1. Compression spring 4. Solenoid

2. Jack 5. Anchor
3. Pistons
PCR 2.0 DW10 TD 12/2005 A - 27

3.3.1 VCV function
VCV not triggered: VCV triggered:
The piston closes the link between the two connections The force exerted by the anchor is proportional to the
by means of the force generated by the spring, without electrical current and works against the force of the
utilising electrical current. spring.
Thus, the opening between the the two connections is

The fuel delivery to the high pressure pump is proportional to the electrical current (proportional
interrupted. directional control valve).
A System
Fig. A - 22 VCV not triggered Fig. A - 23 VCV triggered
a Fuel inlet from the internal transfer pump (ITP) a Fuel inlet from the internal transfer pump (ITP)
b Fuel amount to high pressure pump
A - 28 PCR 2.0 DW10 TD 12/2005

3.3.2 VCV characteristics 3.3.3 VCV pinning
A System
Fig. A - 24 VCV characteristics Fig. A - 25 VCV pinning
Q Fuel volume flow 1. Ignition (KL.15)

I Control current 2. PWM signal (ECU)
Notice
Make current measurement on volumetric control

valve with a diagnostics tool or multimeter.
PCR 2.0 DW10 TD 12/2005 A - 29

3.3.4 VCV marking (in preparation)
A System
Fig. A - 26 VCV characteristics (example)
a
b
c
d
A - 30 PCR 2.0 DW10 TD 12/2005

3.4 Pressure control valve
The pressure control valve PCV (PCV) governs the fuel The pressure control valve is directly flanged to the diesel
pressure at the high pressure outlet of the diesel common rail pump (DCP).
common rail pump (DCP) and thus also fuel pressure in
the rail.
In addition, the pressure control valve dampens the

fluctuations in pressure, which occur during the delivery
of fuel through the diesel common rail pump (DCP) and
through the injection process.
A System
The pressure control valve is triggered in such a manner
by the engine control unit (ECU) that the optimal
pressure exists in the rail for every operational condition
of the engine.
Fig. A - 27 PCV cutaway view
1. Valve seat 4. Solenoid

2. Valve float 5. Anchor
3. Pin 6. Spring
PCR 2.0 DW10 TD 12/2005 A - 31

3.4.1 PCV function
PCV not triggered: PCV triggered:
The valve ball is only operated through the spring force. The current flowing through the solenoid draws down
A smaller amount of the fuel pressure will thus be the anchor which in turn transfers the magnetic force via
withheld. the pin to the valve float.
The pull of the anchor and therewith the pressure on the

valve ball is proportional to the valve flow (proportional
pressure relief-valve)
A System
Fig. A - 28 PCV not triggered Fig. A - 29 PCV triggered
a Fuel pressure at the DCP high pressure connection a Fuel pressure at the DCP high pressure connection
(= Fuel pressure in the rail) (= Fuel pressure in the rail)
b to the fuel return line b to the fuel return line
A - 32 PCR 2.0 DW10 TD 12/2005

3.4.2 PCV characteristics 3.4.3 PCV pinning
A System
Fig. A - 30 PCV characteristics Fig. A - 31 PCV pinning
p Fuel pressure 1. Ignition (KL.15)

I Control current 2. PWM signal (ECU)
Notice
Make current measurement on pressure control valve

with a diagnostics tool or multimeter.
PCR 2.0 DW10 TD 12/2005 A - 33

3.4.4 PCV marking (in preparation)
A System
Fig. A - 32 PCV characteristics (example)
a
b
c
d
A - 34 PCR 2.0 DW10 TD 12/2005

3.5 High-pressure lines
The high pressure lines connect the Diesel Common Rail

Pump (DCP) with the rail and the rail with the Injectors.
Important!
Always replace the high pressure lines during repairs

as the ferrule is plastically deformed when tightening
the coupling nut.
A System
3.5.1 Configuration 3.5.2 Identification
Fig. A - 33 Configuration Fig. A - 34 Identification (example)
1. High pressure pipes to the injectors a Year of manufacture: Last digits of the year
2. High pressure lines to the diesel common rail pump b Month: 01 - 12
c Day: 01 - 31
d Operator number
e Production order number
PCR 2.0 DW10 TD 12/2005 A - 35

A System
A - 36 PCR 2.0 DW10 TD 12/2005

3.6 Rail (High pressure storage)
The rail serves the purpose of providing high pressure

storage for the fuel which will be delivered from the
diesel common rail pump (DCP) and supplies the
injectors with the necessary amount of fuel for all
operational conditions.
The rail storage function dampens the oscillations which

occur during the injection process.
The fuel pressure in the rail is measured by means of a
A System
high pressure sensor (pos. 3).
3.6.1 Connections
Fig. A - 35 Connections
1. High pressure pipe connections to the injectors

2. High pressure pipe connections to
Diesel Common Rail Pump (DCP)
3. High pressure sensor (HPS) connection
4. Fixture for the fuel return line support
PCR 2.0 DW10 TD 12/2005 A - 37

3.6.2 Identification
Welded rail (installed until 11/2004) Forged rail (installed starting 11/2004)
A System
Fig. A - 36 Welded rail identification (example) Fig. A - 37 Forged rail identification (example)
a PSA part number a

b Manufacturer number b
c Year of manufacture c
d Month d
e Day e
f Part number f
g Internal P&P number (manufacturing order number) g
A - 38 PCR 2.0 DW10 TD 12/2005

3.7 High pressure sensor
The High Pressure Sensor (HPS) measures the fuel

pressure in the rail. The pressure on hand will be
converted into an electric potential signal which will be
evaluated by the engine control unit (ECU).
In accordance with the recorded performance

characteristics in the engine control unit, the pressure
signal is used for the computation of the control period
for the injectors and the high pressure regulation through
the high pressure control valve (PCV).
A System
The high pressure sensor is fixed directly to the rail and
sealed with a soft iron washer.
Fig. A - 38 HPS cutaway view
1. Membrane 6. Connector housing

2. EMC (Electro Magnetic Compatibility) shielding 7. Contact spring
3. EMA (Electronic Module Assembly) 8. Metal housing
4. Cover 9. Metal flange
5. Connection 10. Pressure connection
PCR 2.0 DW10 TD 12/2005 A - 39

3.7.1 HPS functioning
The membrane (1) is deformed according to the fuel

pressure in the rail.
The membrane (1) deformation alters the resistance in
the bridge circuit on the membrane.
The EMA (3) evaluates the change of resistance and

transforms this into a voltage signal. The voltage signals
are then transmitted by the EMA (3) to the engine control
unit (ECU).
A System
Fig. A - 39 HPS functioning
1. Membrane 6. Connector housing

2. EMC (Electro Magnetic Compatibility) shielding 7. Contact spring
3. EMA (Electronic Module Assembly) 8. Metal housing
4. Cover 9. Metal flange
5. Connection 10. Pressure connection
A - 40 PCR 2.0 DW10 TD 12/2005

3.7.2 HPS characteristics 3.7.3 HPS pinning
A System
Fig. A - 40 HPS characteristics Fig. A - 41 HPS pinning
V Voltage 1. Output (signal)

p Fuel pressure 2. Ground wire
3. Supply voltage
PCR 2.0 DW10 TD 12/2005 A - 41

3.7.4 HPS Identification
A System
Fig. A - 42 HPS identification (example)
a PSA part number

b Manufacturer number
c Year of manufacture: Last digits of the year
d Day: 0-366
e Running production number
f Barcode
A - 42 PCR 2.0 DW10 TD 12/2005

3.8 Engine control unit
The engine control unit (ECU) checks all the processes

which are necessary for control of the engine system. It
computes the necessary output data for the engine (e.g.
fuel injection amount, rate of exhaust gas re-circulation,
...) in accordance with the driver’s requirements and the
engine and vehicle data (e.g. engine speed, vehicle
speed, engine coolant temperature, intake air mass, ...).
In addition, other functions will be checked such as the

coded immobilizer. The engine control unit
A System
communicates with other control equipment (e.g. ABS,
ASR, ESP) via the CAN bus.
Danger!


devices!
Fig. A - 43 Engine control unit

Important!
1. Final stage
Do not remove plugs from the engine control unit
when the motor is running. 2. Power stage
3. ECU housing
Danger of causing engine damage! 4. ECU pcb
The engine control unit can become very hot during

operation. High temperature on the housing does not
indicate damage.
Comply with the testing specifications (chapter B,

section 4.5) when inspecting the engine control unit!
PCR 2.0 DW10 TD 12/2005 A - 43

3.8.1 Input and output signals ECU
A System
Fig. A - 44 ECU signals
A - 44 PCR 2.0 DW10 TD 12/2005

3.8.2 Injector control (ECU)
Circuit Diagram
A System
Fig. A - 45 Circuit diagram — Injector control
1. Microprocessor
2. AC / DC - converter
3. Control IC
4. Discharge timing resistance
PCR 2.0 DW10 TD 12/2005 A - 45

Piezo charge
During the piezo charge, switch S1 is closed, switch S2

is open. The piezo is charged up. The intermediary diode
prevents current flowing out of the piezo during charging.
A System
Fig. A - 46 Piezo charge up circuit
Fig. A - 47 Piezo charge — current over time Fig. A - 48 Piezo charge — voltage over time
A - 46 PCR 2.0 DW10 TD 12/2005

Piezo discharge
During the piezo discharge, switch S1 is open, switch S2

is closed. The piezo is discharged. The intermediary
diode prevents current flowing back into the piezo during
discharging.
A System
Fig. A - 49 Piezo discharge circuit
Fig. A - 50 Piezo discharge — current over time Fig. A - 51 Piezo discharge — voltage over time
PCR 2.0 DW10 TD 12/2005 A - 47

3.8.3 ECU pin assignments
Plug A
A System
Fig. A - 52 Plug A pin assignment
A1 Not occupied E1 Not occupied

A3 CAN low E3 Clutch switch
A4 CAN high E4 Redundant brake light switch (option)
B1 Engine coolant preheating (Heating circuit 1) F1 Not occupied
B2 Engine fan (control line 1) F2 Air conditioner pressure sensor (supply)
B3 Not occupied F3 Not occupied
B4 Diagnosis (C line) F4 Air conditioner pressure sensor (ground)
C1 Engine coolant preheating (Heating circuit 2) G1 Not occupied
C2 Accelerator pedal position sensor (signal 2) G2 Accelerator pedal sensor (supply)
C3 Battery plus to ignition start switch (Kl. 15) G3 Accelerator pedal position sensor (signal 1)
C4 Engine fan (diagnosis) G4 Ground (Kl. 31)
D1 Not occupied H1 Not occupied
D1 Not occupied H2 Air conditioner pressure sensor (signal)
D3 Not occupied H3 Accelerator pedal sensor (ground)
D4 Engine fan (control line 2) H4 Ground (Kl. 31)
A - 48 PCR 2.0 DW10 TD 12/2005

Plug B
A System
Fig. A - 53 Plug B pin assignment
A1 Reserved G1 Not occupied

A2 Not occupied G2 Mass air flow meter (booster mass)
A3 Not occupied G3 Not occupied
A4 Reserved G4 Battery plus direct (Kl. 30)
B1 Reserved H1 Power relay (control line)
B2 Not occupied H2 Reserved
B3 Reserved H3 Not occupied
B4 Not occupied H4 Fuel temperature sensor (ground)
C1 Reserved J1 Not occupied
C2 Reserved J2 Reserved
C3 Camshaft sensor (supply) J3 Reserved
C4 Not occupied J4 Crankshaft sensor (ground)
D1 High pressure sensor (supply) K1 Reserved
D1 Not occupied H4 Ground (Kl. 31)
D3 Not occupied K3 Not occupied
D4 Not occupied K4 Crankshaft sensor (supply)
E1 Coolant temperature sensor (ground) L1 Injector cylinder 2 (–)
E2 Pre-glow relay (signal) L2 Injector cylinder 3 (+)
E3 Air temperature (signal) L3 Injector cylinder 1 (+)
E4 Coolant temperature sensor (signal) L4 Injector cylinder 2 (+)
F1 Main relay (control line) M1 Injector cylinder 4 (–)
F2 High pressure sensor (ground) M2 Injector cylinder 1 (–)
F3 Fuel temperature sensor (signal) M3 Injector cylinder 3 (–)
F4 Not occupied M4 Injector cylinder 4 (+)
PCR 2.0 DW10 TD 12/2005 A - 49

Plug C
A System
Fig. A - 54 Plug C pin assignment
A1 Camshaft sensor (ground) E1 Not occupied

A3 Mass air flow meter (signal) E3 Switched plus from the power relay
B1 Reserved F1 Not occupied
B2 Not occupied F2 Switched plus from the power relay
B3 Mass air flow meter (sensor ground) F3 Switched plus from the power relay
B4 Not occupied F4 Not occupied
C1 Pre-glow relay (diagnostics signal) G1 Pressure valve (EPW) for exhaust recirculation
C2 Not occupied G2 Not occupied
C3 Not occupied G3 Volumetric control valve (VCV)
C4 Not occupied G4 Not occupied
D1 Camshaft sensor (Signal) H1 High pressure control valve (PCV)
D1 Not occupied H2 Ground (Kl. 31)
D3 High pressure sensor (signal) H3 High pressure control valve (EPW) for throttle valve
D4 Not occupied H4 Not occupied
A - 50 PCR 2.0 DW10 TD 12/2005

3.8.4 ECU marking
A System
Fig. A - 55 ECU characteristics (example)
a PSA part number

b Manufacturer number
c ECU serial number
PCR 2.0 DW10 TD 12/2005 A - 51

A - 52 PCR 2.0 DW10 TD 12/2005
B Diagnosis
1 System set points and operating conditions
1.1 Typical values for various operating conditions
1.1.1 Conditions:
• Vehicle still
• Tank: at least half-full
• Battery voltage: 12 ... 14,7 V
• Ambient temperature: ca. 20 °C
• Motor operating temperature 80 ... 90 °C
Notice
All electrical and mechanical consumers must be

switched off.
B diagnoses
PCR 2.0 DW10 TD 12/2005 B-1

Ignition on
min max
Motor speed 1/min 0 0
Battery voltage V 7 13
Coolant temperature °C 15 25
Suction air temperature °C 15 25
Accelerator pedal sensor % 0 0
Pre-injection injection amount mg/stroke - -
Main-injection injection amount mg/stroke 20 32
Total-injection injection amount mg/stroke 20 32
Pre-injection trigger period ms 0 0
Main-injection trigger period ms 0 0
Start of pre-injection °after TDC - -
Start of main injection °after TDC -4 0
Rail pressure - nominal value MPa 0 2

B diagnoses
Rail pressure - target value MPa 0 0
PCV PWM % 0 0
PCV current A 0 0,3
VCV PWM % 0 0
VCV current A 0 0,3
Fuel temperature °C 15 25
Smoke limitation mg/stroke 60 70
Air-mass nominal value mg/stroke 0 0
Air-mass target value mg/stroke 0 0
Air-mass without EGR mg/stroke 0 0
PWM throttle % 0 0
PWM EGR valve % 0 0
Absolute pressure before fuel filter (static) mbar 0,9 1,1
Absolute pressure in injector return flow (static) mbar 1 1,1
Absolute pressure in pump return flow (static) mbar 1 1,1
Absolute pressure in total return flow (static) mbar 1 1,1
B-2 PCR 2.0 DW10 TD 12/2005

Cold idle
min max
Battery voltage V 12 14,7
Pre-injection injection amount mg/stroke 1 3
Main-injection injection amount mg/stroke 4,5 12
Pre-injection trigger period ms 0,2 0,35
Main-injection trigger period ms 0,4 0,7
Start of pre-injection °after TDC -15 -5
Start of main injection °after TDC -3,5 1
B diagnoses
PCV PWM % 12 18
PCV current A 0,4 0,6
VCV PWM % 20 24
VCV current A 0,8 1,1
PWM throttle % 9,9 35
PWM EGR valve % 50 60
Absolute pressure before fuel filter (static) mbar 0,8 1
PCR 2.0 DW10 TD 12/2005 B-3

Warm idle
min max
Main-injection injection amount mg/stroke 3,5 6,5
Start of main injection °after TDC 3 4

B diagnoses
PCV PWM % 12 18
VCV PWM % 18 22
B-4 PCR 2.0 DW10 TD 12/2005

2000/min, without load
min max
Pre-injection injection amount mg/stroke 1 1,5
Total-injection injection amount mg/stroke 4,5 7
Start of main injection °after TDC -1,5 0,5
B diagnoses
PCV PWM % 13 19
VCV PWM % 18 24
VCV current A 0,6 1
PCR 2.0 DW10 TD 12/2005 B-5

4000/min, without load
min max
Main-injection injection amount mg/stroke 9 15
Pre-injection trigger period ms 0 0
Start of main injection °after TDC -8 -4

B diagnoses
PCV PWM % 20 24
VCV PWM % 24 30
PWM throttle % 9,9 9,9
PWM EGR valve % 9,9 9,9
B-6 PCR 2.0 DW10 TD 12/2005

1000/min, 1st gear
min max
B diagnoses
PCV PWM % 12 18
VCV PWM % 18 24
VCV current A 0,6 1
PCR 2.0 DW10 TD 12/2005 B-7

2000/min, 1st gear
min max

B diagnoses
PCV PWM % 13 19
VCV PWM % 18 24
VCV current A 0,6 1
B-8 PCR 2.0 DW10 TD 12/2005

1.2 Typical start behavior
1.2.1 Error bands
Speed n Start:
150 - 250 1/min (cold start)

200 - 300 1/min (warm start)
Idle: ± 30 1/min
Battery voltage UBatt ± 10 % (max. 14.7 V)
Injection amount MF ± 10 %
Rail pressure PRail ± 20 %
Pressure control valve PCV ± 10 %

Pulse duty factor
Volumetric control valve VCV + 20 %

Pulse duty factor
B diagnoses
PCR 2.0 DW10 TD 12/2005 B-9

Cold start
Coolant temperature: 0 °C
B diagnoses
B - 10 PCR 2.0 DW10 TD 12/2005

Warm start
Coolant temperature: 80 °C
B diagnoses
PCR 2.0 DW10 TD 12/2005 B - 11

B diagnoses
B - 12 PCR 2.0 DW10 TD 12/2005

2 Troubleshooting plan
Procedure during troubleshooting:
Notice One fault code can have several causes. Look for the
possible causes in this chapter. Use the Acrobat Reader
System faults can cause sequential errors that are to search function for this.
be considered secondary during fault removal.
Sequential errors are marked as such in the fault Please turn to the "Fault code listing" chapter for a
codes. Defects and non-excluded sensors can impede detailed description of the individual faults.
trouble shooting.
Faults and fault removal "CAN" are omitted in Peugeot

Berlingo and Suzuki Vitara.
Fault codes in brackets are "Generic Codes".

These are not displayed in DIAG 2000.
If no codes are shown or reading the codes is not

possible, All relevant tests must be carried out.
(S): Siemens test instructions
B diagnoses
(C): Customer test inspections (PSA)
2.1 MIL control lamp does not illuminate at Kl. 15
Error cause Location of defect Code Fault clearance

Control lamp defective • Control lamp Fault code not ➩ Check the vehicle electrics (C).
entered
No voltage supply • Vehicle electrics defective Fault code not

entered
2.2 MIL control lamp is illuminated while motor is running

Entry of fault diagnosis • Read out fault diagnosis Fault code not ➩ Remove corresponding fault.
entered
PCR 2.0 DW10 TD 12/2005 B - 13

2.3 Engine does not start

Engine control unit not working • Voltage supply to the engine No connection ➩ Supply via the ignition lock / test
control unit is missing between the for continual supply to the control
engine control unit (C)
unit and the
engine tester
Engine control unit not • Hardware or software error in P0601; P0603; ➩ Check engine control unit;
functioning engine control unit P0604; P0605; replace if applicable (S).
P0606; P1169; (see chapter 4.5)
P1621; P1627;
Main voltage supply is missing at • Main relay defective P0215; P1601; ➩ Check the main relay (C).
the engine control unit and the
actuators • Cable harness defective Fault code not ➩ Remove corresponding fault.
entered
No supply voltage on the • Engine control unit defective P0608; ➩ Check connection of the supply
sensors (5 V) line and supply voltage to the
• Cable harness defective P0608; sensors (C) If appropriate, replace
engine control unit.
Immobilizer active • Wrong code Fault code not ➩ Not yet defined.
entered
B diagnoses
No speed detection in the engine • No or incorrect (P0340) ➩ Check the camshaft sensor (C).
control unit camshaft signal P0341; P0344;
• No or incorrect (P0335) ➩ Check the crankshaft sensor (C).

Crankshaft signal P0336;
P0337;
P0339;
Too little or no fuel suction • Internal transfer pump P1113; P1198; ➩ Check low pressure system (S).
defective Sequential (see chapter 4.2)
error:
• Air in low pressure line (P0190)
P0191;
• Empty tank
P0192;
• Fuel filter blocked P0193;
• Leaky low pressure line
B - 14 PCR 2.0 DW10 TD 12/2005

Too little or no rail pressure • Too little or no fuel suction P1113; P1198; ➩ Check low pressure system (S)
(see chapter 4.2)
Sequential
error:
(P0190)
P0191;
P0192;
P0193;
• High pressure pump P1113; P1198; ➩ Check high pressure system (S)
defective (see chapter 4.3)
• PCV / VCV defective P1113;

(P1175)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
• Leaky high pressure lines / rail P1113; P1198;
B diagnoses
Sequential
error:
(P0190)
P0191;
P0192;
P0193;
• Engine control unit defective Fault code not ➩ Check engine control unit;
entered replace if applicable (S)
(see chapter 4.5)
• High rate of injector leakage P1113; P1198; ➩ Check injectors (S)

(see chapter 4.4)
Several or all cylinders not • Injectors defective P1197; ➩ Check injectors (S)
working P1354; Cyl. 1; (see chapter 4.4)
• Cable harness defective P1355; Cyl. 2; ➩ Check the line connections (C).
P1356; Cyl. 3;
P1357; Cyl. 4
• Engine control unit defective P1641; P1169; ➩ Check engine control unit;
If this fault replace if applicable (S)
code appears, (see chapter 4.5)
no injector is
being
triggered.
PCR 2.0 DW10 TD 12/2005 B - 15

2.4 Poor engine starting

Sporadic lack of sensor actuator • Cable harness defective Fault code not ➩ Check the line connections (C).
signals entered
Start speed too low • Battery capacity too low (P0560) ➩ Check the battery (C).
P0562;
Voltage drops on engine control • Poor ground connections (P0560) ➩ Check the ground connections
unit during start P0562; (C).
Rail pressure too low • Fuel suction intake too low P1113; P1198; ➩ Check low pressure system (S)
(see "2.3 Engine does not (see chapter 4.2)
start") Sequential
error:
(P0190)
P0191;
P0192;
P0193;

(P1175)
B diagnoses
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
(see chapter 4.5)
• Leaky high pressure lines / rail P1113; P1198; ➩ Check high pressure system (S)
(see chapter 4.3)
Sequential
error:
(P0190)
P0191;
P0192;
P0193;
• High pressure signal is (P0190) ➩ Check high pressure system (S)

missing or is false P0191; (see chapter 4.3)
P0192;
P0193;

(see chapter 4.4)
B - 16 PCR 2.0 DW10 TD 12/2005

One or several cylinders not • Injectors defective P1197; ➩ Check injectors (S)
working P1354; Cyl. 1; (see chapter 4.4)
• Cable harness defective P1355; Cyl. 2; ➩ Check the line connections (C).
P1356; Cyl. 3;
P1357; Cyl. 4
(see chapter 4.5)
Air suction intake too low • Air filter blocked or (P0100) ➩ Check the air suction system (C).
Suction line bent P0102; P0401;
• Throttle valve is closed / stiff (P0100) ➩ Check the exhaust return system
P0102; (C).
(P0120)
P0122; P0123;
P0124; P0401;
B diagnoses
PCR 2.0 DW10 TD 12/2005 B - 17

2.5 Poor cold start behavior

Start speed too low • Battery capacity too low (P0560) ➩ Check the battery (C).
P0562;
Voltage drops on engine control • Poor ground connections (P0560) ➩ Check the ground connections
unit during start P0562; (C).
Rail pressure too low and • Coolant temperature signal (P0115) ➩ Check the coolant temperature
injection amount too small too high P0116; sensor (C).
during starting P0117; P0118; ➩ Check high pressure system (S)
(see chapter 4.3)
• Fuel temperature signal too (P0180) ➩ Check the fuel temperature

high P0181; sensor (C).
P0182; P0183; ➩ Check high pressure system (S)
(see chapter 4.3)
Glow-plug system defective • One or more glow plugs P1351; P1352; ➩ Check the glow plug system (C).
defective
• Glow plug relay defective P1349; P1350;

P1351; P1352;
(P1353)
B diagnoses
• Glow plug control lamp Fault code not

defective entered
Notice
The faults relate to poor cold start behavior, which

appears especially during low outdoor temperatures.
B - 18 PCR 2.0 DW10 TD 12/2005

2.6 Motor cannot be switched off

Engine control unit does not • Faulty ignition lock Fault code not ➩ Check for supply on the ignition
react entered lock on control unit (C)
• Engine control unit defective P1114; P1192
• Cable harness defective Fault code not

entered
2.7 Engine stops

Too little or no fuel suction • Internal transfer pump P1113; P1198; ➩ Check low pressure system (S)
Sequential
• Air in low pressure line error:
(P0190)
• Empty tank
P0191; P0192;
B diagnoses
P0263; Cyl. 1
• Leaky low pressure line P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
Too little or no rail pressure • Too little or no fuel suction P1113; P1198; ➩ Check low pressure system (S)
(see chapter 4.2)
Sequential
error:
(P0190)
P0191; P0192;
P0193;
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
PCR 2.0 DW10 TD 12/2005 B - 19

Too little or no rail pressure • PCV / VCV defective P1113; ➩ Check high pressure system (S)
(P1175) (see chapter 4.3)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky high pressure lines / rail P1113; P1198; ➩ Check high pressure system (S)
(see chapter 4.3)
Sequential
error:
(P0190)
P0191; P0192;
B diagnoses
P0193;
• High pressure signal is (P0190) ➩ Check high pressure system (S)

missing or is false P0191; P0192; (see chapter 4.3)
P0193;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

(see chapter 4.4)
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
(see chapter 4.5)
Sporadic lack of • Cable harness defective Fault code not ➩ Check the line connections (C).
Sensor actuator signals entered
B - 20 PCR 2.0 DW10 TD 12/2005

2.8 Engine idle too high

Board voltage too low • Board voltage regulator Fault code not ➩ Check the vehicle electrics (C).
defective entered
• Too many consumers Fault code not

switched on entered
Coolant temperature signal • Coolant temperature sensor (P0115) ➩ Check the coolant temperature
too low defective P0116; P0117; sensor and line connections (C).
P0118;
Faulty accelerator pedal signal • Faulty accelerator pedal Fault code not ➩ Test accelerator pedal sensor (C).
position entered
• Cable harness defective (P0220)

P0221; P0222;
P0223; P0227;
P0228; P0609;
• Faulty accelerator pedal (P0220)

sensor P0221; P0222;
P0223; P0227;
P0228; P0609;
B diagnoses
Limp-home • Read out error memory Fault code not ➩ Remove corresponding fault.
entered
PCR 2.0 DW10 TD 12/2005 B - 21

2.9 Engine idle rough / too low

Suction lines bent P0102; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky suction lines after (P0100)
turbocharger P0103; P0402;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Air mass meter signal (P0100) ➩ Check the air mass meter (C).
too high P0103; P0402; ➩ Check the exhaust return system
(-> higher exhaust
B diagnoses
(C).
recirculation rate) Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
P0102; (C).
(P0120)
P0122; P0123;
P0124; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Exhaust return valve open / (P0100)
stiff P0102; P0401;
P0403; P0404;
P0405; P0406;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B - 22 PCR 2.0 DW10 TD 12/2005

Fuel suction intake too low • Internal transfer pump P1113; P1198; ➩ Check low pressure system (S)
Sequential
(P0190)
• Empty tank
P0191; P0192;
P0263; Cyl. 1
P0269; Cyl. 3
P0272; Cyl. 4
Poor carburetion / • Injectors defective P0263; Cyl. 1 ➩ Check injectors (S)

faulty injection P0266; Cyl. 2 (see chapter 4.4)
P0269; Cyl. 3
P0272; Cyl. 4
• Injector nozzle P0263; Cyl. 1

P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses
(see chapter 4.5)
One or several cylinders • Injectors defective P1197, ➩ Check injectors (S)

not working P1354; Cyl. 1 (see chapter 4.4)
• Cable harness defective P1355; Cyl. 2 ➩ Check the line connection (C).
P1356; Cyl. 3
P1357; Cyl. 4
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
(see chapter 4.5)
PCR 2.0 DW10 TD 12/2005 B - 23

Pressure fluctuations within the • PCV / VCV defective P1113, ➩ Check high pressure system (S)
rail (P1175) (see chapter 4.3)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• High pressure pump P1113; P1198;

defective
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
B diagnoses
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky high pressure line P1113; P1198;
Sequential
error:
(P0190)
P0191; P0192;
P0193,
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• High pressure signal incorrect (P0190) ➩ Check high pressure system (S)
P0191; P0192; (see chapter 4.3)
P0193;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B - 24 PCR 2.0 DW10 TD 12/2005

Pressure fluctuations within the • Leaky low pressure line P1113; P1198; ➩ Check low pressure system (S)
rail (see chapter 4.2)
Sequential
error:
(P0190)
P0191; P0192;
P0193;
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Injectors defective P0263; Cyl. 1 ➩ Check injectors (S)

P0266; Cyl. 2 (see chapter 4.4)
P0269; Cyl. 3
P0272; Cyl. 4
• Cable harness defective Fault code not ➩ Check the line connections (C).
entered
(see chapter 4.5)
B diagnoses
Engine control unit does not • Air conditioner pressure P0530; P0532; ➩ Air conditioner pressure sensor
react to the additional load of the sensor defective P0533; check (C).
air-conditioning compressor
PCR 2.0 DW10 TD 12/2005 B - 25

2.10 Engine speed does not increase / too low

Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Turbocharger defective (P0100) ➩ check turbocharger (C).

P0102; P0401;
B diagnoses
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Air mass meter signal too high (P0100) ➩ Check the air mass meter (C).
(-> higher exhaust recirculation P0103; P0402; ➩ Check the exhaust return system
rate) (C).
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Throttle valve is closed / stiff (P0100) P0102; ➩ Check the exhaust return system
(P0120) P0122; (C).
P0123; P0124;
P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B - 26 PCR 2.0 DW10 TD 12/2005

Air suction intake too low • Exhaust return valve open / stiff (P0100) ➩ Check the exhaust return system
P0102; (C).
P0401; P0403;
P0404; P0405;
P0406;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
Fuel suction too low • Internal transfer pump P1113; P1198; ➩ Check low pressure system (S)
Sequential
(P0190)
• Empty tank
P0191, P0192;
P0263; Cyl. 1
B diagnoses
P0269; Cyl. 3
P0272; Cyl. 4
Accelerator pedal signal is • Faulty accelerator pedal Fault code not ➩ Test accelerator pedal sensor (C).
missing or is false position entered

P0221; P0222;
P0223; P0227;
P0228; P0609;
• Faulty accelerator pedal sensor (P0220)

P0221; P0222;
P0223; P0227;
P0228; P0609;
Brake light signal defective (if • Faulty brake switch (P0220) ➩ check ABS (C).
the brake light signal and a P0226; P0571;
constant accelerator signal are
pending, the accelerator pedal • Cable harness defective (P0220)
signal is reduced for safety P0226; P0571;
reasons)
PCR 2.0 DW10 TD 12/2005 B - 27

Injection amount too low or • Injectors defective P0263; Cyl. 1 ➩ Check injectors (S)
incorrect injection timing P0266; Cyl. 2 (see chapter 4.4)
P0269; Cyl. 3
P0272; Cyl. 4
• Air mass meter signal too low (P0100) ➩ Check the air suction system (C).
(->Reduce the injection P0102; P0401; ➩ Check the air mass meter (C).
amount to prevent black
➩ Check the exhaust return system
smoke) Sequential
(C).
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky suction lines (P0100)

before turbocharger P0102; P0401;
(->Reduce the injection P0263; Cyl. 1
amount to prevent black P0266; Cyl. 2
smoke) P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses

(see chapter 4.5)
Rail pressure too low • Fuel suction too low P1113; P1198; ➩ Check low pressure system (S)
(see chapter 4.2)
Sequential
error:
(P0190)
P0191; P0192;
P0193;
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky high pressure lines / P1113: P1198:

rail
Sequential
error:
(P0190)
P0191; P0192;
P0193;
B - 28 PCR 2.0 DW10 TD 12/2005

Rail pressure too low • PCV / VCV defective P1113; ➩ Check high pressure system (S)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;

(see chapter 4.4)
P0191; P0192; (see chapter 4.3)
P0193;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses
(see chapter 4.5)
PCR 2.0 DW10 TD 12/2005 B - 29

2.11 Vehicle jerks at constant speed

No or false gear detection in • Clutch pedal slightly actuated P0704; ➩ Check clutch switch (C).
engine control unit (-> no anti-
jerk control) • Clutch switch incorrectly P0704;
adjusted or defective
(see chapter 4.5)
• Faulty CAN connection U1000; U1003; ➩ check CAN connection (C).

between ABS control unit and U1104; U1113;
engine control unit U1118; U1204;
U1213; U1218,
• Speed signal missing or P0500; ➩ check speed signal (C).

incorrect
Faulty injection • Injectors defective P0263; Cyl. 1 ➩ Check injectors (S)

P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses

(see chapter 4.5)
Pressure fluctuations within the • PCV / VCV defective P1113; ➩ Check high pressure system (S)
rail (P1175) (see chapter 4.3)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B - 30 PCR 2.0 DW10 TD 12/2005

Pressure fluctuations within the • High pressure pump P1113; P1198; ➩ Check high pressure system (S)
rail defective (see chapter 4.3)
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky high pressure line P1113; P1198;
Sequential
error:
(P0190)
P0191; P0192;
P0193;
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses
P0191; P0192; (see chapter 4.3)
P0193;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky low pressure line P1113; P1198; ➩ Check low pressure system (S)
(see chapter 4.2)
Sequential
error:
(P0190)
P0191; P0192;
P0193;
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

P0269; Cyl. 3
P0272; Cyl. 4
PCR 2.0 DW10 TD 12/2005 B - 31

Pressure fluctuations within the • Cable harness defective Fault code not ➩ Check the line connections (C).
rail entered
(see chapter 4.5)
position entered

P0221; P0222;
P0223; P0227;
P0228; P0609;

P0223; P0227;
P0228; P0609,
Signal fluctuations in the mass • Water in the air suction (P0100) ➩ Check the air suction system (C).
air flow meter system P0102; ➩ Check the air mass meter (C).
B diagnoses
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
Sporadic lack of • Cable harness defective Fault code not ➩ Check the line connections (C).
Sensor actuator signals entered
B - 32 PCR 2.0 DW10 TD 12/2005

2.12 Vehicle accelerates without actuation of the accelerator pedal

Too high or uncontrolled • Engine control unit defective Fault code not ➩ Check engine control unit;
injection amount entered replace if applicable (S)
(see chapter 4.5)
• Open injector P0263; Cyl. 1 ➩ Check injectors (S)

P0269; Cyl. 3
P0272; Cyl. 4
Faulty accelerator pedal signal • Faulty accelerator pedal signal Fault code not ➩ Test accelerator pedal sensor (C).
entered

P0221; P0222;
P0223; P0227;
P0228; P0609;

P0223; P0227;
P0228; P0609;
Sudden rail pressure increase • PCV / VCV defective P1113; ➩ Check high pressure system (S)
B diagnoses
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;

defective
P0191; P0192; (see chapter 4.3)
P0193;
(see chapter 4.5)
PCR 2.0 DW10 TD 12/2005 B - 33

2.13 Vehicle does not decelerate (no coastdown)

Faulty accelerator pedal signal • Accelerator pedal defective or P0226; ➩ Test accelerator pedal sensor (C).
pedal sticks

P0223; P0227;
P0228; P0609;

P0221; P0222;
P0223; P0227;
P0228; P0609;
Faulty injection • Open injector P0263; Cyl. 1 ➩ Check injectors (S)

P0269; Cyl. 3
P0272; Cyl. 4
(see chapter 4.5)
B diagnoses
2.14 Vehicle jerks during travel (without load)

Engaged gear too high Fault code not
entered
No or incorrect gear detection in • Clutch pedal slightly actuated P0704; ➩ Check clutch switch (C).
engine control unit (-> no anti-
jerk control) • Clutch switch incorrectly P0704;
(see chapter 4.5)

engine control unit U1213;
• Speed signal is missing or is P0500; ➩ check speed signal (C).

false
B - 34 PCR 2.0 DW10 TD 12/2005

2.15 Not enough power

Coolant temperature signal too • Cooling system defective P0480; P0481; ➩ Check cooling system (C).
high (-> max. rail pressure and P0483; ➩ Check the coolant sensor (C).
injection amount reduction to
protect the engine) • Coolant temperature sensor (P0115)
defective P0116; P0117;
P0118;
Fuel temperature signal too high • Too little fuel in the tank Fault code not
(-> max. rail pressure and entered
injection amount reduction to
protect the engine) • Internal transfer pump sensor (P0180) ➩ Check the fuel temperature
defective P0181; P0182; sensor (C).
P0183;
engine control unit ( -> defective
torque control) • Clutch switch incorrectly P0704;
(see chapter 4.5)
B diagnoses
• missing or incorrect speed P0500; ➩ check speed signal (C).

signal
Limp-home • Read out fault diagnosis Fault code not

entered


P0102; P0401;
• Air mass meter signal too (P0100) ➩ Check the air mass meter (C).
high ( -> higher exhaust P0103; P0402; ➩ Check the exhaust return system
recirculation rate) (C).
PCR 2.0 DW10 TD 12/2005 B - 35

Air suction intake too low • Throttle valve is closed / stiff (P0100) ➩ Check the exhaust return system
P0102; (C).
(P0120)
P0122; P0123;
P0124; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Exhaust return valve open / (P0100) ➩ Check the exhaust return system
stiff P0102; P0401; (C).
P0403; P0404;
P0405; P0406;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
B diagnoses
P0269; Cyl. 3
P0272; Cyl. 4
Injection amount too low • Injectors defective P0263; Cyl. 1 ➩ Check injectors (S)
P0269; Cyl. 3
P0272; Cyl. 4
• Air mass meter signal missing (P0100) ➩ Check the air mass meter (C).
or too low P0102; P0401; ➩ Check the exhaust return system
(->Reduce the injection (C).
amount to prevent black Sequential
smoke) error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Leaky suction lines before (P0100) ➩ Check the air suction system (C).
turbocharger P0102; P0401; ➩ Check the air mass meter (C).
(->Reduce the injection
➩ Check the exhaust return system
amount to prevent black Sequential
(C).
smoke) error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B - 36 PCR 2.0 DW10 TD 12/2005

Injection amount too low • High pressure signal incorrect (P0190) ➩ Check high pressure system (S)
P0191; P0192; (see chapter 4.3)
P0193,
(see chapter 4.5)
position entered

P0223; P0227;
P0228; P0609;

P0221; P0222;
P0223; P0227;
P0228; P0609;
Rail pressure too low • Fuel suction P1113; P1198; ➩ Check low pressure system (S)
too low (see chapter 4.2)
B diagnoses
Sequential
error:
(P0190)
P0191; P0192;
P0193;
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

(P1175)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
• Leaky high pressure lines / rail P1113; P1198;
Sequential
error:
(P0190)
P0191; P0192;
P0193;
PCR 2.0 DW10 TD 12/2005 B - 37

Rail pressure too low • High rate of injector leakage P1113; P1198; ➩ Check injectors (S)
(see chapter 4.4)
P0191; P0192; (see chapter 4.3)
P0193;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
(see chapter 4.5)
B diagnoses
B - 38 PCR 2.0 DW10 TD 12/2005

2.16 Too much power

Injection amount too high • Engine control unit defective Fault code not ➩ Check engine control unit;
(see chapter 4.5)

P0269; Cyl. 3
P0272; Cyl. 4
P0191; P0192; (see chapter 4.3)
P0193;
Rail pressure too high • PCV / VCV defective P1113; ➩ Check high pressure system (S)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;
B diagnoses
defective
P0191; P0192; (see chapter 4.3)
P0193;
(see chapter 4.5)
No or false gear detection in • Clutch pedal slightly actuated P0704; ➩ Check clutch switch (C).
engine control unit
( -> defective torque control) • Clutch switch incorrectly P0704;

(see chapter 4.5)

signal
Boost pressure too high • Boost pressure control (P0100) ➩ check turbocharger (C).
defective P0103;
PCR 2.0 DW10 TD 12/2005 B - 39

2.17 Bouncing while accelerating or decelerating

engine control unit
( -> no load bounce damping) • Clutch switch incorrectly P0704;

(see chapter 4.5)

signal
2.18 Vehicle accelerates quickly while coasting after releasing the brakes

B diagnoses
No brake detection in the engine • Faulty CAN connection U1000; U1003; ➩ check CAN connection (C).
control unit between ABS control unit and U1113; U1118;
( -> defective idle-speed control) engine control unit U1213;
• Brake switch in ABS P0571; ➩ check ABS (C).

system defective
(see chapter 4.5)
2.19 Engine smokes during starting

Rail pressure too high and • Coolant temperature signal (P0115) ➩ Check the coolant temperature
injection amount too high during too low P0116; P0117; sensor (C).
starting P0118; ➩ Check high pressure system (S)
(see chapter 4.3)
• Fuel temperature signal too (P0180) ➩ Check the fuel temperature

low P0181; P0182; sensor (C).
P0183; ➩ Check high pressure system (S)
(see chapter 4.3)
B - 40 PCR 2.0 DW10 TD 12/2005

2.20 Engine smokes / blue smoke

Engine oil level too high • Open injectors P0263; Cyl. 1 ➩ Check injectors (S)
P0269; Cyl. 3
P0272; Cyl. 4
Dripping injector nozzles • Injectors defective P0263; Cyl. 1 ➩ Check injectors (S)
P0269; Cyl. 3
P0272; Cyl. 4
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

B diagnoses
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

P0102; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Air mass meter signal (P0100) ➩ Check the air mass meter (C).
too high ( -> higher exhaust P0103; P0402; ➩ Check the exhaust return system
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
PCR 2.0 DW10 TD 12/2005 B - 41

Air suction intake too low • Throttle valve is closed / stiff (P0100) ➩ Check the exhaust return system
P0102; (C).
(P0120)
P0122; P0123;
P0124; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

stiff P0102; P0401;
P0403; P0404;
P0405; P0406;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses
Rail pressure too high (thus • PCV / VCV defective P1113; ➩ Check high pressure system (S)
larger exhaust recirculation rate) (P1175) (see chapter 4.3)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;

defective
P0191; P0192; (see chapter 4.3)
P0193;
(see chapter 4.5)
B - 42 PCR 2.0 DW10 TD 12/2005

2.21 Engine smokes while passing

Air pressure signal too high • Air pressure sensor defective P0105; P0107; ➩ Check air pressure sensor (C).
P0108; ➩ Check engine control unit;
replace if applicable (S)
(see chapter 4.5)
Air temperature signal too low • Air temperature sensor (P0110) ➩ Check the air mass meter (C).
defective P0112; P0113;
2.22 Engine smokes white (especially during starting)

Pre-glow system defective • One or more pre-glow plugs Sequential ➩ Check the glow plug system (C).
defective error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses
• Pre-glow relay defective P1349; P1350;
P1351; P1352;
(P1353)
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
• Pre-glow control lamp Sequential

defective error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
Frequent cold starts without • Unburned fuel in the exhaust Fault code not
warm-up phase system entered
Faulty injection • Open injector P0263; Cyl. 1 ➩ Check injectors (S)

P0269; Cyl. 3
P0272; Cyl. 4
PCR 2.0 DW10 TD 12/2005 B - 43

2.23 High fuel consumption

Fuel leaks • Leaks in high / low pressure P1113; P1198; ➩ Check high pressure system (S)
system (see chapter 4.3)
➩ Check low pressure system (S)
(see chapter 4.2)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;

defective
P0191; P0192; (see chapter 4.3)
P0193,
B diagnoses
(see chapter 4.5)
Injection amount too high • Coolant temperature signal (P0115) ➩ Check the coolant temperature
incorrect P0116; P0117; sensor (C).
P0118;
(see chapter 4.5)
P0269; Cyl. 3
P0272; Cyl. 4
position entered

P0223; P0227;
P0228; P0609;

P0221; P0222;
P0223; P0227;
P0228; P0609;
Poor mixture preparation • Injectors / nozzles defective P0263; Cyl. 1 ➩ Check injectors (S)
P0269; Cyl. 3
P0272; Cyl. 4
B - 44 PCR 2.0 DW10 TD 12/2005

2.24 Engine knocks

P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;

defective
P0191; P0192; (see chapter 4.3)
P0193,
(see chapter 4.5)
Permanent preheating • Glow-plug system defective P1349; P1350; ➩ Check the glow plug system (C).
P1351; P1352;
B diagnoses
(P1353)
P0269; Cyl. 3
P0272; Cyl. 4
2.25 Engine gets too hot

No or poor cooling • Fan defective Fault code not ➩ Check cooling system (C).
entered
• Coolant temperature signal (P0115) ➩ Check the coolant temperature

incorrect P0116; P0117; sensor (C).
P0118;
• Cable harness defective P0480; P0481; ➩ Check the line connections (C).
P0483;
(see chapter 4.5)
PCR 2.0 DW10 TD 12/2005 B - 45

2.26 Engine does not fulfill the AU requirements

Rail pressure too high (thus • PCV / VCV defective P1113; ➩ Check high pressure system (S)
larger exhaust recirculation rate) (P1175) (see chapter 4.3)
P1176; P1177;
P1179; P1180;
P1198;
(P1206)
P1207; P1208;
P1209; P1210;

defective
P0191; P0192; (see chapter 4.3)
P0193,
(see chapter 4.5)
B diagnoses
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4

P0102; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B - 46 PCR 2.0 DW10 TD 12/2005

Air suction intake too low • Air mass meter signal too (P0100) ➩ Check the air mass meter (C).
high ( -> higher exhaust P0103; P0402; ➩ Check the exhaust return system
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
P0102; (C).
(P0120)
P0122; P0123;
P0124; P0401;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
B diagnoses
stiff P0102; P0401;
P0403; P0404;
P0405; P0406;
Sequential
error:
P0263; Cyl. 1
P0266; Cyl. 2
P0269; Cyl. 3
P0272; Cyl. 4
P0269; Cyl. 3
P0272; Cyl. 4
PCR 2.0 DW10 TD 12/2005 B - 47

B diagnoses
B - 48 PCR 2.0 DW10 TD 12/2005

3 List of fault codes
Notice
Faults and fault removal "CAN" are omitted in Peugeot

Berlingo and Suzuki Vitara.
Specific Type of defect Limp-home strategy substitute- Reset conditions of

DTC value the limp-home
system
P0102 Mass air flow meter signal undercuts a • AGR function deactivated: If the tolerances
defined threshold. have been reached again.
Possible faults: Control
• Short-circuit to - or linebreak Valve & throttle valve AGR = 5 %.
• Mass air flow meter defective
• Exhaust gas recirculation system Measurement = target value without
defective AGR.
• Suction line before turbocharger
B diagnoses
leaking Substitute value = f (speed, load).
P0103 Mass air flow meter signal exceeds a • AGR function deactivated: When the tolerances
defined threshold. have been reached again.
Possible faults: Control
• Short-circuit to + Valve & throttle valve AGR = 5 %.
• Mass air flow meter defective
• Leaky suction line after turbocharger Measurement = target value without
leaky AGR.
Substitute value = f (speed, load).
P0107 Air pressure signal undercuts a defined When the tolerances

threshold. Substitute value = 900 mbar. have been reached again.
Engine control unit: internal short-circuit
to - or interruption of line.
➩ Replace engine control unit!
P0108 Air pressure signal exceeds a defined When the tolerances

threshold. Substitute value = 900 mbar. have been reached again.
Engine control unit: Internal short-circuit
to +.
PCR 2.0 DW10 TD 12/2005 B - 49

system
P0112 Suction air temperature exceeds a If the tolerances have
defined threshold. substitute value = 40 °C. been reached again.
Possible faults:
• Short-circuit after -
• manifold air temperature sensor
defective
P0113 Suction air temperature undercuts a When the tolerances

defined threshold. Substitute value = 40 °C. have been reached again.
Possible faults:
• Short-circuit to +
• Line interruption
• manifold air temperature sensor
defective
P0116 Coolant temperature change too large or • AGR interruption. • Ignition switched off
sensor signal does not change or too Control
slowly. Valve & throttle valve AGR = 5 %. When the tolerances
➩ Check line interruption and plug Nominal value = measurement. have been reached again.
connector for loose connection and ➩ Switch off the AC compressor.
check sensor for resistance change. Engine fan at maximum speed.
B diagnoses
Coolant temperature warning lamp.

substitute value:
Coolant temperature > 90 °C =
measurement
otherwise = fuel temperature +
increase by 0.5 °C/sec until 90 °C are
reached.
For fuel temperature error start at 10 °C.
P0117 Coolant temperature exceeds a defined • AGR interruption. When the tolerances
threshold. Control have been reached again.
Possible faults: Valve & throttle valve AGR = 5 %.
• Short-circuit to - Nominal value = measurement.
• Coolant temperature sensor defective ➩ Switch off the AC compressor.
Engine fan at maximum speed.
Substitute value:
measurement
reached.
B - 50 PCR 2.0 DW10 TD 12/2005

system
P0118 Coolant temperature undercuts a • AGR interruption. When the tolerances
defined threshold. Control have been reached again.
Possible faults: Valve & throttle valve AGR = 5 %.
• Short-circuit to + Nominal value = measurement.
• Line interruption ➩ Switch off the AC compressor.
• Coolant temperature sensor defective Engine fan at maximum speed.
Substitute value:
measurement
reached.
P0122 Short-circuit to - in the line connection to • AGR function deactivated: during next start.
the pressure control valve to trigger the
throttle valve. Control
Valve & throttle valve AGR = 5 %.
B diagnoses
Nominal value air amount =
measurement.
P0123 Short-circuit to + in the line connection to • AGR function deactivated: during next start.
throttle valve. Control

measurement.
P0124 Line interruption to pressure control • AGR function deactivated: during next start.
valve to trigger the throttle valve
Control

measurement.
P0181 Fuel temperature change too large: If the tolerances have

➩ Check line interruption and plug substitute value = 90 °C. been reached again.
connector for loose connection.
P0182 Coolant temperature exceeds a defined If the tolerances have

threshold. substitute value = 90 °C. been reached again.
Possible faults:
• Short-circuit to -
• Internal transfer pump sensor
defective
PCR 2.0 DW10 TD 12/2005 B - 51

system
P0183 Fuel temperature undercuts a defined If the tolerances have
threshold. substitute value = 90 °C. been reached again.
Possible faults:
• Line interruption
• Internal transfer pump sensor
defective
P0191 • Rail pressure peaks or • PCV control. Regeneration of the

• Rail pressure change too large, • VCV adaptation VCV deactivated. performance in ramp
• Sensor voltage during idling engine form after clearing the
and activated ignition too large. 350 bar < nominal rail pressure < error.
➩ Check line interruption and plug 800 bar.
connector for loose contacts and
junction resistance as well as high Function diagnosis
pressure sensor and, if applicable, Rail pressure control blocked.
high pressure system.
substitute value = f (speed, quantity).
P0192 High pressure sensor voltage undercuts • PCV control. Regeneration of the
a defined threshold. • VCV adaptation VCV deactivated. performance in ramp
B diagnoses
Possible faults: form after clearing the

• Short-circuit to - 350 bar < nominal rail pressure < error.
• High pressure sensor defective 800 bar.
Function diagnosis
Rail pressure regulation blocked.
P0193 High pressure sensor voltage exceeds a • PCV control. Regeneration of the
defined threshold. • VCV adaptation VCV deactivated. performance in ramp
Possible faults: form after clearing the
• Short-circuit to + 350 bar < nominal rail pressure < error.
• Line interruption 800 bar.
• High pressure sensor defective
Function diagnosis
Rail pressure regulation blocked.
P0215 Line connection to main relay defective. • System reaction: Engine stop.
• Short-circuit to - or line break
Can cause a series of subsequent errors.
B - 52 PCR 2.0 DW10 TD 12/2005

system
P0221 • Ratio of channel 1 and 2 of the Cruise control in stand by. If one channel plausible
accelerator signal defective or Pedal value = minimum both channels. and ignition off.
• accelerator signal of one channel
changes but the other channel does If both channels incorrect,
not change. idle speed =
➩ Check line connection, voltage supply 1200 1/min and pedal value = 0.
and accelerator pedal sensor.
P0222 Accelerator signal from channel 1 Cruise control • Ignition

undercuts a defined threshold. in stand by. switched off
➩ Check line connection, voltage supply Take other channel into account:
and accelerator pedal sensor • Channel 2 > 0 % => limp-home
mode
(Driver wish =0 %) until accelerator
pedal is no longer activated,
then amount limitation.
• Channel 2 = 0 % => amount
restriction.
P0223 Accelerator signal from channel 1 Cruise control • Ignition switched off
exceeds a defined threshold. in stand by.
B diagnoses
➩ Check line connection, voltage supply • Other channel as reference.
and accelerator pedal sensor
P0226 • Switching signal from brake switch Ramp formed increase of the idle speed • Brake pedal in passive
and brake test switch are not to lime-home mode speed. position
plausible (in vehicles with ESP or • or brake pedal
Tempomat) Cruise control in stand by. defective,
• Error reading with simultaneous • or modification pedal
activation of accelerator and brake Accelerator pedal substitute value = value.
pedals 0 %.
P0227 Accelerator signal from channel 2 Cruise control in stand by. • Ignition switched off
undercuts a defined threshold. Take other channel into account:
➩ Check line connection, voltage supply • Channel 1 > 0 % => limp-home
and accelerator pedal sensor mode
(Driver wish =0 %) until accelerator
pedal is no longer activated,
then amount limitation.
• Channel 1 = 0 % =>
amount restriction.
PCR 2.0 DW10 TD 12/2005 B - 53

system
P0228 Accelerator signal from channel 2 Cruise control in stand by. • Ignition switched off
exceeds a defined threshold. • Other channel as reference.
➩ Check line connection, voltage supply
and accelerator pedal sensor
P0263 Cylinder balancing factor in cylinder 1 From 1500 1/min

undercuts or exceeds a defined correction is cut back.
threshold.
• Too much injection amount
dispersion or injectors among one
another.
➩ Check injectors.

threshold.
another.
B diagnoses

threshold.
another.

threshold.
another.
P0336 Crankshaft signal not plausible 1. Injection interruption.

2. Re-synchronization
(if fails: Engine stop).
3. Injection.
P0337 Line to crankshaft sensor interrupted
P0339 Crankshaft signal does not exist 1. Injection interruption.

2. Re-synchronization
(if fails: Engine stop).
3. Injection.
B - 54 PCR 2.0 DW10 TD 12/2005

system
P0341 Camshaft signal is outside a defined Invalid signal before synchronization: • Ignition switched off
range. • Engine start impossible.
➩ Check sensor position and, if
applicable, engine timing
P0344 Camshaft signal does not exist Invalid signal before synchronization: • Ignition switched off
• Engine start impossible.
P0401 Exhaust recirculation rate at lower limit. • AGR function deactivated: during next start.
Possible faults:
• Air suction system defective Control
• Exhaust gas recirculation system Valve & throttle valve AGR = 5 %.
defective
(exhaust recirculation rate too high) substitute nominal value =
• Mass air flow meter signal defective measured air volume.
P0402 Exhaust recirculation rate at top limit. • AGR function deactivated: during next start.
Possible faults:
• Air suction system defective Control
• Exhaust gas recirculation system Valve & throttle valve AGR = 5 %.
defective
B diagnoses
(exhaust recirculation rate too low) substitute nominal value =
• Mass air flow meter signal defective measured air volume.
P0404 Line interruption to pressure control • AGR function deactivated: during next start.
valve to trigger the exhaust return valve.
Control

measurement.
P0405 Short-circuit to - in the line connection to • AGR function deactivated: during next start.
exhaust return valve. Control

measurement.
P0406 Short-circuit to + in the line connection to • AGR function deactivated: during next start.
exhaust return valve. Control

measurement.
PCR 2.0 DW10 TD 12/2005 B - 55

system
P0480 Line connection to fan 1 defective. Air conditioner compressor After clearing the error.
• Short-circuit to + disconnection
• Short-circuit to - or (if coolant temperature = 115 °C).
Line interruption
Activation
Coolant temperature warning lamp (if

coolant temperature = 118 °C).
P0481 Line connection to fan 2 defective. Air conditioner compressor After clearing the error.
• Short-circuit to + disconnection
Short-circuit to - or (if coolant temperature = 115 °C).
Line interruption
Activation

P0483 Fan relay is triggered, Air conditioner compressor After clearing the error.
B diagnoses
but does not switch in. disconnection

➩ Check fan relay. (if coolant temperature = 115 °C).
Activation

P0500 Speed signal via Gradient limitation pedal value. If the tolerances have
CAN defective been reached again.
Cruise control in stand by.
Drive behavior functions off
substitute value 6th gear.
Speed substitute value =

last confirmed value.
P0532 Short to - or line interruption in line • Air conditioner compressor If the tolerances have
connection to pressure sensor - air disconnection. been reached again.
conditioner
substitute value = 97.25 KPa.
P0533 Short-circuit to + or line connection to • Air conditioner compressor If the tolerances have
pressure sensor - air conditioner disconnection. been reached again.
substitute value = 97.25 KPa.
B - 56 PCR 2.0 DW10 TD 12/2005

system
P0562 Battery voltage:
• too low
P0563 Battery voltage:

• too high
P0568 Cruise Control - error • Cruise control deactivated.
P0571 • Brake light signal not plausible (check • Cruise control deactivated.
ABS).
• Brake test signal not plausible in
vehicles with ESP or Tempomat
(check brake test switch)
• Brake light signal with brake test
signal not plausible in vehicles with
ESP or Tempomat
(check ABS or brake test switch).
P0601 Internal self-test error in the engine

control unit.
B diagnoses
• NVMY memory error
• CRC ECU software error
• CRC calibration data error
P0603 Internal error in engine control unit.

• Check sum error in the EEPROM
memory

• Internal RAM error

• CRC boot software error
P0606 • On chip X RAM failure, • AGR function switch off.

• CAN RAM failure or
• Injector output stage error • System reaction: Engine stop.
• Energy controller DC/DC - converter
deactivated.
PCR 2.0 DW10 TD 12/2005 B - 57

system
P0608 5V voltage supply for high pressure • PCV control. Regeneration of the
sensor, camshaft sensor • VCV adaptation VCV deactivated. performance in ramp
and pressure sensor - air conditioner form after clearing the
• exceeded 350 bar < nominal rail pressure < error.
• or undercut. 800 bar.
Note: Function diagnosis
Fault entry can also occur if there is a Rail pressure regulation blocked.
defective line connection.
P0609 5V voltage supply for accelerator pedal Regeneration of the

• exceeded Idle nominal speed = 1200 rpm. performance in ramp
• or undercut. form after clearing the
➩ Replace engine control unit! Pedal value = 0 %. error.
Note:
Fault entry can also occur if there is a
defective line connection.
P0704 Signal from the clutch switch not Cruise control in stand by. Next positive test after a
plausible. new start.
B diagnoses
➩ Check clutch switch, adjustment and Substitute signal: in gear.

check for a defective line connection.
P1113 Nominal rail pressure not reached. • PCV control. If the tolerances have
Rail pressure controller is at • VCV adaptation VCV deactivated. been reached again.
• upper or
• lower limit. 350 bar < nominal rail pressure <
➩ High-/ low pressure system 800 bar.
Check injectors if applicable
P1114 Engine switch off via injectors defective System reaction:

• Engine stop / Rail pressure loss
• Final stage is switched off.
P1169 Final stage voltage for the injectors in

engine control unit
• too high
• or too low.
B - 58 PCR 2.0 DW10 TD 12/2005

system
P1176 Current consumption in VCV too high. System reaction: Regeneration of the
• Engine stop performance in ramp
➩ Electrically check VCV • VCV current limitation form after clearing the
(possibly interturn short circuit). error.
P1177 Short-circuit to - or line connection to VCV control = 6.7 %. Regeneration of the

VCV. VCV adaptation VCV deactivated. performance in ramp
form after clearing the
PCV control. error.
P1179 Short-circuit to - or line connection to System reaction: Regeneration of the

VCV. • Engine stop performance in ramp
VCV control = 6.7 %. error.
VCV adaptation VCV deactivated.
PCV control.
P1180 Line interruption to VCV System reaction: Regeneration of the

B diagnoses
VCV control = 6.7 %. error.
PCV control.
P1192 Engine switch off via pump defective. System reaction:

• Engine stop
• Rail pressure loss.
• Final stage is switched off.
P1197 Final stage error, injector error or wire System reaction:

harness defect. • Engine stop feasible
➩ Perform corresponding test. • Energy controller DC/DC - converter
deactivated.
• Pre and post injection deactivated.
P1198 VCV adaptation signal exceeds a defined System reaction: when the tolerances have
threshold. • Engine stop feasible been reached again.
• Injector leak amount too high
➩ Check injectors and high pressure
system.
PCR 2.0 DW10 TD 12/2005 B - 59

system
P1207 Current consumption in PCV too high. System reaction: Regeneration of the
➩ Electrically check PCV • Engine stop performance in ramp
(possibly interturn short circuit). form after clearing the
PCV current restriction. error.
P1208 Short-circuit to - or line connection to PCV control = 12.8 %. Regeneration of the

PCV. performance in ramp
VCV control. form after clearing the
error.
400 bar < nominal rail pressure <

1400 bar.
P1209 Short-circuit to - or line connection to System reaction: Regeneration of the

PCV. • Engine stop performance in ramp
PCV control = 12.8 %. error.
VCV control.

B diagnoses

1400 bar.
P1210 Line interruption to PCV. System reaction: Regeneration of the

PCV control = 12.8 %. error.
VCV control.

1400 bar.
P1349 Short-circuit to + or line connection to

pre-glow relay.
P1350 Line interruption or short-circuit to - or

line
connection to pre-glow relay.
P1351 Pre-glow relay is triggered,

but does not switch in.
➩ Check the pre-glow system.
P1352 Pre-glow relay not

triggered, but switches on.
➩ Check the pre-glow system.
B - 60 PCR 2.0 DW10 TD 12/2005

system
P1354 Defective injector cylinder 1 • Cylinder balancing deactivated. During next start, after a
• Charge or discharge procedure • Energy controller DC/DC - converter positive test over a
defective or deactivated. minimum injection
• Injector voltage defective • Defective injector is switched off. period.
➩ Check injectors and line connections.
B diagnoses
P1403 Line connection to auxiliary heater 1

defective
P1404 Line connection to auxiliary heater 2

defective
• Short-circuit to +,
P1517 Error: Note: Not in 307!

serial communication immobilizer
PCR 2.0 DW10 TD 12/2005 B - 61

system
P1601 Line connection to power relay (main System reaction:
relay) defective. • Engine stop
• Short-circuit to - or Line interruption
Can cause a series of subsequent errors.
P1613 Variant coding Kl. 15 on ->

Variant coding ->
Kl. 15 off ->
20's wait -> Start.
P1621 Internal monitoring error in the engine Reaction error specific: • Ignition switched off
control unit.
• Speed System reaction:
• Torque • Engine stop
• Microunit
• Conversion • ECU reset.
• Fuel cut off • Rail pressure loss.
• MSR intervention • Final stage switched off.
• Cruise intervention • ESP torque intervention deactivated.
• Temporary micro unit
B diagnoses
➩ Replace engine control unit! Speed governor at 2000 rpm.

Speed control unit deactivated.
P1627 Internal monitoring error in the engine Speed governor at 2000 rpm. • Ignition switched off
control unit.
• Accelerator pedal monitor not
plausible.
P1641 Final stage error, injector error or wire System reaction:

harness defect. • Engine start impossible.
➩ Perform corresponding test. • Energy controller DC/DC - converter
deactivated.
➩ If applicable, replace engine control
unit!
U1000 Engine control unit cannot transmit via • Cruise control deactivated.
CAN. No torque intervention by speed control
➩ Check CAN connection. unit and ESP.
B - 62 PCR 2.0 DW10 TD 12/2005

system
U1003 CAN connection defective. • Cruise control deactivated.
➩ Check CAN connection. No torque intervention by speed control
unit and ESP.
CAN substitute value.
U1104 Defective CAN connection between • Cruise control deactivated.

engine control unit and ESP controller. No torque intervention by speed control
U1113 Defective CAN connection between • Cruise control deactivated.

engine control unit and ABS controller. No torque intervention by speed control
U1118 Engine control unit cannot receive via • Cruise control deactivated.
CAN. No torque intervention by speed control
B diagnoses
Or defective CAN connection between CAN substitute value.

engine control unit and air conditioner
controller.
➩ Check CAN connection.
U1204 CAN message between engine- control • Cruise control deactivated.

unit and ESP controller. implausible. No torque intervention by speed control
U1213 CAN message between engine control • Cruise control deactivated.

unit and ABS controller implausible. No torque intervention by speed control
U1218 CAN message implausible. • Cruise control deactivated.

➩ Check CAN connection. No torque intervention by speed control
unit and ESP.
PCR 2.0 DW10 TD 12/2005 B - 63

B diagnoses
B - 64 PCR 2.0 DW10 TD 12/2005

4 Test specifications
4.1 Conditions for working on the system
4.1.1 Recommendations
Important!
Do not use any fuel line cleaner or metal coating

agents.
Fuel line cleaners and metal coating agents can cause
damage to the fuel system.
4.1.2 Safety instructions
Introduction:
The relevant rules and directives apply to all work Notice

performed on the injection system regarding:
The waiting time is necessary so that the pressure
B diagnoses
• accident prevention within the high pressure fuel system has a chance to
drop down to the ambient pressure.
• environmental protection
• the competent health authorities
The work must be carried out by skilled professional

Danger!
craftsmen who are familiar with the safety regulations
and who take special measures to ensure that these are
followed. When working on the diesel fuel system, the risk of
injury exists due to the highly pressurized fuel.
Safety instructions:
In consideration of the extremely high pressure (up to

1500 bar), which can prevail in the fuel system, the Danger!
following instructions are to be observed::
Comply with the regulations for accident prevention
• Do not work near flames or sparks concerning working with highly flammable or fire
• Never work on high pressure fuel systems with hazardous substances when working on the diesel
the motor running fuel system.
• Wait about 30 seconds after switching the motor

off before starting work
• Smoking is absolutely prohibited in the immediate
vicinity of the high pressure system during work
PCR 2.0 DW10 TD 12/2005 B - 65

Running engine:
Important!
• Do not put hands near a leak in the high pressure
fuel system.
When shipping the Diesel Common Rail Pump, do not
• Always stay outside the range of a possible jet of carry the pump by the connectors, pipe connections or
fuel since this can cause serious injuries on the volumetric control valve or pressure control
• Do not disconnect plugs on the injectors and the valve housings.
engine control unit (ECU);
this could damage the engine! When installing or removing the rail, do not carry on or
pull out the high pressure sensor.
If you do, you can cause damage!

Danger!

Notice
Danger of death if touched! *

When working on these parts comply with the operation.
regulations on accident prevention for high-voltage High temperatures on the housing does not indicate
devices! damage.

B diagnoses

Work area:
• The working area must be clean and orderly.

• Parts which are in for repair must be stored in a Important!
dust free environment.
Cleanliness rules:
Preparatory work:
• Workers must wear clean clothing.
It may be necessary to clean the sensitive system before
working on the system (see corresponding instructions). • Directly after dismantling all connections of the
high pressure system the openings are to be
Component parts of the sensitive equipment are: closed by means of stoppers/plugs to avoid any
pollutants penetrating into the high pressure
• Injectors system.
• High-pressure fuel pump Safety torque:
• Injector distribution pipe (Rail) • Only use periodically checked torque wrenches.
• High-pressure fuel lines • Always comply with tightening torques for the
high pressure system (lines, injector flanges,
rail).
B - 66 PCR 2.0 DW10 TD 12/2005

4.1.3 Instructions on replacing parts
The following parts are not to be removed from the high

pressure pump (1):
• Screw for the pump return flow (6)

• Pressure Control Valve (PCV) (2)
• High pressure outlet connection (4)
• Volumetric control valve VCV (3)
• Hollow screw ring fitting pump-inlet (5)
Important!
If one of these parts is damaged, always send the

pump back to the Diesel Repair Service Partner for
diagnosis.
After the warranty time has expired, high pressure

control valves (2) and volumetric control valves (3) may
be replaced separately.
B diagnoses
Fig. B - 1 Overview High pressure pump
Important!
All work on the high pressure valve (2) or volumetric

control valve (3) always require these to be replaced.
Do not detach the high pressure sensor (7) from the rail
(8).
Important!
If case of damage, always send the rail with the high

pressure sensor back to the Diesel Repair Service
Partner for diagnosis.
Fig. B - 2 High pressure sensor and rail
PCR 2.0 DW10 TD 12/2005 B - 67

Do not take the injector (9) apart:
• Do not detach the high pressure connection (10)

• Do not release nut (11) on the injector head.
Important!
If case of damage, always send the injector back to

the Diesel Repair Service Partner for diagnosis.
If reusing an injector, the nozzle shank must be freed

from all loose contamination with a soft cloth (if
Fig. B - 3 Overview Injector
necessary, use brake cleaner). The injector injection
nozzle can be cleaned in an ultrasonic bath.
B diagnoses
Never let cleaning agents or liquids reach the electrical

connections.
You must absolutely lock the electrical switch with a

protection socket while cleaning (part no. X39-800-
100-040).
To prevent contamination reaching the nozzle holes,

do not mechanically clean the nozzle cone (e.g. wiping
off with a cloth or use of a wire brush).
Important!
Any work on high pressure lines (12) requires that they

always be replaced!
Fig. B - 4 Overview High pressure lines
B - 68 PCR 2.0 DW10 TD 12/2005

Never open the engine control unit (ECU) (13).
Important!
If damaged, the engine control unit (ECU) is only

available from the vehicle manufacturer.
Opening the engine control unit is prohibited!
Fig. B - 5 Engine control unit
B diagnoses
4.1.4 Test conditions
You must comply with the following conditions before

testing the piezo common rail injection-system:
Notice
• Fuses are all in order
During the test it is possible that error codes could be
• Battery has sufficient capacity
entered in the system additionally to those originally
• The exactness of the test equipment being utilized stored in the error memory.
has been taken into consideration
Therefore, the error memory is to be cleared after a
• All mechanical parts of the engine except the
repair has been successfully completed.
injection system are okay
Compare online data with the characteristic values as
far as possible.
PCR 2.0 DW10 TD 12/2005 B - 69

B diagnoses
B - 70 PCR 2.0 DW10 TD 12/2005

4.2 Check low pressure system
Danger! Danger!
When working on the diesel fuel system, the risk of Comply with the regulations for accident prevention
injury exists due to the highly pressurized fuel. concerning working with highly flammable or fire
hazardous substances when working on the diesel
fuel system.
4.2.1 Check internal fuel transfer system
Symptoms:
Large sized air bubbles or no fuel (small bubbles are Important!

allowed) in the transparent supply line to the DCP can be
observed: The fuel line between the fuel filter and the DCP must
not be opened in the field.
• Engine does not start
It is recommended that the fuel lines to the fuel filter
not be opened as otherwise the system must be
B diagnoses
Prerequisites ventilated (bled).
Read out error codes and carry out the appropriate

checks. Re-program or replace the engine control unit in case of
the following error codes:
Test steps:
Possible Possible
• Bleed the internal fuel transfer system with the list of fault codes Sequential error
hand pump P1113; P0191;
P1198;
If too little or no fuel can be pumped with the hand pump,
check the following components:
• Check fuel filter for dirt accumulation

• Check contents of the tank (gasoline instead of
diesel, contaminated fuel)
• Check supply and return lines for leakage,
damage, as well as for a proper installation of the
lines
• Dismantle helical filter pot and check for tightness
(acc. to manufacturer's specifications)
• Check strainer in helical filter pot for blockage
PCR 2.0 DW10 TD 12/2005 B - 71

4.2.2 Check internal transfer pump
Danger! Notice
When working on the diesel fuel system, the risk of The fuel is drawn from the tank by internal transfer
injury exists due to the highly pressurized fuel. pump integrated in the DCP through the fuel filter.
The fuel reaches the high pressure pump via the

volumetric control valve to the High Pressure Pump
(HPP) for one, but also via the scavenger valve to
Danger! lubricate the pump elements in the pump interior and
from there back to the return flow.
concerning working with highly flammable or fire
hazardous substances when working on the diesel Test steps:
fuel system.
• Turn ignition off
Symptoms: • Disconnect connector on the VCV (color: orange)

• Open fuel return line at the DCP
Fuel is present in the transparent supply line to the DCP
but the fuel column doesn’t move during the start. • Start engine for a minimum of 15 sec.
B diagnoses
• Cranking engine speed 250 rpm.

• Measure transfer amount (VITP) at the return flow
Prerequisites: connection of the DCP
Read out error codes and carry out the appropriate • Compare transfer amount (VITP) with the minimum
checks. transfer amount (VITP,min)
• Internal fuel transfer system is found to be in an VITP,min = 100 ml/min

orderly condition (Cranking engine speed 250 250 rpm).
(See also "4.2.1 Check internal fuel transfer If VITP < VITP,min, replace DCP.
system" for this point)
Possible Possible
list of fault codes Sequential error
P1113; P0191;
P1198;
B - 72 PCR 2.0 DW10 TD 12/2005

4.3 Check high pressure system
Danger! Danger!
fuel system.
4.3.1 Check high pressure control valve
Symptom:
Rail pressure approx. 50 bar during the start phase (PCV Notice
net positive suction head).
If the high pressure control valve is defective (e.g. no
current) a rail pressure of only approx. 50 bar will be
reached during the start phase.
Prerequisite
This holding pressure is set through the closing
pressure of a spring in the pressure control valve.
B diagnoses
checks.
Nominal rail pressure during the start phase: at least
150 bar
• High pressure lines and high pressure connections
have been checked for tightness.
• Complete low pressure system is found to be in an Possible Possible
orderly condition list of fault codes Sequential error
(see section "4.2 Check low pressure system" for P1176; P1113;
information concerning this process) P1177; P1198;
P1179;
P1180;
Important! P1207;
P1208;
P1209;
Measure current on high pressure control valve using P1210;
a diagnostics tool or multimeter.
PCR 2.0 DW10 TD 12/2005 B - 73

Test steps:
5NPLUG6#6CONNECTORCOLORORANGE AND
MEASURETHERESISTANCEONTHE6#6
.OMINALRESISTANCE
-EASUREVOLTAGEONTHE0#6CONNECTOR
0).ANDGROUND WITHTHEIGNITIONSWITCHEDON
.OMINALVOLTAGE"ATTERYVOLTAGE
B diagnoses
-EASURETHEACTIVATIONCURRENTONCONNECTED
0#6CONNECTORDURINGSTARTING

.OMINALCURRENT !STARTPHASE
3EERAILPRESSURECURRENTDIAGRAM
B - 74 PCR 2.0 DW10 TD 12/2005

#HECKTHELINECONNECTION
!CTIVATIONCURRENT ./ ANDCONNECTORTOTHE%#5
/+
,INECONNECTION
-AKETHE

ANDCONNECTORTO
NECESSARYREPAIRS ./
THE%#5OKAY
9%3 9%3
B diagnoses
#HECKMAIN !CTIVATIONCURRENT
9%3
POWERRELAY !
./
0#6OKAY 2EPLACE%#5
#HECK(00
PCR 2.0 DW10 TD 12/2005 B - 75

Rail pressure current diagram
B diagnoses
Fig. B - 6 Rail pressure current diagram
B - 76 PCR 2.0 DW10 TD 12/2005

4.3.2 Check high pressure pump and VCV
Danger! Notice
When working on the diesel fuel system, the risk of Nominal rail pressure during the start phase: at least
injury exists due to the highly pressurized fuel. 150 bar
Possible Possible
Danger! list of fault codes Sequential error
P1176; P0191;
Comply with the regulations for accident prevention P1177;
concerning working with highly flammable or fire P1179; P1113;
hazardous substances when working on the diesel P1180; P1198;
fuel system.
P1207;
P1208;
Symptom: P1209;
P1210;
Too little or no rail pressure during the start phase.
B diagnoses
Prerequisites:

checks. Important!
Measure current on volumetric control valves using a
diagnostics tool or multimeter.
• Pressure control valve has been checked
(See section "4.3.1 Check PCV" for information

concerning this process)
• Complete low pressure system is found to be in an

orderly condition
(see section "4.2 Check low pressure system" for

information concerning this process)
PCR 2.0 DW10 TD 12/2005 B - 77

Test steps:
$ISCONNECT6#6CONNECTORCOLORORANGE
ANDMEASURETHERESISTANCEONTHE6#6
.OMINALRESISTANCE
2ESISTANCEOKAY ./ 2EPLACE6#6
WITHINTHEWARRANTYPERIOD
REPLACETHE$#0
9%3
-EASUREVOLTAGEON
THE6#6CONNECTOR0).OR
B diagnoses
WITHTHEIGNITIONSWITCHEDON
.OMINALVOLTAGE"ATTERYVOLTAGE
6OLTAGEOKAY ./ #HECKMAIN POWERRELAY
9%3
-EASURETHEACTIVATIONCURRENT
ONCONNECTED6#6
CONNECTORDURINGSTARTING
.OMINALCURRENT !STARTPHASE
B - 78 PCR 2.0 DW10 TD 12/2005

#HECKTHELINECONNECTION

4RIGGERCURRENT ./ ANDPLUGTOTHE%#5
/+
,INECONNECTION
-AKETHE
ANDPLUGTOTHE
NECESSARYREPAIRS ./
%#5OKAY
9%3
9%3
B diagnoses
#HECKMAIN !CTIVATIONCURRENT
9%3
POWERRELAY !
./
/PENHIGH PRESSURELINESTOPREVENT
CREATIONOFRAILPRESSURE ANDOPEN
RETURN FLOWCONNECTIONONTHE$#0
#ONNECT0#6AND6#6
2EPLACE%#5
4EST!
3TARTENGINEFORATLEASTS #OLLECTEMERGINGFUELINAN
#RANKINGENGINESPEEDRPM APPROPRIATECONTAINER
-EASUREFUELAMOUNTATTHERETURN FLOW
CONNECTIONWHILESTARTING
PCR 2.0 DW10 TD 12/2005 B - 79

-EASUREDFUELAMOUNT 2EPLACE6#6
OVERMLMIN
9%3 WITHINTHEWARRANTYPERIOD
&ORMINSCRANK TIMEAND
MINCRANKSPEED REPLACETHE$#0
&LUSHVALVEIN$#0ISOPEN
OR6#6ISMECHANICALLY
JAMMEDINACLOSEDSTATE
./
(00OKAY 2EPEATTHEFUELAMOUNT
TEST4EST!
B diagnoses
)FTHENOMINALRAILPRESSUREISNOTREACHED )FFUELAMOUNTISNOTOKAY
DURINGSTARTINGITISPOSSIBLE
THATTHEINJECTORLEAKAGEISTOOHIGH REPLACETHE$#0
ORTHEPRESSURESIGNALINCORRECT
B - 80 PCR 2.0 DW10 TD 12/2005

Typical VCV flow characteristic dependent on the pump speed (np)
B diagnoses
Fig. B - 7 Flow characteristic
PCR 2.0 DW10 TD 12/2005 B - 81

4.3.3 Check rail pressure control circuit
Danger! Notice
When working on the diesel fuel system, the risk of The appropriate rail pressure will be set for every
injury exists due to the highly pressurized fuel. engine operating condition. The engine control unit
continually monitors the momentary rail pressure
through the high pressure sensor, adjusts it to the
nominal value stored in the characteristics and
regulates the pressure control valve and the
Danger! volumetric control valve.
A closed rail pressure control loop is thereby created.
concerning working with highly flammable or fire The volumetric control valve serves the purpose of
hazardous substances when working on the diesel customising the delivered amount of fuel from the
fuel system. high pressure pump according to the needs of the
engine.
Symptoms: The power requirement of the high pressure pump
will thereby be reduced.
• Unstable idling
• Pressure fluctuations within the rail
B diagnoses
• Nominal rail pressure not reached

Important!
• Possibly loud or atypical combustion noises
If the DCP is blocked, i.e. if the pump shaft cannot be
turned by hand even with the impeller mounted, or if
Prerequisites:
heavy pollution (filings) in the transparent fuel return
can be seen, then the complete injection system
(injectors, DCP, rail, high pressure lines and all return
checks.
lines) have to be replaced.
• Switch off air-conditioning unit
• At least a half full fuel tank
Possible Possible
• Coolant temperature 80 - 90 °C list of fault codes Sequential error
• Switch off all electrical power consuming P0191; P0192;
equipment. P0193;
P0263; P0266;
• Hydraulic lines have been checked and are tight P0269; P0272;
• Connectors and line connections have been P1113; P1176;
checked P1177; P1179;
P1180; P1198;
P1207; P1208;
P1209; P1210;
B - 82 PCR 2.0 DW10 TD 12/2005

Test steps:
3TARTENGINE
ANDLETITIDLE
!RETHERELARGE
AIRBUBBLESINTHE 9%3 #HECKLOW

TRANSPARENTSUPPLYLINE PRESSURESYSTEM
TOTHE$#0
./
$ISCONNECT6#6CONNECTORCOLORORANGE
B diagnoses
$OESTHEENGINESTOP ./ 2EPLACE6#6
REPLACETHE$#0
9%3
6#6REMAINSMECHANICALLYOPEN
#ONNECTTHE6#6PLUG .OTE
RESTARTENGINEANDLETITIDLE 4URNOFFTHEIGNITIONBEFORERESTARTING
THEENGINEANDWAITAPPROXS
%#5SWITCH OFFDELAY TIME
$ISCONNECT0#6CONNECTORCOLORWHITE
PCR 2.0 DW10 TD 12/2005 B - 83

$OESTHEENGINESTOP ./ 2EPLACE0#6
9%3 REPLACETHE$#0
#ONNECTTHE0#6CONNECTOR 0#6ISMECHANICALLYJAMMED
RESTARTENGINEANDLETITIDLE INACLOSEDSTATE
/UTPUTCYLINDER
BALANCINGFACTORSONLINE
B diagnoses
#YLINDERBALANCINGERROR
.OMINALVALUE 9%3 #HECKINJECTORS
0ERMISSIBLEDEVIATION

./
/UTPUTFUELTEMPERATUREANDCOOLING
WATERTEMPERATUREONLINE
4ECHNICALBACKGROUND
I
.OMINALVALUEFORTHEFUEL !TAFUELTEMPERATUREOFOVER
TEMPERATUREDURINGIDLING ¥# ¥#THEMAXIMUMRAILPRESSURE
.OMINALVALUEFORCOOLANT ISREDUCEDTOPROTECTTHEPLASTIC
TEMPERATURE ¥# LINES
ATAWATERTEMPERATUREOFOVER
¥#THEMAXIMUMRAILPRESSURE
ISREDUCEDTOPROTECTTHEENGINE
B - 84 PCR 2.0 DW10 TD 12/2005

!RETHEFUELAND
COOLANTTEMPERATURES ./ #HECKTHECORRESPONDING
INTHENOMINALVALUERANGE SENSORS
9%3
3WITCHOFFENGINE
-EASURETHERESISTANCEONTHE0#6AND6#6
ANDCHECKTHELINECONNECTIONS
0#6NOMINALRESISTANCE
6#6NOMINALRESISTANCE
B diagnoses
2ESISTANCESOKAY ./ 2EPLACE0#6
2EPLACE0#6
9%3 WITHINTHEWARRANTYPERIOD
REPLACETHE$#0
)GNITION/.
#ONNECTORISCONNECTEDTO
THEHIGH PRESSURESENSOR
-EASURETHESUPPLYVOLTAGEONTHE
HIGH PRESSURESENSORBETWEEN0).AND
.OMINALSUPPLYVOLTAGE6 !TTENTION
-EASURETHESENSORVOLTAGEONTHE $ONOTMAKEANYRESISTANCEORCAPACITANCE
HIGH PRESSURESENSORBETWEEN0).AND MEASUREMENTSONTHEHIGH PRESSURESENSOR
.OMINALSENSORVOLTAGE6
3EEHIGHPRESSURESENSORVOLTAGE 4HATCOULDLEADTODESTRUCTIONOFTHESENSOR
RAILPRESSUREDIAGRAM
PCR 2.0 DW10 TD 12/2005 B - 85

High pressure sensor voltage - Rail pressure diagram
B diagnoses
Fig. B - 8 Rail pressure diagram
Supply voltage and 1.) If the voltage supply is defective,

Sensor voltage O.K.? NO
check the line connection and
replace the engine control unit.
YES 2.) If the sensor voltage is incorrect,
check the high-pressure sensor
contacts and replace if applicable.
Start engine
and let it idle. If the contacts are okay, replace
the high-pressure sensor.
Measure the parameters listed

in table A at various speeds.
B - 86 PCR 2.0 DW10 TD 12/2005

$OTHEMEASUREMENTS
MATCHTHENOMINALVALUES
INTABLE! 9%3 2AILPRESSURE
CONTROL LOOPOKAY
./
#ANYOUDETECTALOUD
ORATYPICALCOMBUSTIONNOISE
%XCHANGETHEHIGH PRESSURE
SENSORANDMEASUREAGAIN
B diagnoses
$OTHEMEASUREMENTSNOWMATCH
THENOMINALVALUESIN4ABLE! ./ UHSODFHWKH'&3
9%3
2EPLACETHEHIGHPRESSURESENSOR
$OTHEMEASUREMENTSNOWMATCH 4ECHNICALBACKGROUND
THENOMINALVALUESIN4ABLE! .OMINALVALUEDEVIATIONSINTHERAILPRESSURE
CONTROL LOOPCANBECAUSEDBYWEARDIRTYOR
DEFECTIVESENSORSORACTUATORS4HESEDEVIATIONS
9%3 CANBEONLYBECOMPENSATEDFORBYTHEPRESSURE
REGULATORWITHINCERTAINTOLERANCES!SACONSEQUENCE
EXCESSIVELYHIGHLOWOROSCILLATINGRAILPRESSURECAN
2AILPRESSURECONTROL LOOPOKAY ARISE
PCR 2.0 DW10 TD 12/2005 B - 87

Table A
Speed Rail pressure Voltage on high pressure PWM signal Current

sensor between PIN 1 and 2 on PCV on PCV
(no load)
[RPM] [Mpa] [V] [%] [A]
Idle 210 - 230 0,9 - 1,1 12 - 18 0,30 - 0,50
2000 300 - 350 1,0 - 1,2 13 - 19 0,35 - 0,60
3000 300 - 350 1,0 - 1,2 15 - 22 0,45 - 0,70
4000 650 - 800 1,8 - 2,3 20 - 28 0,65 - 0,95

B diagnoses
B - 88 PCR 2.0 DW10 TD 12/2005

4.4 Check injectors
Danger! Danger!
fuel system.
4.4.1 High injector leakage / injectors remain open
Prerequisites:
Danger!
checks.
• PCV has been checked
concerning this process)
B diagnoses
• Pressure sensor has been checked
devices!
(See section "4.3.3 Check rail pressure control
Symptoms: loop" for information concerning this process)
Too little or no rail pressure during the start phase. • High pressure lines and high pressure connections
• Engine does not start • The entire low pressure system is operating
correctly
Notice (see section "4.2 Check low pressure system" for

information concerning this process)
Wear and tear or dirt particles in the injector can lead
to tolerable return flow fuel amounts through the • High pressure pump and volumetric control valve
injector being exceeded or that the injector remains were checked.
open to the cylinder. This has the result that the
amount of fuel delivered from the high pressure pump (See section "4.3.2 Check high pressure pump and
is no longer sufficient to build up pressure in the rail. VCV" for information concerning this process)
The injectors will not be triggered at a pressure which

lies under 150 bar. Possible Possible
list of fault codes Sequential error
P1113;
P1198;
PCR 2.0 DW10 TD 12/2005 B - 89

Injector triggering characteristics
B diagnoses
Fig. B - 9 Injector triggering characteristics
B - 90 PCR 2.0 DW10 TD 12/2005

Test steps:
CKCAPACITANCESANDRESISTANCESONTHEINJECTORCONNECTIONS
.OMINALCAPACITANCE&
.OMINALRESISTANCEnK
MEASUREATROOMTEMPERATUREAROUND¥#
LETTHEENGINECOOLOFFFORATLEASTMIN
#APACITANCESAND 2EPLACETHECORRESPONDING
./
RESISTANCESOKAY INJECTOR
9%3
3EPARATETHERETURN FLOWCONNECTIONSATTHE
INJECTORSANDTIGHTLYSEALTHELINES3TARTTHE
B diagnoses
ENGINEANDCHECKTHERETURN FLOWAMOUNT
ONTHEINJECTOR
)STHERETURN FLOWAMOUNTOFTHEINJECTORS
ATMAXIMUMINTHEDRIPRANGEBOTHDURING 2EPLACETHECORRESPONDING
./
THECRANKPHASEASWELLASWHILEIDLING INJECTOR
9%3
2EMOVETHEGLOWPLUGSANDCHECKFORWETNESS
)FTHEGLOWPLUGSAREDAMPWITHFUELTHISCOULD
INDICATEANINJECTORTHATISOPENTOWARDTHECYLINDER
ORALEAKYINJECTOR
PCR 2.0 DW10 TD 12/2005 B - 91

!RETHEGLOWPLUGSDAMP 9%3 2EPLACETHECORRESPONDING
WITHFUEL INJECTOR
./
2EMOVETHEHIGH PRESSURELINESBETWEEN .OTE

THEINJECTORANDRAIL 0ERFORMANINJECTORTESTFOREACHINDIVIDUAL
4IGHTLYSEALTHEHIGH PRESSURELINESON INJECTORONEAFTERTHEOTHER!DEFECTIVE
THERAIL INJECTORCANBELOCATEDBYCOMPARING
.OTE3EALTHERAILATTHEFERRULEINTHE THEPRESSURES
HIGH PRESSURECONNECTION
$ISCONNECTTHECONNECTORFROMTHEINJECTORS
3TARTENGINEANDOBSERVETHESELF ADJUSTINGRAILPRESSURE
.OMINALRAILPRESSUREMINBAR
B diagnoses
7ASTHENOMINAL )NSTALLHIGH PRESSURELINESFROM

9%3
RAILPRESSUREREACHEDWHILESTARTING CYLINDERS ONEAFTERTHEOTHER
UNTILTHERAILPRESSUREFALLS
./
2EPLACEHIGHPRESSURESENSOR 2EPLACETHE
CORRESPONDINGINJECTOR
)STHENOMINALRAILPRESSUREREACHED
9%3
3YSTEMOKAY
B - 92 PCR 2.0 DW10 TD 12/2005

4.4.2 Injection amount incorrect.
Symptom:
Danger!
Engine idle runs rough, possibly produces white smoke.
When working on the diesel fuel system, the risk of
Prerequisites:

checks.
Danger!
• Switch off air-conditioning unit
concerning working with highly flammable or fire • Engine temperature minimum 80 °C
hazardous substances when working on the diesel • Switch off all electrical power consuming
fuel system. equipment.
• PCV has been checked

Danger! concerning this process)
B diagnoses
energized parts of the pump carry high voltages! have been checked for tightness.
Danger of death if touched! • The entire low pressure system is operating

correctly
regulations on accident prevention for high-voltage (see section "4.2 Check low pressure system" for
devices! information concerning this process)
• High pressure pump and volumetric control valve

were checked.
Notice (See section "4.3.2 Check high pressure pump and

VCV" for information concerning this process)
Wear and tear or dirt particles in the injector can lead
to the injected amounts passed through the injectors
deviating from one another, or that the sealing of the Possible Possible
injectors to the cylinder is no longer guaranteed. list of fault codes Sequential error
Different injection amounts between the individual P0263;

cylinders lead to power variations, which causes the P0266;
crankshaft to be accelerated with differing forces. P0269;
P0272;
The allocation of injection amounts to the individual
P1354;
cylinders can be compensated by the Cylinder
P1355;
Balancing Factors, so that a smoother-running engine P1356;
can be achieved. P1357;
PCR 2.0 DW10 TD 12/2005 B - 93

Test steps:
3WITCHOFFENGINE
-EASURETHECAPACITANCESANDRESISTANCES
EINJECTORCONNECTIONSANDCHECKTHELINECONNECTIONS
.OMINALCAPACITANCE&
.OMINALRESISTANCEnK
MEASUREATROOMTEMPERATUREAROUND¥#
LETTHEENGINECOOLOFFFORATLEASTMIN
#APACITANCESRESISTANCES
ANDLINECONNECTIONSOKAY ./ -AKETHENECESSARYREPAIRS
B diagnoses
9%3
3TARTENGINEANDLETITIDLE
!FTERTHATOUTPUTTHECYLINDER
BALANCINGFACTORSONLINE
3EPARATETHERETURN FLOWCONNECTIONS
#YLINDERBALANCINGERROR ONTHEINJECTORSANDTIGHTLYSEALTHE
.OMINALVALUE ./ OPENLINES#HECKRETURN FLOWAMOUNT
0ERMISSIBLEDEVIATION ONINJECTORWHILEIDLING

9%3
B - 94 PCR 2.0 DW10 TD 12/2005

Locate the corresponding
injector and replace it Is the injector return-flow
with one without deviations. amount at a maximum
within the drip range?
NO YES
Does the cylinder - Replace the Injectors okay.

YES
balancing deviation corresponding injector.
follow the injector?
NO
B diagnoses
Check line connection, and
possibly the engine compression.
If applicable, replace the engine
control unit.
PCR 2.0 DW10 TD 12/2005 B - 95

B diagnoses
B - 96 PCR 2.0 DW10 TD 12/2005

4.5 Check the engine control unit
Danger! Important!
The Engine Control Unit (ECU), injectors and When starting troubleshooting, check the cable
energized parts of the pump carry high voltages! harness, its contacts to the engine control unit, to the
voltage supply, to the injectors and to the ground
Danger of death if touched! connection and repair any possible faults.
When working on these parts comply with the Before replacing the engine control unit (ECU), make
regulations on accident prevention for high-voltage sure all other possible error sources have been
devices! excluded.

operation. High temperatures on the housing do not
indicate damage.
Replace the engine control unit in case of the following error code entries:
B diagnoses
Error code Cause
P0107; Atmospheric pressure sensor defective.
• Short-circuit to - or open line
P0108; Atmospheric pressure sensor defective.

• Short-circuit to +.
P0601; • Internal self-test error in engine control unit
P0603; • EEPROM checksum error
P0604; • Internal RAM error
P0605; • CRC boot software error
P0606; Internal hardware error in engine control unit.

• Power stage fault
• SPI communication error
• On chip X RAM error or CAN RAM error
PCR 2.0 DW10 TD 12/2005 B - 97

Error code Cause
P0608; 5V voltage supply for high pressure sensor, camshaft sensor
and pressure sensor for air conditioner too high or too low.
Note: Fault entry can also occur if there is a defective lead connection.
P0609; 5V power supply for accelerator pedal sensor too high or too low.
Note: Fault entry can also occur if there is a defective lead connection.
P1169; • Voltage of the power stage too high or too low.
P1621; • Processor monitoring fault
P1641; • Injector power stage fault in the engine control unit
P1627; Internal monitoring error in engine control unit.

B diagnoses
• Accelerator pedal monitoring implausible.
B - 98 PCR 2.0 DW10 TD 12/2005

5 Diagnostics tools
In addition to the transfer of error codes, the system also

supports the application of a diagnosis device with the
following functions: Danger!
• Online data The Engine Control Unit (ECU), injectors and

• Freeze Frames
• Actuator tests Danger of death if touched!

devices!
5.1 Freeze Frames
In the case of every fault diagnosed, system data is Furthermore, one of the following data packets will be
stored which can then be read-out with the diagnosis stored (fault dependent):
device.
B diagnoses
The following values will be stored with every fault
(common freeze frame): Specific freeze frame 0:
• speed • ESP status

• ECU operating period • ECU/CAN status
• Battery voltage • Driver requested torque
• Engine operating condition • Accelerator pedal position 1 and 2
• Total injected fuel amount
• Vehicle speed Specific freeze frame 1:
• Measured coolant temperature
• CPU load
• Power stage voltage
• Supply voltage 1 and 2
PCR 2.0 DW10 TD 12/2005 B - 99

Specific freeze frame 2: Specific freeze frame 5:
• Rail pressure • Cylinder balancing factors

• Pressure control valve • Injection period for pre- and main injection
• Volumetric control valve
• Measured fuel temperature
Specific freeze frame 6:
Specific freeze frame 3: • ECU status

• Speed in MU
• AC pressure
• Controller error code
• Status flags for AC
• Monitoring unit error code
• Status flags for cooler air control
• PWG voltage 2 from MC and MU
• PWM cooler air control "high speed"

• Air mass
• ECU status
• Ambient pressure
• Speed in MU
B diagnoses
• PWM EGR valve

• Accelerator position
• Nominal value air mass
• PWG input voltage
• PWM throttle valve
• "Disabled injectors" status
B - 100 PCR 2.0 DW10 TD 12/2005

5.2 Online data using diagnostics tool
The following data packets can be called up on-line with

the diagnosis device:
C0 APV: INJECTION C4 INFO.ROULAGE
speed ACC on
"Pull" flag speed
Engine status Actual gear
Ambient pressure "Pull" flag
Battery voltage Engine status
Supply voltage 1 AC request
Corrected air temperature "Main relay" flag
Measured air temperature Ambient pressure
Delivered torque Battery voltage
Main-injection duration Supply voltage 1
Corrected coolant temperature Vehicle speed
Measured coolant temperature Corrected air temperature
Delivered torque
B diagnoses
C3 APV: CAPTEURS Injection start main-injection
Corrected coolant temperature
ACC on
Main-injection duration
speed
Actual gear
Engine status
C5 INFO1
AC request
Ambient pressure speed
Battery voltage Battery voltage
Supply voltage 1 Radiator fan status
Corrected air temperature Radiator fan high speed
Measured air temperature Corrected air temperature
Delivered torque Delivered torque
Corrected coolant temperature Radiator fan speed
Measured coolant temperature Corrected coolant temperature
PCR 2.0 DW10 TD 12/2005 B - 101

C6 DIESEL MECA 01 C8 COMMON RAIL
speed speed
Pedal value Rail pressure
Ambient pressure Air mass
Battery voltage Engine status
Fuel temperature PWM EGR valve
Supply voltage 1 Power stage voltage
Corrected air temperature Pressure control valve
Injection start main-injection PWM throttle valve
Corrected coolant temperature Driver requested torque
Supply voltage via ignition lock (Kl. 15) Total injected fuel amount
Volumetric control valve
C7 DIESEL MECA 02 Cylinder balancing factor 1
Cylinder balancing factor 3
AC on
speed
Engine status
Delivered torque
Idle speed fuel mass
Injection start pre-injection
B diagnoses
PWM EGR valve

Injection start main-injection
Battery voltage
Brake light switch
CC COMMON RAIL 2
Driver requested torque
Glow plug relay triggering speed
Supply voltage 1 Rail pressure
Smoke limitation amount Air mass
Vehicle speed Engine status
Torque limitation amount Rail pressure - nominal value
Supply voltage via ignition lock (Kl. 15) Pre-injection amount
Air-mass target value
Main injection amount
Injection start pre-injection
Injection period pre-injection
Injection start main-injection
Corrected coolant temperature
Main-injection duration
B - 102 PCR 2.0 DW10 TD 12/2005

5.3 Actuator tests using diagnostics tool
With the help of a diagnosis tool it is possible in the

workshop to trigger several actuators to check them for
their operativeness. Danger!
Prerequisites: The Engine Control Unit (ECU), injectors and

• Motor OFF
• Ignition on
• ECU enabled When working on these parts comply with the
devices!
B diagnoses
Fig. B - 10 Test pressure control valve
5.3.1 Test pressure control valve 5.3.2 Test volumetric control valve
(Diagram see above) (Diagram see above)
• 10 cycles (T) • 10 cycles (T)

• 5 % (min) / 0.5 s (t2) • 5 % (min) / 0.5 s (t2)
• 40 % (max) / 0.5 s (t1) • 30 % (max) / 0.5 s (t1)
Notice Notice
An alternating buzzing may be heard during the test. An alternating buzzing may be heard during the test.
PCR 2.0 DW10 TD 12/2005 B - 103

Fig. B - 11 Test pressure control valve
5.3.3 Test glow relay 5.3.5 Test EGR valve and throttle
(Diagram see above) (Diagram see above)
• 10 cycles (T) • 10 cycles (T)

• 0,5 s (t1) an / 0.5 s (t2) off • 5 % (min) / 0.5 s (t2)
B diagnoses
• 95 % (max) / 0.5 s (t1)
5.3.4 Test main and power relay
(Diagram see above)
• 1 cycle (T)
• 10 s (t1) an / 10 s (t2) off
B - 104 PCR 2.0 DW10 TD 12/2005

5.3.6 Test GMV (radiator fan)
Notice Danger!
Depending upon the vehicle, either a proportional The Engine Control Unit (ECU), injectors and
control or a 2 step control are installed. energized parts of the pump carry high voltages!

devices!
Radiator fan proportional:
B diagnoses
Fig. B - 12 Radiator fan proportional
From 0 % (min) to 100 % (max) within 25 s (t1), then

hold 10 s (t2) to 100 %, switch off after additional 10 s
(t3), the test is complete.
PCR 2.0 DW10 TD 12/2005 B - 105

Radiator fan 2-staged:
Low speed (GMV2):
Fig. B - 13 Low speed
Fan is switched on one time for 20 s (t1).

B diagnoses
High speed (GMV1):
Fig. B - 14 High speed
Switch on GMV2 for 5 s (t1), then trunk GMV1.

Notice
After 20 s (t2) or a total of 25 s (t1+t2), the test is
To test GMV1, the fan has to be running at low speed. complete.
B - 106 PCR 2.0 DW10 TD 12/2005

C Repairs
1 Conditions for working on the system
1.1 Recommendations
Important!

agents.
1.2 Safety instructions
Introduction:
The relevant rules and directives apply to all work Notice

performed on the injection system regarding:
The waiting time is necessary so that the pressure
• accident prevention within the high pressure fuel system has a chance to
• environmental protection
The work must be carried out by skilled professional

Danger!
and who take special measures to ensure that these are
followed. When working on the diesel fuel system, the risk of
Safety instructions:

1500 bar), which can prevail in the fuel system, the Danger!
C Repairs
following instructions are to be observed:
• Do not work near flames or sparks concerning working with highly flammable or fire
• never work on high pressure fuel systems with the hazardous substances when working on the diesel
motor running fuel system.
• Wait about 30 seconds after switching the motor

• Smoking is absolutely prohibited in the immediate
vicinity of the high pressure system during work
PCR 2.0 DW10 TD 12/2005 C-1

Running engine:
Important!
fuel system.
When installing or removing the Diesel Common Rail
• Always stay outside the range of a possible jet of Pump, do not carry the pump by the connectors, pipe
fuel since this can cause serious injuries connections or on the volumetric control valve or
• Do not disconnect plugs on the injectors and the pressure control valve housings.
engine control unit (ECU); this could cause engine
damage. When installing or removing the rail, do not carry on or
pull out the high pressure sensor.
If you do, you can cause damage!

Danger!

Notice
Danger of death if touched! *

When working on these parts comply with the operation. High temperatures on the housing does not
regulations on accident prevention for high-voltage indicate damage.
devices!
Work area:

Important!
• parts which are in for repair must be stored gin a
dust free environment. Cleanliness rules:
Preparatory work: • Workers must wear clean clothing.
It may be necessary to clean the sensitive system before • Directly after dismantling all connections of the
working on the system (see corresponding instructions). high pressure system the openings are to be
closed by means of stoppers/plugs to avoid any
C Repairs
Component parts of the sensitive equipment are: pollutants penetrating into the high pressure
system.
• Injectors Safety torque:
• High-pressure fuel pump
• Only use periodically checked torque wrenches.
• Injector distribution pipe (Rail)
• Always comply with tightening torques for the
• High-pressure fuel lines high pressure system (lines, injector flanges,
rail).
C-2 PCR 2.0 DW10 TD 12/2005

1.3 Instructions on replacing parts
The following parts are not to be removed from the high

pressure pump (1):
• Screw for the pump return flow (6)

• Pressure Control Valve (PCV) (2)
• High pressure outlet connection (4)
• Volumetric control valve VCV (3)
• Hollow screw from the ring fitting pump-inlet (5)
Important!
If one of these parts is damaged, always send the

pump back to the Diesel Repair Service Partner for
diagnosis.
After the warranty time has expired, high pressure

control valves (2) and volumetric control valves (3) may
be replaced separately.
Fig. C - 1 Overview high pressure pump
Important!
All work on pressure control valve (2) or volumetric

control valve (3) require that they always be replaced!
C Repairs
Do not detach the high pressure sensor (7) from the rail
(8).
Important!
If case of damage, always send the rail with the high

pressure sensor back to the Diesel Repair Service
Partner for diagnosis.
Fig. C - 2 High pressure sensor and rail
PCR 2.0 DW10 TD 12/2005 C-3

Do not take the injector (9) apart:
• Do not detach the high pressure connection (10)

• Do not release nut (11) on the injector head.
Important!
If case of damage, always send the injector back to

the Diesel Repair Service Partner for diagnosis.
If reusing an injector, the nozzle shank must be freed

from all loose contamination with a soft cloth (if
Fig. C - 3 Overview Injector
necessary, use brake cleaner). The injector injection
nozzle can be cleaned in an ultrasonic bath.
Never let cleaning agents or liquids reach the electrical

connections.
You must absolutely lock the electrical switch with a

protection socket while cleaning (part no. X39-800-
100-040).
To prevent contamination reaching the nozzle holes,

do not mechanically clean the nozzle cone (e.g. wiping
off with a cloth or use of a wire brush).
C Repairs
Important!
All work on high pressure lines (12) require that they

always be replaced!
Fig. C - 4 Overview high pressure lines
C-4 PCR 2.0 DW10 TD 12/2005

Never open the engine control unit (ECU) (13).
Important!

Opening the engine control unit is prohibited!
Fig. C - 5 Engine control unit
C Repairs
PCR 2.0 DW10 TD 12/2005 C-5

C Repairs
C-6 PCR 2.0 DW10 TD 12/2005

2 Cleaning the high pressure connections
2.1 Special tools

Danger!
• Brush
regulations for accident prevention concerning • Suction pump
working with highly flammable or fire hazardous
• Degreasing agent
substances when working on the diesel fuel system.
• Cleaning bath
• Round adaptor for the suction pump
Danger!
The Engine Control Unit (ECU), injectors and 2.2 Preparatory work

Notice
regulations on accident prevention for high-voltage Clean the engine before working on the injection
devices! system to roughly clean the parts.
Do not direct the spray at the electrical connections!
Danger! That reduces the hazard of contaminations in the high

pressure system.
Comply with the safety regulations concerning • Protect the generator.

handling injection systems. • Remove the battery minus pole clamp.
(see "Conditions for working on the system")!
C Repairs
• Remove the engine cover.
2.3 Work process
Clean high pressure connections of the DCP, rail and

injectors which are affected by the repair with the
degreasing agent and at the same time suck up the
affected area.
• Clean the suction pump after use.
PCR 2.0 DW10 TD 12/2005 C-7

C Repairs
C-8 PCR 2.0 DW10 TD 12/2005

3 Installing and removing the high pressure lines.
Danger!

regulations for accident prevention concerning
Danger!

Comply with the safety regulations concerning

handling injection systems.
Important!
Any work on high pressure lines requires that they are

always replaced!
C Repairs
PCR 2.0 DW10 TD 12/2005 C-9

3.1 Special tools
• Plug set
• Torque wrenches
• Pipe line socket wrench,
e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)
Fig. C - 7 Pipe line socket wrench

C Repairs
Fig. C - 6 Plug set Fig. C - 8 Torque wrenches
C - 10 PCR 2.0 DW10 TD 12/2005

3.2 Removing high-pressure lines
• Remove the battery minus pole clamp.

• Pull plug (1) from the injectors.
• Pull plug (2) from the camshaft position sensor
• cable duct (3) and put aside.
Fig. C - 9 Remove supply plug
Notice
*
In order to dismantle the high pressure pipe to the

injector of the 3rd cylinder, the support (4) must be
removed first.
C Repairs
Fig. C - 10 Remove bracket
PCR 2.0 DW10 TD 12/2005 C - 11

Notice
*
In order to dismantle the high pressure pipe at the high

pressure pump, the support (5) must first be removed.
Fig. C - 11 Remove bracket
• Release the connection of the high pressure pipe

(6) at the rail.
C Repairs
Fig. C - 12 Remove high-pressure lines
C - 12 PCR 2.0 DW10 TD 12/2005

at the injector, in order to do this, counter hold at
(a).
Fig. C - 13 Release connection on injector

at the high pressure pump, in order to do this
counter hold at (b).
• Unscrew the union nut of the high pressure pipe at
the rail and at the injector or the high pressure
pump, lift off the high pressure pipe.
Important!
To prevent damaging the fuel system, close the C Repairs

connections at the rail, the injectors and the high
pressure pump with the plugs.
Fig. C - 14 Release connection on high-pressure pump
PCR 2.0 DW10 TD 12/2005 C - 13

3.3 Installing high-pressure lines
Important!

always replaced!
Install the high pressure lines the reverse order of

removal.
Tightening torques:
• High-pressure line coupling nut on rail 25 Nm

• High-pressure line coupling nut on injector: 25 Nm
• High-pressure line coupling nut on high-pressure
pump: 25 Nm
Important!
To complete work, check the connections for seal

tightness.
• Install the engine cover.

• Reinstall the battery minus pole clamp.
C Repairs
C - 14 PCR 2.0 DW10 TD 12/2005

4 Installing and removing the rail.
Danger!

Danger!


Important!

always replaced!
C Repairs
PCR 2.0 DW10 TD 12/2005 C - 15

4.1 Special tools
• Plug set
• Torque wrenches
e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)

C Repairs
C - 16 PCR 2.0 DW10 TD 12/2005

4.2 Removing rail

• Remove high-pressure lines (see "3.0 Installing
and removing the high pressure lines").
Important!
To prevent damaging the fuel system, close the

• Remove fuel temperature detector (1) support.
Fig. C - 18 Remove fuel temperature detector support.
• Pull plug off high pressure sensor (3).

• Loosen the oil vapour scavenge pipe (2) on the
camshaft cover and pull off.
• Unscrew bolts (4) and nuts (5) and remove the rail.
C Repairs
Fig. C - 19 Removing rail
PCR 2.0 DW10 TD 12/2005 C - 17

4.3 Installing the rail
Important!

always replaced!
• Install studs (6), if removed. Torque: 23 Nm

• Install the rail, screw bolts (4) and nuts (5) hand
tight (rail should still be movable).
• Attach high pressure lines to the injectors, hand
tighten union nuts on the rail and on the injectors.
• Assemble the high pressure pipe to the high
pressure pump, hand tighten union nut.
Fig. C - 20 Installing the rail

• Tighten the union nuts of the high pressure pipes
to the rail.
Notice
Welded rail installed until 11/2004 (A):

Torque: 25 Nm
Forged rail installed until 11/2004 (B):

C Repairs
Torque: 28 Nm
• Tighten nut (5).

Torque: 23 Nm
• Tighten bolt (4).
Torque: 23 Nm
Fig. C - 21 Rail labelling
C - 18 PCR 2.0 DW10 TD 12/2005

• Tighten high pressure pipe union-nut on the high
pressure pump, in order to do this, counter hold at
(b).
Fig. C - 22 High-pressure pump union nut.
• Tighten union nut of the high pressure pipe at the

injector, in order to do this, counter hold at (a).
Torque: 25 Nm
C Repairs
Fig. C - 23 Injector union nut
PCR 2.0 DW10 TD 12/2005 C - 19

• Push plug onto the fuel high pressure sensor
• Install fuel temperature detector support.
• Push the oil vapour scavenger pipe onto the
connection piece and secure with hose clamp.
• Install support (7).
Fig. C - 24 Install support
• Install cable duct support (8)

C Repairs
Fig. C - 25 Install support cable duct
C - 20 PCR 2.0 DW10 TD 12/2005

• Install the cable duct (9).
• Connect plug (10) to the injectors.
• Connect plug (11) to the the camshaft position
sensor
Important!
• To prevent an unintentional removal of the plug

due to vibrations, Make sure all plugs have
clicked in.
• Finally, check the seal tightness of all
connections.

Fig. C - 26 Connect the supply plug
C Repairs
PCR 2.0 DW10 TD 12/2005 C - 21

C Repairs
C - 22 PCR 2.0 DW10 TD 12/2005

5 Installing and removing the injectors.
Danger!

Danger!


devices!
Danger!


C Repairs
Important!

always replaced!
PCR 2.0 DW10 TD 12/2005 C - 23

5.1 Special tools
• Plug set
• Torque wrenches
e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)

C Repairs
C - 24 PCR 2.0 DW10 TD 12/2005

5.2 Injector installation

• Remove high pressure pipes to the injectors (see
"3.0 Installing and removing the high pressure
lines").
Important!

• Remove fuel return pipe (1). To do this push the

holding clamp (2) to the outside and pull out the
connection nipple (3).
• Unscrew the nuts (4), lift off the washers (5) and
pull out the injectors and the claw lugs.
Fig. C - 30 Remove injector
• Remove the plastic seal ring (6).
C Repairs
Fig. C - 31 Plastic seal ring
PCR 2.0 DW10 TD 12/2005 C - 25

• Remove the copper sealing ring (7)
Important!
To prevent causing damage to the fuel system:
• Close injector borings in the cylinder head.

• Close connections and nozzle on injector.
Fig. C - 32 Injector components

C Repairs
C - 26 PCR 2.0 DW10 TD 12/2005

5.3 Install injectors
Important!

always replaced!
• Clean the injector seats if necessary.

• Install the plastic seal ring (6).
Notice
Please acquire the plastic seal ring from the vehicle

manufacturer.
Fig. C - 33 Plastic seal ring
• Push the claw (8) onto the injectors (9).

• Insert the injectors with the new copper sealing
rings (7) in the cylinder head.
C Repairs
Fig. C - 34 Injector components
PCR 2.0 DW10 TD 12/2005 C - 27

Important!
Check O-rings on the connection nipple (3) and the

fuel return flow line (1).
If damaged or leaking, the fuel return-flow line unit

must be replaced.
Notice
*
• Grease the O-rings at the connection nipples

with an acid free fat.
• Push the connection nipples (3) into the bore on
the injectors
using a light backwards and forwards rotation
till they have engaged.
• Push on retaining clamps (2) and install fuel
Fig. C - 35 Install high-pressure lines return flow line.
• Install high pressure pipes, hand tighten union

nuts on the rail and injectors.
• Install new nuts (4) and washers (5) and tighten.
Torque: 30 Nm
• Tighten union nuts of the high pressure pipes on
the rail.
Torque: 25 Nm
• Tighten union nut of the high pressure pipe at the
injector, in order to do this, counter hold at (a).
C Repairs
Torque: 25 Nm
Proceed with the subsequent assembly in the reverse

order of the disassembly.
Important!
Fig. C - 36 Tighten connections • To prevent an unintentional removal of the plug

due to vibrations, make sure all plugs have
• Install the engine cover. clicked in.
• Reinstall the battery minus pole clamp. • Finally, check the seal tightness of all
connections.
C - 28 PCR 2.0 DW10 TD 12/2005

6 Installing and removing the high pressure pump.
Danger!

Danger!


Fig. C - 37 Plug set
Important!

always replaced!
6.1 Special tools
• Lifting chain
C Repairs
• Lifting beam
• Plug set
• Torque wrenches
e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)
• Pulley wheel set pin Fig. C - 38 Pipe line socket wrench
• Extractor tool for pulling off the drive wheel from

the high pressure pump gear-wheel
PCR 2.0 DW10 TD 12/2005 C - 29

Fig. C - 39 Torque wrenches Fig. C - 40 High pressure pump gear-wheel extractor
6.2 Remove high pressure pump

• Remove cable duct support (1).

• Remove synchronous belt.
C Repairs
Notice
Please read the respective vehicle manufacturer repair

manual for more information about removing the
synchronous belt.
• Unclip the fuel return flow pipe (2)

and remove from the connecting piece.
Fig. C - 41 Remove connections/attached parts
C - 30 PCR 2.0 DW10 TD 12/2005

• Unclip the fuel return flow pipe (3) and remove
from the connecting piece.
• in order to do this, dismantle high pressure pipe
(4), counter hold at (a).
• Pull off the connectors on volumetric control valve
(5) and pressure control valve (6).
Important!

Fig. C - 42 Remove high-pressure lines
• Loosen the nut (7), for this purpose utilize the

locking pin [8] for the belt pulley wheel.
C Repairs
Fig. C - 43 Remove the belt pulley wheel fixture
PCR 2.0 DW10 TD 12/2005 C - 31

• Pull off the drive wheel (9) of the high pressure
pump with the extractor tool (10).
• Dismantle the lower support of the high pressure
pump.
Fig. C - 44 Remove synchronous belt
• Unscrew the high pressure pump fixing-screws

(11) and remove the pump.
C Repairs
Fig. C - 45 Remove high pressure pump
C - 32 PCR 2.0 DW10 TD 12/2005

6.3 High pressure pump installation.
Install the high pressure pump in the reverse order of

removal.
Important!

always replaced!
Do not interchange the high pressure pump

connectors:
• Plug (6, white) to pressure control valve

• Plug (5, orange) to volumetric control valve
Tightening torques:
• Mounting bolts
High pressure pump: 23 Nm
Fig. C - 46 Connect plugs
• Drive wheel nut: 17 Nm
• Coupling nut
High pressure line on rail: 25 Nm
• Coupling nut
High-pressure line on high-pressure pump: 25 Nm
Important!
• To prevent an unintentional removal of the plug
C Repairs
due to vibrations, make sure all plugs have
clicked in.
• Finally, check the seal tightness of all
connections.

PCR 2.0 DW10 TD 12/2005 C - 33

C Repairs
C - 34 PCR 2.0 DW10 TD 12/2005

8 Installing and removing the pressure control valve
Danger!

Danger!


Important!

always replaced!
C Repairs
PCR 2.0 DW10 TD 12/2005 C - 39

8.1 Special tools

e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)
• Torque wrenches
• Torque wrench adapter
• Special tool to remove and
tighten the pressure control valve
• Pressure control valve repair kit

C Repairs
Fig. C - 47 Torque wrenches Fig. C - 49 Torque wrench adapter
C - 40 PCR 2.0 DW10 TD 12/2005

Special tool to remove and tighten the pressure control
valve.
Fig. C - 50 Special tool pressure control valve
Pressure control valve repair kit
C Repairs
Fig. C - 51 Pressure control valve repair kit
PCR 2.0 DW10 TD 12/2005 C - 41

8.2 Removing the pressure control valve

• Remove the engine cover. Important!

• Pull plug (1) from the pressure control valve.

• Pull plug (2) from the volumetric control valve.
• Create some work space to remove the pressure
control valve (e.g. by removing the cables
pipelines above).
Notice
Please refer to the vehicle manufacturer

documentation for more information on exposing the
pressure control valve.
Fig. C - 52 PCV characteristics (example)
Notice
Before reinstalling the new pressure control valve,

look at the identification label to identify the pressure
control valve type.
C Repairs
Fig. C - 53 Pull plug
C - 42 PCR 2.0 DW10 TD 12/2005

• Remove the pressure control valve (3) with special
tool (4).
Important!
When removing the pressure control valve, make sure

you do not damage the plug connection to the
volumetric control valve!
• Manually unscrew the pressure control valve (3)

from the high pressure pump (5).
Important!
To prevent damaging the fuel system, be sure to

comply with the safety instructions on handling Fig. C - 54 Remove pressure control valve
injection systems (see "Conditions for working on
system")!
Cleanliness rules:

• Directly after dismantling all connections of the
high pressure system the openings are to be
system.
C Repairs
PCR 2.0 DW10 TD 12/2005 C - 43

8.3 Installing high-pressure lines
• Manually screw in the pressure control valve.

• Tighten the pressure control valve with the special
tool.
Torque:
• Pressure control valve on

High pressure pump: 28 Nm
Important!

always replaced!

connectors:
Fig. C - 55 Pressure control valve

• Plug (1, white) pressure control valve
• Plug (2, orange) volumetric control valve
To prevent an unintentional removal of the plug due to
vibrations, make sure all plugs are properly seated. To
complete work, check the connections for seal
tightness.

C Repairs
Important!
Finally, perform a pressure control valve function-test

(see chapter B in section "4.3.1 Checking the pressure
control valve").
C - 44 PCR 2.0 DW10 TD 12/2005

9 Installing and removing the volumetric control valve
Danger!

Danger!


Important!

always replaced!7
C Repairs
PCR 2.0 DW10 TD 12/2005 C - 45

9.1 Special tools

e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)
• Torque wrenches
• Special tool to remove and
Tighten the volumetric control valve
• Volumetric control valve repair kit

C Repairs
Fig. C - 57 Torque wrenches Fig. C - 59 Torque wrench adapter
C - 46 PCR 2.0 DW10 TD 12/2005

Special tool to remove and
tighten the volumetric control valve.
Fig. C - 60 Special tools for the volumetric control valve
Volumetric control valve repair kit
C Repairs
Fig. C - 61 Volumetric control valve repair kit
PCR 2.0 DW10 TD 12/2005 C - 47

9.2 Removing the volumetric control valve

• Remove the engine cover. Important!

• Pull plug (1) from the pressure control valve.

• Pull plug (2) from the volumetric control valve.
• Create some work space to remove the volumetric
control valve (e.g. by removing the cables
pipelines above).
Notice
Please refer to the vehicle manufacturer

documentation for more information on exposing the
volumetric control valve.
Fig. C - 62 VCV characteristics (example)
Notice
Before reinstalling the new volumetric control valve,

look at the identification label to identify the volumetric
control valve type.
C Repairs
Fig. C - 63 Pull plug
C - 48 PCR 2.0 DW10 TD 12/2005

• Remove the volumetric control valve (3) with
special tool (4).
• Manually unscrew the volumetric control valve (3)
Important!
To prevent damaging the fuel system, be sure to

comply with the safety instructions on handling
injection systems (see "Conditions for working on
system")!
Cleanliness rules:

• Directly after dismantling all connections of the
high pressure system the openings are to be Fig. C - 64 Remove the volumetric control valve
system.
C Repairs
PCR 2.0 DW10 TD 12/2005 C - 49

9.3 Volumetric control valve installation
• Manually screw in the volumetric control valve.

• Tighten the volumetric control valve with the
special tool.
Torque:
• Volumetric control valve on high pressure pump:

12 Nm
Important!

always replaced!

connectors:
Fig. C - 65 Volumetric control valve

• Plug (1, white) pressure control valve
• Plug (2, orange) volumetric control valve
To prevent an unintentional removal of the plug due to
vibrations, make sure all plugs are properly seated. To
complete work, check the connections for seal
tightness.

C Repairs
Important!
Finally, perform a volumetric control valve function-

test (see chapter B in section "4.3.1 Checking the
pressure control valve and VCV").
C - 50 PCR 2.0 DW10 TD 12/2005

10 Installing and removing the engine control unit
Danger! Danger!
The Engine Control Unit (ECU), injectors and When working on the diesel fuel system, the risk of
energized parts of the pump carry high voltages! injury exists due to the highly pressurized fuel.
Danger of death if touched! Comply with the safety regulations concerning

When working on these parts comply with the (see "Conditions for working on the system")!
devices!
10.1 Removing the engine control unit

• Remove the cover of the control unit box.
• Unscrew the fixing screws of the engine control
unit and pull out the engine control unit.
• Pull out the connectors at the engine control unit
in the consecutive sequence A - B - C, in order to
do this swing each of the securing stays (1)
through 90°
Important!

Opening the engine control unit is prohibited! C Repairs
Fig. C - 67 Removing the engine control unit

10.2 Installing the engine control unit:
Proceed with the assembly in the reverse order of the

disassembly.
Important!
Follow this procedure when installing the plugs: first,

push the plug in all the way, then close the securing
stay.
PCR 2.0 DW10 TD 12/2005 C - 51

C Repairs
C - 52 PCR 2.0 DW10 TD 12/2005

11 Injector system startup
Danger!


11.1 Initial start in vehicle
• The fuel system must be filled automatically. The

engine is supplied from the engine with 2/3 filled
filter.
Filling of the fuel line from the tank up to the fuel
filter.
• Operate the hand pump (1) which is installed in the
fuel supply line 3 to 4 times
Notice
In order to operate the pump, it must be fully enclosed

in the hand and then squeezed tightly.
C Repairs
• The starter shall then be operated for a maximum
of 20 seconds. Should the engine not start, then
the operation described in 2 shall be repeated
once more. Should the engine still not start then a Fig. C - 68 Hand pump
fault analysis will have to be performed.
PCR 2.0 DW10 TD 12/2005 C - 53

11.2 Initial start after a repair / Start after an empty tank
To facilitate the venting of air from the fuel supply line

after a repair, or when the fuel tank has been run dry,
A hand pump (1) has been integrated within the engine
compartment in the fuel supply line.
• Check whether there is enough fuel in the fuel

tank.
In the case of a tank which has been run dry, at
least 5 L of fuel should be poured into the tank.
• Operate the hand pump (1) until the pump is
clearly filled with fuel and bubble-free fuel is
present in the return line.
Notice
In order to operate the pump, it must be fully enclosed

in the hand and then squeezed tightly. Fig. C - 69 Hand pump
• Subsequently pump approx. five more time.

• The starter shall then be operated for a maximum
of 20 seconds. Should the engine not start, then
the operation described in 2 shall be repeated
once more. Should the engine still not start then a
fault analysis will have to be performed.
C Repairs
C - 54 PCR 2.0 DW10 TD 12/2005

12 Special tools / Repair kits
12.1 Special tools
Torque wrenches
Fig. C - 70 Torque wrenches
C Repairs
Pipe line socket wrench, e.g. HAZET:
- no. 4550 (3/8"-drive)
- no. 4550 (-1/2"-drive)
PCR 2.0 DW10 TD 12/2005 C - 55

Special tool pressure control valve
Siemens VDO catalogue number: X39-800-200-001

Fig. C - 72 Special tool pressure control valve
C Repairs
Special tools for the volumetric control valve
Fig. C - 73 Special tools for the volumetric control valve
C - 56 PCR 2.0 DW10 TD 12/2005

Torque wrench adapter
Fig. C - 74 Torque wrench adapter
C Repairs
High pressure pump gear-wheel extractor
(Please purchase from vehicle manufacturer)
Fig. C - 75 High pressure pump gear-wheel extractor
PCR 2.0 DW10 TD 12/2005 C - 57

12.2 Repair kits
Plug set
Siemens VDO catalogue number: X39-800-300-003Z

Fig. C - 76 Plug set
C Repairs
C - 58 PCR 2.0 DW10 TD 12/2005

Repair kit high pressure sensor
Siemens VDO catalogue number: in preparation
Fig. C - 77 High pressure sensor repair kit
C Repairs
Fig. C - 78 Pressure control valve repair kit
PCR 2.0 DW10 TD 12/2005 C - 59


Fig. C - 79 Volumetric control valve repair kit
12.3 Other accessories
• Injector protection socket
Siemens VDO catalogue number:
X39-800-100-040
• Injector copper seal ring
X11-800-002-001Z
(Bag with 100 each)
C Repairs
• Injector plastic seal ring

• Clamp for return on injector
(Leakage-Clip)
X11-800-001-003Z
C - 60 PCR 2.0 DW10 TD 12/2005

D DCP inspection / repair
1 Conditions for inspection / repair
1.1 Recommendations
Important!

agents.
1.2 Safety instructions
Introduction: Safety instructions:

Important! 1500 bar), which can prevail in the fuel system, the
following instructions are to be observed::
The safety instructions apply to all work performed
high pressure pump test-stand. • Do not work near flames or sparks
• Never work on high pressure fuel systems with
the motor running
The following apply to work on the high pressure pump:
the relevant regulations and stipulations regarding: • Wait about 30 seconds after switching the motor
• accident prevention • Smoking is absolutely prohibited in the immediate
• environmental protection vicinity of the high pressure system during work
The work must be carried out by trained professional

Notice
and who take special measures to ensure that these are The waiting time is necessary so that the pressure
followed. within the high pressure fuel system has a chance to
D Inspection / repair
PCR 2.0 DW10 TD 12/2005 D-1

Preparatory work:
Danger! Clean the assembly before working on the high pressure

pump.
injury exists due to the highly pressurized fuel. You need to perform a received condition test on the test
stand before dismantling the high pressure pump (see
external test specification)
Danger!
Important!
concerning working with highly flammable or fire
hazardous substances when working on the diesel When moving the Diesel Common Rail Pump, do not
fuel system. carry the pump by the connectors, pipe connections or
on the volumetric control valve or pressure control
valve housings.
Work on the test stand: If you do, you can cause damage!

fuel system.
• Always stay outside the range of a possible jet of Important!
fuel since this can cause serious injuries
Cleanliness rules:
Danger! • Workers must wear clean clothing.

• The following work (dismantling and
The Engine Control Unit (ECU), injectors and reassembly of the high pressure pump) may
energized parts of the pump carry high voltages! only be performed in the "Clean Cabinet"!
Safety torque:
• Only use periodically checked torque wrenches.
regulations on accident prevention for high-voltage • Always comply with tightening torques for the
devices! high pressure
Comply with the pressure control valve,
volumetric control valve, displacement units,
Work area: high-pressure pump flange and connections.

• parts which are in for repair must be stored gin a
dust free environment.
D-2 PCR 2.0 DW10 TD 12/2005

2 Cleaning before inspection / repair
2.1 Recommendations 2.2 Special tools
• Brush
Important! • Suction pump

• Cleaning bath
agents.
Fuel line cleaners and metal coating agents can cause • Round adaptor for the suction pump
2.3 Preparatory work

Danger!
When working on these parts comply with the Notice

working with highly flammable or fire hazardous Do a thorough cleaning before working on the high
substances when working on the diesel fuel system. pressure pump.
That reduces the hazard of contamination in the high

pressure system.
Danger!
Before cleaning, plug the high pressure pump
When working on the diesel fuel system, the risk of connections with the plug set.
Comply with the safety regulations concerning 2.4 Work process

(see "Conditions for inspection / repair")!
Clean the high-pressure pump with the degreasing agent
and draw off from the area at the same time.
• Clean the suction pump after use. D Inspection / repair
PCR 2.0 DW10 TD 12/2005 D-3

D-4 PCR 2.0 DW10 TD 12/2005

3 Disassembling the high-pressure pump.
Important!
All jobs described in the following are based on

working on a previously removed high-pressure pump.
Danger!

Danger!
Caution: danger of injury due to pinching or bumping

when working on the removed high-pressure pump.
The assembly appliance must be firmly attached and

be placed on a non-slip base (workbench or similar).
Comply with the prevailing safety regulations from the

competent trade associations for workshop
operations!
PCR 2.0 DW10 TD 12/2005 D-5

3.1 Special tools
• Torque wrenches
• Special tool to remove and tighten the pressure
control valve
• Special tool to remove and tighten the volumetric
control valve
• Assembly jig to carry out work on on the removed
high pressure pump
• Extractor tool for pulling off the cam disk / shaft
Fig. D - 2 Special tool pressure control valve

Fig. D - 1 Torque wrenches Fig. D - 3 Special tools for the volumetric control valve
D-6 PCR 2.0 DW10 TD 12/2005

Fig. D - 4 Torque wrench adapter
Extractor tool for pulling off the cam disk / shaft
Fig. D - 5 Extractor
PCR 2.0 DW10 TD 12/2005 D-7

Assembly jig to carry out work on the removed high
pressure pump.
1. Pump specific support

2. Basic assembly jig
Fig. D - 6 Assembly jig
3.2 Clamping the high-pressure pump.
• Mount the pump-specific support (1) on the

assembly jig (2).
• Clamp the high pressure pump (3) to the assembly

jig by screwing the thumbscrews (4) into both
existing holes in the high pressure pump
enclosure.
Fig. D - 7 High pressure pump clamped
D-8 PCR 2.0 DW10 TD 12/2005

3.3 Removing the Pressure Control Valve (PCV)
• Remove the pressure control valve (5) with special

tool (6).
• Manually unscrew the pressure control valve (5)
Important!
If you remove the pressure control valve, you must

replace it!
Fig. D - 8 Remove pressure control valve
3.4 Removal Volumetric Control Valve (VCV)
• Remove the volumetric control valve (7) with

special tool (8).
• Manually unscrew the volumetric control valve (7)
Important!
If you remove the volumetric control valve, you must

replace it!
Fig. D - 9 Remove the volumetric control valve
PCR 2.0 DW10 TD 12/2005 D-9

3.5 Removing the fuel connections
• Loosen the fuel intake (9) hollow-screw and

remove it.
• Loosen fuel return line screw (10) and remove it.
• Loosen and detach the high pressure connection
(11)
Fig. D - 10 High-pressure pump connections
• Remove the panel (12).

Fig. D - 11 Panel behind high-pressure connector
D - 10 PCR 2.0 DW10 TD 12/2005

3.6 Remove displacement units
Danger!
The displacement units are spring mounted and carry

current (are live)!
The parts can jump out and cause injuries!
Therefore, counter-hold the displacement units when

removing the fixing screws.
Fig. D - 12 Displacement unit labelling
• Loosen and remove the fastening screws (13) in

the first- displacement unit (A).
• Completely remove the displacement unit (A).
Fig. D - 13 Displacement unit
PCR 2.0 DW10 TD 12/2005 D - 11

Notice
To remove the displacement units (B) and (C), swivel

the assembly appliance by 120 °.
Fig. D - 14 Swiveled assembly appliance
3.7 Remove high pressure pump flange
• Tilt the high-pressure pump (3) in the assembly

appliance (2) by 90 ° to the rear.
• Loosen and detach the high pressure pump flange
(15) fastening screws (14).
• Carefully pull out the high pressure pump flange
(15) toward the top.
Important!
Do not twist the high pressure pump flange when

removing because you do not want to change the
position of the adjusted cam disk.
• Remove the flange seal.
Fig. D - 15 High pressure pump tilted
D - 12 PCR 2.0 DW10 TD 12/2005

3.8 Remove the Internal Transfer Pump (ITP)
Notice
Because of the concave and convex grind in the

internal transfer pump, you must mark its assembly
position.
• Mark the assembly position of the internal transfer

pump (16) with a water-soluble marker.
• Completely remove the internal transfer pump (16)
(with ring, rotor and blades).
• Remove the cylinder disk / clutch disk.
Fig. D - 16 Removing the internal transfer pump
3.9 Remove pump shaft / cam disk / eccentric
• Put on the extractor tool (17) for pulling off the cam
disk.
• Screw the extractor (17) with the ring nut (18) to
the shaft.
• Unscrew the extractor (17) thumbwheel (19) to the
left.
The shaft will be pulled out of the high pressure
pump enclosure.
• Remove the cam disk, shaft and eccentric.
Fig. D - 17 Extractor on shaft
PCR 2.0 DW10 TD 12/2005 D - 13

D - 14 PCR 2.0 DW10 TD 12/2005

4 Component testing
After disassembling the high pressure pump, the high

pressure pump elements have to be checked for wear
and tear before reassembling or replacing components.
Notice
When making measurements with an inside caliper or

micrometer, do not bend the measuring instruments
as this can lead to erroneous results.
4.1 Measure the pump shaft bearing
• Using the inside caliber, measure the bearing of

the pump shaft:
Nominal value: 20,011 mm
tolerance: +0,030 mm
Important!
Replace the high pressure pump if the tolerance is

exceeded.
Fig. D - 18 Pump shaft bearing

PCR 2.0 DW10 TD 12/2005 D - 15

4.2 Measure eccentric

the eccentric:
tolerance: + 0,030 mm
Important!
If the tolerance is exceeded, replace the eccentric

including all displacement units as a set.
Fig. D - 19 Eccentric bearing
4.3 Measure cam disk

the cam disk:
tolerance: + 0,030 mm
Important!
Replace the high cam disk if the tolerance is

exceeded.
Fig. D - 20 Cam disk bearing
D - 16 PCR 2.0 DW10 TD 12/2005

4.4 Measure pump shaft
• Perform a visual inspection of the threading on the

shaft head.
• Measure the pump shaft on the mating surface to
the flange bearing with a micrometer:
tolerance: - 0,013 mm
Notice
Perform a measurement at two points offset by 90 °.
Important!

exceeded.
Fig. D - 21 Measure the pump shaft bearing (front)
• Measure the pump shaft on the mating surface to

the housing bearing with a micrometer:
Notice
Important!

exceeded.
Fig. D - 22 Measure the pump shaft bearing (rear)
PCR 2.0 DW10 TD 12/2005 D - 17

• Use a micrometer to measure the cams on the
pump shaft:
Notice
Important!

exceeded.
Fig. D - 23 Pump-shaft cams
4.5 Check / measure the high-pressure pump-flange
• Check the internal transfer pump support-area on

the high-pressure pump-flange for signs of wear.
Notice
Visually check the surface for sign of start-up wear and

scoring and measure at to points offset by 90 °.
Important!
Replace the high-pressure pump-flange if the

tolerance is exceeded.

the internal transfer pump:

Fig. D - 24 Internal transfer pump bearing tolerance: + 0,030 mm
D - 18 PCR 2.0 DW10 TD 12/2005

5 Assembling the high-pressure pump
Important!
All jobs described in the following are based on

working on a previously removed high-pressure pump.
Danger!

Danger!
Caution: danger of injury due to pinching or bumping

when working on the removed high-pressure pump.
The assembly appliance must be firmly attached and

be placed on a non-slip base (workbench or similar).
Comply with the prevailing safety regulations from the

competent trade associations for workshop
operations!
PCR 2.0 DW10 TD 12/2005 D - 19

5.1 Installation eccentric / pump shaft / cam disk
Notice
Replace the entire high pressure pump if the shaft is

defective. It is not possible to repair!
• Prepare tested or new eccentrics (20), shaft (21)

and cam disk (22).
Notice
When inserting the shaft, make sure the shaft does

not get tilted in the housing bearing.
• Insert the eccentric (20) and shaft (21).
Fig. D - 25 Eccentric
Notice
Do not damage the rubber ring when pressing the cam

disk into the housing.
• Place the cam disk (22) on the shaft (21) and press
into the pump enclosure.
• Align the cam disk (22).
Important!
If the cam disk is misaligned, the high pressure pump

will malfunction.
Fig. D - 26 Cam disk and shaft
D - 20 PCR 2.0 DW10 TD 12/2005

5.2 Install the internal transfer pump
• Get the checked or new high-pressure pump-

flange (16) ready.
Important!
Use new screws and new seals when mounting to

ensure the high pressure pump is leakproof.
Fig. D - 27 High pressure pump flange seal set
• Insert the cylinder roller / tappet into the pump

shaft.
• Insert and align the entire internal transfer pump
(16) (ring, rotor, blade).
• Position a new flange seal.
Notice
Pay attention to the installation position marking when

using the old internal transfer pump.
The holes on the internal transfer pump outer-ring and

the cam disk must lay exactly over each other.
Fig. D - 28 Internal transfer pump reassembled
PCR 2.0 DW10 TD 12/2005 D - 21

• Set the high pressure pump flange (15) onto the
high pressure pump enclosure (3).
Important!
• Make certain the flange seal is well seated!

• Pay attention to the guide-pin click-stop position
in the cam disk!
Fig. D - 29 High-pressure pump flange
• Put on the high pressure pump flange (15) fixation

screws (14) and tighten in the prescribed
sequence.
Important!
Tightening sequence: 1, 3, 5, 2, 4, 6 of the fastening

screws must absolutely be complied with!
Torque:
• High pressure flange screw on

high pressure pump housing: 10 Nm
Fig. D - 30 Flange screw tightening sequence

D - 22 PCR 2.0 DW10 TD 12/2005

5.3 Installing the displacement units
Important!
Always use new seals and screws to ensure the high

pressure pump is leakproof.
Notice
The seal set contains seals and screws for all 3

displacement units.
Fig. D - 31 Displacement unit seal set
• Tilt the high-pressure pump (3) in the assembly

appliance (2) to the front.
• Insert the displacement unit (A) into the high
pressure pump (3), pull down in one motion,
counter-hold and fixate with a fastening screw
(13).
• Insert and ready the rest of the fastening screws
(13).
• Tighten the fastening screws (13) using the
prescribed torque.
Torque:
• Screw the displacement unit to the high pressure

pump: 14 Nm
Notice
To install the other two displacement units, swivel the

assembly appliance 120 °. Fig. D - 32 Insert the displacement unit
PCR 2.0 DW10 TD 12/2005 D - 23

5.4 Installing the fuel connections
• Insert the fuel intake (9) using new seals, align and
tighten using the special tool.
Torque:
• Fuel intake hollow screw on

high pressure pump: 16 Nm
• Insert the fuel return line screw (10) and tighten.
Torque:
• Fuel return line screw on

Notice
Always replace the fuel return line screws.

Fig. D - 33 High pressure pump connection repair kit
• Insert a new panel with washers into the high

pressure connection (11).
Important!
If you do not insert the panel, the high pressure pump

will malfunction.
• Insert ant tighten the high pressure connection

(11).
Torque:
• High pressure connection to

Fig. D - 34 Tighten the high pressure pump connections
D - 24 PCR 2.0 DW10 TD 12/2005

Fig. D - 35 Panel behind high-pressure connector
5.5 Installing the Volumetric Control Valve (VCV)
• Manually screw in the volumetric control valve (7)

into the high pressure pump (3).
• Tighten the volumetric control valve (7) with
special tool (8).
Torque:
• Volumetric control valve on

Important!
If you remove the volumetric control valve, you must

replace it!
Fig. D - 36 Tighten the volumetric control valve
PCR 2.0 DW10 TD 12/2005 D - 25

5.6 Installing the Pressure Control Valve (PCV)
• Manually screw in the pressure control valve (5)

into the high pressure pump (3).
• Tighten the pressure control valve (5) with special
tool (6).
Torque:
• Pressure control valve on

Important!
If you remove the pressure control valve, you must

replace it!
Fig. D - 37 Tighten the pressure control valve
5.7 Replace / exchange the identification place
• Locate the old identification and use a suitable tool

to remove it.
• Clean the surface.
• Attach a new identification plate in the same
position.
Fig. D - 38 Identification plate position
D - 26 PCR 2.0 DW10 TD 12/2005

5.8 Check the high pressure pump on the Hartrigde AVM2-PC
5.8.1 Check the high pressure pump
• Inspect the mounted high pressure pump on the

test stand (see external inspection specifications).
Important!
The high pressure pump may be installed only after

inspection on the high pressure pump test stand.
Fig. D - 39 High pressure pump test stand.
5.8.2 Close all pump connections
• After installation, all connections must be blocked

with the plugs.
Fig. D - 40 Close connections
PCR 2.0 DW10 TD 12/2005 D - 27

D - 28 PCR 2.0 DW10 TD 12/2005

6 Special tools / spare parts/ repair parts
6.1 Special tools
Torque wrenches
Fig. D - 41 Torque wrenches
Pipe line socket wrench, e.g. HAZET:
- no. 4550 (3/8"-drive)

- no. 4550 (-1/2"-drive)
Fig. D - 42 Pipe line socket wrench
PCR 2.0 DW10 TD 12/2005 D - 29

Special tool pressure control valve

Fig. D - 43 Special tool pressure control valve
Special tools for the volumetric control valve
Fig. D - 44 Special tools for the volumetric control valve

D - 30 PCR 2.0 DW10 TD 12/2005


Fig. D - 45 Torque wrench adapter
High pressure pump shaft extractor

Fig. D - 46 High pressure pump shaft extractor
PCR 2.0 DW10 TD 12/2005 D - 31

Assembly jig to carry out work on the removed high
pressure pump.
1. DCP support DW10 TD

X39-800-200-009
2. Assembly jig (basic jig)
X39-800-200-005
Fig. D - 47 Assembly jig for high pressure pump.
6.2 Spare parts

Plug set

Fig. D - 48 Plug set
D - 32 PCR 2.0 DW10 TD 12/2005


Fig. D - 49 Pressure control valve repair kit

Fig. D - 50 Volumetric control valve repair kit
PCR 2.0 DW10 TD 12/2005 D - 33

6.3 Repair parts
High pressure pump flange seal set
Fig. D - 51 High pressure pump flange seal set
Displacement unit seal set


Fig. D - 52 Displacement unit seal set
D - 34 PCR 2.0 DW10 TD 12/2005

Internal transfer pump repair kit

Fig. D - 53 Internal transfer pump repair kit
Cam disk repair kit

Fig. D - 54 Cam disk repair kit
PCR 2.0 DW10 TD 12/2005 D - 35

High pressure pump connection repair kit

Fig. D - 55 High pressure pump connection repair kit
Displacement unit / eccentric repair kit

Fig. D - 56 Displacement unit / eccentric repair kit
D - 36 PCR 2.0 DW10 TD 12/2005

6.4 Other accessories
• Injector protection socket
Siemens
VDO catalogue number: X39-800-100-040
• Injector copper seal ring
Siemens
VDO catalogue number: X11-800-002-001Z
(Bag with 100 each)
• Injector plastic seal ring
• Clamp for return on injector (Leakage-Clip)
Siemens
VDO catalogue number: X11-800-001-003Z
PCR 2.0 DW10 TD 12/2005 D - 37

D - 38 PCR 2.0 DW10 TD 12/2005
Index
A Cleanliness rules: B-66
Index
Close pump connections D-27
Accelerator pedal A-3
Component testing D-15
Accelerator pedal sensor A-3
Coolant temperature sensor A-3
Accessories D-37
Crankshaft sensor A-3
Actuator A-13
Actuator tests B-103
D
Air filters A-3
DCP A-5, A-21
Admission pressure control valve A-23
B Components A-3
Cutaway view A-21
Battery minus pole C-11, C-14, C-17, C-21, C-25, C-28,
Displacement unit A-21
C-30, C-33, C-42, C-44, C-48, C-50
Fuel delivery A-24
Fuel feed A-21, A-23
C Fuel return A-21
Fuel suction A-24
Cable duct C-11, C-20, C-21 Function chart A-22
High pressure elements A-24
Cam disk
Installation D-20 High pressure pump element A-21, A-23
High-pressure connection A-21, A-23
Removal D-13
Identification A-25
Camshaft sensor A-3 Internal Transfer Pump (ITP) A-21, A-23
Catalytic converter A-3 Pressure Control Valve PCV A-21, A-23
Transmission ratio A-1
Check injectors B-89 Volumetric Control Valve VCV A-21, A-23
Prerequisites B-89
Symptoms B-89 Diesel Common Rail Pump A-7, A-21
Test steps B-91 see also DCP
Check internal fuel transfer system Displacement units

Prerequisites B-71 Installation D-23
Symptoms B-71 Removal D-11
Test steps B-71
Check internal transfer pump B-72 E
Prerequisites B-72
Symptoms B-72 Eccentric
Test steps B-72 Installation D-20
Removal D-13
Check low pressure system B-71
ECU A-43
Check rail pressure control circuit B-82
Board A-43
Rail pressure diagram B-86
Design A-43
Symptoms B-82
Housing A-43
Check rail pressure control circuit Inspection Identification A-51
steps B-83 Input signals A-44
Output signals A-44
Clean
Pin assignments A-48
high pressure connection C-7
High pressure pump D-3 Edge filter A-23
Preparatory work D-3
Recommendations D-3
Work process D-3
PCR 2.0 DW10 TD 12/2005 1

Engine control unit C-5, C-51 High pressure pump C-29
Installation C-51 Assembly D-19
Index
Removal C-51 Clamping D-8

see also ECU A-43 Disassembly D-5
Drive wheel C-32
Error code
Listing B-49 Installation C-33
Plug C-33, C-44, C-50
Exhaust emissions A-1 Removal C-30
Exhaust return valve A-3 Verify D-27
High Pressure Pump (HPP) A-5, A-7
F High pressure sealing surface A-16
High pressure section A-5
Fault clearance B-13
High pressure sensor A-3, A-39, C-17, C-35
Final stage A-43
Characteristic curve A-41
Flush valve A-23 Connection A-39, A-40
Fuel connections Connector housing A-39, A-40
Installation D-24 Contact spring A-39, A-40
Removal D-10 Cover A-39, A-40
Cutaway view A-39
Fuel feed A-7 EMA (Electronic Module Assembly) A-39, A-40
Loosen D-10 EMC sign A-39, A-40
Fuel feed pipe C-30 Fuel pressure A-41
Function A-40
Fuel filter A-3
Identification A-42
Fuel return A-7, A-23 Input and output signals A-44
Loosen D-10 Membrane A-39, A-40
Metal flange A-39, A-40
Fuel return pipe C-25, C-31
Metal housing A-39, A-40
Fuel supply A-5, A-6 Pinning A-41
Diagram A-6 Pressure connection A-39, A-40
Fuel tank A-3 Voltage A-41
Fuel temperature sensor A-3 High pressure storage

see also rail A-37
Fuel temperature-detector C-17
High-pressure lines A-35, C-9
Configuration A-35
G Identification A-35
Installation C-14
Glow plug relay A-3 Removal C-11
High-pressure pump flange
H Removal D-12
Hand pump A-3, C-53, C-54

I
HD tolerance A-17
High pressure bore A-16 Identification plate
Replacement D-26
High pressure chamber A-16
Ignition sequence A-3
High pressure connection
Loosen D-10 Injection amount incorrect B-93
Prerequisites B-93
Symptom B-93
Test steps B-94
2 PCR 2.0 DW10 TD 12/2005

Injector A-3, A-7, A-9 M
Actuator A-13
Index
Anchoring attachment C-25, C-27 Main injection A-1
Control characteristics A-12, B-90
Mass air flow meter A-3
Control piston A-10
Copper seal C-27 Measure
Copper seal ring C-26, C-60, D-37 Cam disk D-16
Drive unit A-14 Eccentric D-16
Electrical connection A-9 High-pressure pump flange D-18
Fuel return A-9, A-10 Pump shaft D-17
Function A-11 pump shaft position D-15
High pressure chamber nozzle A-10
High pressure connection A-9, A-10
Identification A-19
N
Injector head A-9, A-15
Needle guide A-16
Injector nozzle A-9, A-16
not triggered: A-11 Needle seat A-16
Nozzle needle A-10 Nozzle body A-16
Nozzle retaining nut A-9
Piezo actuator A-9, A-10 Nozzle needle A-16
Piezo stack A-13 Nozzle shaft A-16
Pinning A-19
Nozzle shoulder A-16
Plastic seal ring C-25, C-27, C-60, D-37
Plug connector to Engine Control Unit (ECU)
A-10 O
Protection socket C-60, D-37
Spray hole A-10 Operating conditions
triggered A-11 1000/min, 1st gear B-7
Valve mushroom A-10 2000/min, 1st gear B-8
Valve piston A-10 2000/min, without load B-5
4000/min, without load B-6
Injector control A-45
AC/DC - converter A-45 Cold idle B-3
Control IC A-45 Ignition on B-2
Discharge timing resistance A-45 Warm idle B-4
Microprocessor A-45
Injector system C-53 P
Hand pump C-53, C-54
PCV A-31
Injectors C-23 Anchor A-31
Installation C-27 Characteristic curve A-33
Removal C-25 Cutaway view A-31
Internal transfer pump Function A-32
Installation D-21 Identification A-34
Removal D-13 not triggered: A-32
Pin A-31
Internal Transfer Pump (ITP) A-5, A-7
Pinning A-33
Solenoid A-31
L Spring A-31
triggered A-32
Leakage-Clip C-60, D-37 Valve float A-31
Valve seat A-31
Lever A-10
Piezo actuator
see also actuators A-13
PCR 2.0 DW10 TD 12/2005 3

Piezo actuators S
see also actuators A-9
Index
Piezo charge A-46 Safety instructions B-65, C-1

Cleanliness rules: C-2
Piezo discharge A-47 Introduction C-1, D-1
Piezo injector Preparatory work C-2, D-2
see also injectors A-5, A-9 Work area B-66, C-2, D-2
Piezo stack Safety torque B-66
Design A-13 Seal set
Power stage A-43 Displacement unit D-34
High-pressure pump flange D-34
Preinjection A-1
Special tool D-3
Pressure control valve A-3, C-31, C-39
Installation C-44, D-26 Special tools C-7, C-10, C-16, C-24, C-29, C-40, C-46,
Removal C-42, D-9 C-55, D-3, D-6, D-29
see also PCV A-5, A-31 Assembly appliance D-6
Brush C-7, D-3
Pressure Control Valve (PCV) A-7
Cam disk extractor D-6
Pressure regulating valve A-3 Cleaning bath C-7, D-3
Degreasing agent C-7, C-60, D-3, D-37
Pump shaft
Installation D-20 High pressure pump gear-wheel extractor C-29
Removal D-13 High pressure pump shaft extractor D-31
Lifting beam C-29
Lifting chain C-29
R Pipe line socket wrench C-10, C-16, C-24,
C-29, C-40, C-46, C-55, D-29
Rail A-3, A-7, A-37, C-15 Plug set C-10, C-16, C-24, C-29
Connections A-37 Pressure control valve C-56, D-6, D-30
Forged rail C-18 Pulley wheel set pin C-29
Identification A-38 Round adaptor for the suction pump C-7, D-3
Installation C-18 Special tool pressure control valve C-40
Removal C-17 Special tools for the volumetric control valve
Welded rail C-18 C-46
Rail pressure current diagram B-76 Suction pump C-7, D-3
Torque wrench adapter C-40, C-46, C-57, D-6,
Remove the camshaft position sensor C-11, C-21 D-31
Remove the engine cover C-11, C-14, C-17, C-21, C-25, Torque wrenches C-10, C-16, C-24, C-29, C-40,
C-28, C-30, C-33, C-42, C-44, C-48, C-50 C-46, C-55, D-6, D-29
Volumetric control valve C-56, D-6, D-30
Repair kit C-58
Cam disk D-35 Spray hole A-16
Displacement unit / eccentric D-36 Spray holes A-17
High pressure sensor C-59 Conicity A-17
High-pressure pump connections D-36
Internal transfer pump D-35 Start behavior B-9
Plug set C-58, D-33 Cold start B-10
Pressure control valve C-40, C-59, D-33 Warm start B-11
Volumetric control valve C-46, C-60, D-33 Start-up operation C-53, C-54
Replacement of parts B-67 Synchronous belt C-30
Running engine: C-2 System components A-9
4 PCR 2.0 DW10 TD 12/2005

T V
Index
Tank transducer A-3 Vacuum pump A-3
Test pressure control valve B-103 VCV A-27
Anchor A-27
Test specification
Engine control unit (ECU) B-97 Characteristic curve A-29
Compression spring A-27
High Pressure Pump (HPP) B-77
Control current A-29, A-33
Pressure Control Valve (PCV) B-73
Cutaway view A-27
Test volumetric control valve B-103 Flasks A-27
Throttle valve A-3 Fuel pressure A-33
Fuel volume flow A-29
Through-flow coefficients A-17 Function A-28
Tightening torques Identification A-30, A-34
High pressure pump C-33 Jack A-27
High-pressure lines C-14 not triggered: A-28
Pinning A-29, A-30
Torque
Solenoid A-27
Forged rail C-18
triggered A-28
High-pressure lines D-9
Injectors C-28 Verification specifications B-65
Pressure control valve C-44 Volumetric control valve C-31, C-45
Rail C-18 Identification C-48
Volumetric control valve C-50 Installation C-50, D-25
Welded rail C-18 Removal C-48, D-9
Total system see also VCV A-1, A-5, A-7, A-27
Components A-3
Schematic representation A-2
W
Trouble shooting plan B-13
Turbocharger A-3 Wastegate A-3
PCR 2.0 DW10 TD 12/2005 5

Index
6 PCR 2.0 DW10 TD 12/2005

ÓÑ ¡ÔCommon Rail Diesel Systems - PCR 2.0 DW10 TD

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ÓÑ ¡ÔCommon Rail Diesel Systems - PCR 2.0 DW10 TD

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Common Rail Diesel Systems

PCR 2.0 DW10 TD

This manual is applicable to:

System: Siemens VDO PCR 2.0 DW10 TD

Engine: PSA DW10 TD

Vehicle: PSA T5 Peugeot 307

PSA N7 Citroën Xsara

PSA D9 Peugeot 406

PSA M49 Peugeot Partner

Suzuki Vitara Suzuki Vitara

The following safety instructions and warning notices are

You could suffer severe or deadly injury.

You could suffer severe or deadly injury.

When this notice appears, comply with the regulations

You could suffer severe or deadly injury.

Piezo Common Rail (PCR) total system ............................................................................A - 1

System limits Fuel supply..................................................................................................A - 5

PCR 2.0 DW10 TD 12/2005 1

System set points and operating conditions ...................................................................B - 1

Troubleshooting plan .........................................................................................................B - 13

List of fault codes................................................................................................................B - 49

2 PCR 2.0 DW10 TD 12/2005

Diagnostics tools ................................................................................................................B - 99

Conditions for working on the system .............................................................................C - 1

Cleaning the high pressure connections ..........................................................................C - 7

Installing and removing the high pressure lines. ............................................................C - 9

PCR 2.0 DW10 TD 12/2005 3

Installing and removing the rail.........................................................................................C - 15

Installing and removing the injectors. ..............................................................................C - 23

Installing and removing the high pressure pump. ..........................................................C - 29

Installing and removing the high pressure sensor ..........................................................C - 35

Installing and removing the pressure control valve........................................................C - 39

Installing and removing the volumetric control valve ....................................................C - 45

Installing and removing the engine control unit .............................................................C - 51

Injector system startup ......................................................................................................C - 53

Special tools / Repair kits...................................................................................................C - 55

4 PCR 2.0 DW10 TD 12/2005

Conditions for inspection / repair......................................................................................D - 1

Cleaning before inspection / repair ...................................................................................D - 3

Disassembling the high-pressure pump...........................................................................D - 5

Component testing .............................................................................................................D - 15

Assembling the high-pressure pump ...............................................................................D - 19

PCR 2.0 DW10 TD 12/2005 5

Replace / exchange the identification place .....................................................D - 26

Special tools / spare parts/ repair parts ............................................................................D - 29

6 PCR 2.0 DW10 TD 12/2005

PCR 2.0 DW10 TD 12/2005 7

8 PCR 2.0 DW10 TD 12/2005

1 Piezo Common Rail (PCR) total system

1.1 General information about the PCR system

PCR 2.0 DW10 TD 12/2005 A-1

Fig. A - 1 Schematic representation Total system

A-2 PCR 2.0 DW10 TD 12/2005

1. Air filters 17. Pre-glow relay

a High Pressure Pump (HPP) C4 Cylinder 4 cyl 2

PCR 2.0 DW10 TD 12/2005 A-3

A-4 PCR 2.0 DW10 TD 12/2005

Diesel Common Rail Pump (DCP) • Volumetric Control Valve (VCV)

The high pressure pump is constructed as a • Rail

PCR 2.0 DW10 TD 12/2005 A-5

Fig. A - 2 Fuel supply

A-6 PCR 2.0 DW10 TD 12/2005

1. Diesel Common Rail Pump (DCP):