Engine Control Module (ECM) Diagnostic Trouble Codes (Xc) - 5 of 9: Other Volvo V70 II

Fault-tracing

See Fault-tracing

Intermittent fault

The control module has previously detected a fault in the leak diagnostic unit but the fault is not active at present.

Check the leak diagnostic unit connectors. Check for contact resistance and oxidation.

Check the hose and the filter for the air intake on the leak diagnostic unit. Check for blockages.

Remedy as necessary.

Other information

1. For resistance values: For 5-cylinder turbocharged engines and 6-cylinder engines 2001, see «Component specifications»(ref-430975-S12681654262011101900000) . For 5-cylinder turbocharged engines and 6-cylinder engines 2002, see «Component specifications»(ref-430975-S24294221072011101900000) . For 5 cylinder turbocharged engines and 6 cylinder engines 2003-, see «Component specifications»(ref-430975-S37637200832011101900000) . For B5254T4 2004-, see «Component specifications»(ref-430975-S19541977602011101900000) . For 5-cylinder normally aspirated engines 1999-, see «Component specifications»(ref-451848-S36406831262012020900000)
2. To connect the breakout box, see «Connecting the breakout box»(ref-430911-S30587875092011101900000)
3. To access or replace the leak diagnostic unit, see «Leak diagnostic pump, replacing»(ref-451850-S04505719982012020900000)
4. For information about signals: For 5 cylinder turbocharged engines -2001, see «Signal specification»(ref-430975-S34273110602011101900000) For 5 cylinder turbocharged engines 2002, see «Signal specification»(ref-430975-S11230688812011101900000) For B5254T2 -2004, see «Signal description»(ref-430975-S13000059482011101900000) For B5204T5, B5234T3, B5234T7 and B5244T3 -2004, see «SIGNAL SPECIFICATION (B5204T5, B5234T3, B5234T7 AND B5244T3 -2004)»(ref-430978-S25137021352012011700000) For B5254T4 2004, see «SIGNAL SPECIFICATION (B5254T4 2004)»(ref-430978-S06851592402012011700000) For 5 cylinder turbocharged engines 2005-, see «Signal specification»(ref-430975-S24350024032011101900000) .
5. See «Checking wiring and terminals»(ref-430909-S26456997912011101900000) .

1. Continue Refer to «Information - intermittent fault»(ref-430984-S29976979172011101900000)

Checking the status

1. The status of the leak can be determined by activating the quick test of the fuel tank system
2. The fault is permanent if leakage is detected when running the quick test of the fuel tank system
3. The fault is intermittent if no leakage is detected when running the quick test of the fuel tank system
4. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
5. Ignition on
6. Activate the quick test of the fuel tank system
7. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble codes (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 are not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
8. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND" If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. HINT: If the test result is "FAULT FOUND" and the fault type is displayed after the completed test, a diagnostic trouble code (DTC) for the fault will be stored in the control module. HINT: Other information: For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For further information about leak diagnostic parameters, see «Description of parameters, quick test of the fuel tank system»(ref-430984-S32597385962012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) . Select an alternative to continue when the test is completed: The test result for the fuel tank system and leak diagnostic unit is "OK, NO FAULT FOUND". Refer to «Intermittent fault»(ref-430984-S23879888442011101900000) The test result for the fuel tank system is "FAULT FOUND, MAJOR LEAK" or "FAULT FOUND, MINOR LEAK". Refer to «Checking components»(ref-430984-S39785749552011101900000) The quick test does not start or the test result for the leak diagnostic unit is "FAULT FOUND" (and the fault type). Refer to «Fault-tracing information»(ref-430984-S02540419812011101900000)

Checking components

1. Check that the fuel tank filler cap is properly installed and that its seal is not damaged
2. Check the hoses and connections on the leak diagnostic unit, the EVAP canister, EVAP canister purge valve and fuel filler pipe visually for damage or loose installation
3. Remedy as necessary. HINT: Diagnostic trouble codes (DTCs) caused by a loose fuel filler cap or hose connection may be difficult to find. If no leakage if detected by the control module when activating the quick test of the fuel tank system after the above checks and remedies, the fault may have been fixed. Other information To test pressurize the fuel tank system, see «Test pressurizing the tank system»(ref-430981-S12713956662011101900000) .

1. Continue Refer to «Activating the quick test of the fuel tank system»(ref-430984-S05962841202011101900000)

Checking the EVAP canister purge valve

HINT: Leakage through the EVAP canister purge valve can be checked by blocking the hose between the EVAP canister and the purge valve and then running the quick test of the fuel tank system. If leakage was detected in a previous quick test of the fuel tank system but is not now detected when the hose between the EVAP canister and the purge valve is blocked, the leakage may be through the EVAP canister purge valve.

Scheme 644

1. Disconnect the hose between the EVAP canister purge valve and the EVAP canister from the connection to the EVAP canister purge valve. Block the hose while running the quick test of the fuel tank system. Other information: For the location of components: For 5 cylinder turbocharged engines -2001, see «Location of components»(ref-430982-S15631897472011101900000) For 5 cylinder turbocharged engines 2002, see «Location of components, engine compartment»(ref-430982-S26522438492011101900000) For 5 cylinder turbocharged engines 2003-, see «Location of components, engine compartment»(ref-430982-S36428841102011101900000) For B5254T4 2004-, see «Location of components, engine compartment»(ref-430982-S37883263132011101900000) .

1. Continue Refer to «Activating the quick test of the fuel tank system»(ref-430984-S37387154182011101900000)

Replacing the component

1. Try a new EVAP canister purge valve. See «Location of components, engine compartment»(ref-430982-S26522438492011101900000) .

1. Continue Refer to «Verification»(ref-430984-S17830109102011101900000)

Checking the fuel tank system

HINT: The fault may be due to leakage in the fuel tank, fuel filler pipe, fuel tank filler cap, evaporative emission (EVAP) canister, EVAP canister purge valve, leak diagnostic unit or in the hoses between these components.

1. Ignition off
2. Pressurize the tank system to locate any leaks. See «Test pressurizing the tank system»(ref-430981-S12713956662011101900000) . When the fuel tank system is pressurized: Check the fuel tank system for leakage by spraying soap solution on the components for the fuel tank system, such as the tank, fuel filler pipe, fuel tank filler cap, EVAP canister purge valve, EVAP canister and the hoses and hose terminals between these components. Remedy as necessary. Reinstall components, hoses etc. If no leakage can be found in the fuel tank system after the above checks and corrective action but the fault remains after the quick test, the leak diagnostic unit may be defective. Run a quick test of the fuel tank system after the above checks and corrective action to check if the fault is still present. Other information: To lower the tank, see «Fuel tank, replacing»(ref-451850-S04021547172012020900000)

1. Continue Refer to «Activating the quick test of the fuel tank system»(ref-430984-S12296315342011101900000)

Safety regulations for handling fuel

General

Scheme 645

Fault-tracing information

1. The control module cannot run the leak diagnostic when the quick test of the fuel tank system is activated. This may be because the conditions for starting the quick test of the fuel tank system have not been met, that the fault occurred during fault-tracing or that the fault existed before the fault-tracing began. Check that all conditions for starting the quick test of the fuel tank system are met and that all hoses, connectors, components etc. are correctly reinstalled and undamaged
2. The quick test for the fuel tank system cannot be run if the battery voltage varies too much. The voltage may vary if the battery is being charged with a battery charger. Charge the battery before beginning the quick test to avoid voltage variations. HINT: Cancel fault-tracing for this fault. Then read off diagnostic trouble codes (DTCs) from the vehicle communication socket. Fault trace any other diagnostic trouble codes (DTCs) stored in the control module.
3. Remedy as necessary. Select a suitable alternative to continue: Start this fault-tracing from the beginning again Refer to «Checking other diagnostic trouble codes (DTCs)»(ref-430984-S18099029302011101900000) Cancel fault-tracing for this fault. FAULT NOT FOUND: Troubleshooting has been completed.

The control module has previously detected a leak in the tank system but the fault is no longer active. The fault may be due to leakage in the fuel tank, fuel filler pipe, fuel tank filler cap, evaporative emission system (EVAP) canister, EVAP canister purge valve, leak diagnostic unit or in the hoses between these components.

Other information

1. To check the fuel tank system for leakage, see «Test pressurizing the tank system»(ref-430981-S12713956662011101900000)
2. For the location of components: For 5 cylinder turbocharged engines -2001, see «Location of components»(ref-430982-S15631897472011101900000) For 5 cylinder turbocharged engines 2002, see «Location of components, engine compartment»(ref-430982-S26522438492011101900000) For 5 cylinder turbocharged engines 2003-, see «Location of components, engine compartment»(ref-430982-S36428841102011101900000) For B5254T4 2004-, see «Location of components, engine compartment»(ref-430982-S37883263132011101900000) .
3. To replace the leak diagnostic unit, see «Leak diagnostic pump, replacing»(ref-451850-S04505719982012020900000) .

1. Continue Refer to «Verification»(ref-430984-S17830109102011101900000)

Verification

HINT: After carrying out the repair, check that the fault has been remedied.

Scheme 646

1. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
2. Ignition on
3. Activate the quick test of the fuel tank system
4. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble code (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 is not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
5. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND" If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. Other information For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) .

Is the test result "NO FAULT FOUND" for both the leak diagnostic unit and the fuel tank system?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S24071880202011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

HINT: After carrying out the repair, check that the fault has been remedied.

1. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
2. Ignition on
3. Activate the quick test of the fuel tank system
4. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble code (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 is not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
5. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND" If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. Other information For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) .

Is the test result "NO FAULT FOUND" for both the leak diagnostic unit and the fuel tank system?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S24071880202011101900000)

See Fault-tracing

1. The status of the fault can be determined by activating a quick test of the fuel tank system
2. The fault is permanent if a fault is detected in the leak diagnostic unit when running the quick test of the fuel tank system
3. The fault is intermittent if no fault is detected in the leak diagnostic unit when running the quick test of the fuel tank system
4. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
5. Ignition on
6. Activate the quick test of the fuel tank system
7. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble codes (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 are not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
8. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND". If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. HINT: If the test result is "FAULT FOUND" and the fault type is displayed after the completed test, a diagnostic trouble code (DTC) for the fault will be stored in the control module. HINT: Other information For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) . Select an alternative to continue when the test is completed: The test result for the fuel tank system and leak diagnostic unit is "OK, NO FAULT FOUND" Refer to «Intermittent fault»(ref-430984-S29111703462011101900000) The test result for the leak diagnostic unit is "FAULT FOUND" (with the fault type) Refer to «Checking components and wiring»(ref-430984-S08882459762011101900000) The quick test does not start Refer to «Fault-tracing information - quick test does not start»(ref-430984-S01468687222011101900000) The test result for the fuel tank system is "FAULT FOUND" (with the fault type). Refer to «Fault-tracing information - test result: FAULT FOUND»(ref-430984-S34789792662011101900000)

The control module has previously detected a fault in the leak diagnostic unit but the fault is not active at present.

Check the leak diagnostic unit connectors. Check for contact resistance and oxidation.

Check the hose and the filter for the air intake on the leak diagnostic unit. Check for blockages.

Remedy as necessary.

Other information

1. For resistance values: For 5-cylinder turbocharged engines and 6-cylinder engines 2001, see «Component specifications»(ref-430975-S12681654262011101900000) . For 5-cylinder turbocharged engines and 6-cylinder engines 2002, see «Component specifications»(ref-430975-S24294221072011101900000) . For 5 cylinder turbocharged engines and 6 cylinder engines 2003-, see «Component specifications»(ref-430975-S37637200832011101900000) . For B5254T4 2004-, see «Component specifications»(ref-430975-S19541977602011101900000) . For 5-cylinder normally aspirated engines 1999-, see «Component specifications»(ref-451848-S36406831262012020900000)
2. To connect the breakout box, see «Connecting the breakout box»(ref-430911-S30587875092011101900000)
3. To access or replace the leak diagnostic unit, see «Leak diagnostic pump, replacing»(ref-451850-S04505719982012020900000)
4. For information about signals: For 5 cylinder turbocharged engines -2001, see «Signal specification»(ref-430975-S34273110602011101900000) For 5 cylinder turbocharged engines 2002, see «Signal specification»(ref-430975-S11230688812011101900000) For B5254T2 -2004, see «Signal description»(ref-430975-S13000059482011101900000) For B5204T5, B5234T3, B5234T7 and B5244T3 -2004, see «SIGNAL SPECIFICATION (B5204T5, B5234T3, B5234T7 AND B5244T3 -2004)»(ref-430978-S25137021352012011700000) For B5254T4 2004, see «SIGNAL SPECIFICATION (B5254T4 2004)»(ref-430978-S06851592402012011700000) For 5 cylinder turbocharged engines 2005-, see «Signal specification»(ref-430975-S24350024032011101900000) .
5. See «Checking wiring and terminals»(ref-430909-S26456997912011101900000) .

1. Continue Refer to «Information - intermittent fault»(ref-430984-S02248912212011101900000)

1. The status of the leak can be determined by activating the quick test of the fuel tank system
2. The fault is permanent if leakage is detected when running the quick test of the fuel tank system
3. The fault is intermittent if no leakage is detected when running the quick test of the fuel tank system
4. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
5. Ignition on
6. Activate the quick test of the fuel tank system
7. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble codes (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 are not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
8. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND" If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. HINT: If the test result is "FAULT FOUND" and the fault type is displayed after the completed test, a diagnostic trouble code (DTC) for the fault will be stored in the control module. HINT: Other information: For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For further information about leak diagnostic parameters, see «Description of parameters, quick test of the fuel tank system»(ref-430984-S32597385962012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) . Select an alternative to continue when the test is completed: The test result for the fuel tank system and leak diagnostic unit is "OK, NO FAULT FOUND". Refer to «Intermittent fault»(ref-430984-S31158981592011101900000) The test result for the fuel tank system is "FAULT FOUND, MAJOR LEAK" or "FAULT FOUND, MINOR LEAK". Refer to «Checking components»(ref-430984-S41909612972011101900000) The quick test does not start or the test result for the leak diagnostic unit is "FAULT FOUND" (and the fault type). Refer to «Fault-tracing information»(ref-430984-S25971503052011101900000)

1. Check that the fuel tank filler cap is properly installed and that its seal is not damaged
2. Check the hoses and connections on the leak diagnostic unit, the EVAP canister, EVAP canister purge valve and fuel filler pipe visually for damage or loose installation
3. Remedy as necessary. HINT: Diagnostic trouble codes (DTCs) caused by a loose fuel filler cap or hose connection may be difficult to find. If no leakage if detected by the control module when activating the quick test of the fuel tank system after the above checks and remedies, the fault may have been fixed. Other information To test pressurize the fuel tank system, see «Test pressurizing the tank system»(ref-430981-S12713956662011101900000) .

1. Continue Refer to «Activating the quick test of the fuel tank system»(ref-430984-S18369998062011101900000)

HINT: Leakage through the EVAP canister purge valve can be checked by blocking the hose between the EVAP canister and the purge valve and then running the quick test of the fuel tank system. If leakage was detected in a previous quick test of the fuel tank system but is not now detected when the hose between the EVAP canister and the purge valve is blocked, the leakage may be through the EVAP canister purge valve.

1. Disconnect the hose between the EVAP canister purge valve and the EVAP canister from the connection to the EVAP canister purge valve. Block the hose while running the quick test of the fuel tank system. Other information: For the location of components: For 5 cylinder turbocharged engines -2001, see «Location of components»(ref-430982-S15631897472011101900000) For 5 cylinder turbocharged engines 2002, see «Location of components, engine compartment»(ref-430982-S26522438492011101900000) For 5 cylinder turbocharged engines 2003-, see «Location of components, engine compartment»(ref-430982-S36428841102011101900000) For B5254T4 2004-, see «Location of components, engine compartment»(ref-430982-S37883263132011101900000) .

1. Continue Refer to «Activating the quick test of the fuel tank system»(ref-430984-S28526388632011101900000)

1. Try a new EVAP canister purge valve. See «Location of components, engine compartment»(ref-430982-S26522438492011101900000) .

1. Continue Refer to «Verification»(ref-430984-S24942925162011101900000)

HINT: The fault may be due to leakage in the fuel tank, fuel filler pipe, fuel tank filler cap, evaporative emission (EVAP) canister, EVAP canister purge valve, leak diagnostic unit or in the hoses between these components.

1. Ignition off
2. Pressurize the tank system to locate any leaks. See «Test pressurizing the tank system»(ref-430981-S12713956662011101900000) . When the fuel tank system is pressurized: Check the fuel tank system for leakage by spraying soap solution on the components for the fuel tank system, such as the tank, fuel filler pipe, fuel tank filler cap, EVAP canister purge valve, EVAP canister and the hoses and hose terminals between these components. Remedy as necessary. Reinstall components, hoses etc. If no leakage can be found in the fuel tank system after the above checks and corrective action but the fault remains after the quick test, the leak diagnostic unit may be defective. Run a quick test of the fuel tank system after the above checks and corrective action to check if the fault is still present. Other information: To lower the tank, see «Fuel tank, replacing»(ref-451850-S04021547172012020900000)

1. Continue Refer to «Activating the quick test of the fuel tank system»(ref-430984-S40209824942011101900000)

1. Ignition off. Try a new leak diagnostic unit. See «Leak diagnostic pump, replacing»(ref-451850-S04505719982012020900000) .

1. Continue Refer to «Verification»(ref-430984-S24942925162011101900000)

1. The control module cannot run the leak diagnostic when the quick test of the fuel tank system is activated. This may be because the conditions for starting the quick test of the fuel tank system have not been met, that the fault occurred during fault-tracing or that the fault existed before the fault-tracing began. Check that all conditions for starting the quick test of the fuel tank system are met and that all hoses, connectors, components etc. are correctly reinstalled and undamaged
2. The quick test for the fuel tank system cannot be run if the battery voltage varies too much. The voltage may vary if the battery is being charged with a battery charger. Charge the battery before beginning the quick test to avoid voltage variations. HINT: Cancel fault-tracing for this fault. Then read off diagnostic trouble codes (DTCs) from the vehicle communication socket. Fault trace any other diagnostic trouble codes (DTCs) stored in the control module.
3. Remedy as necessary. Select a suitable alternative to continue: Start this fault-tracing from the beginning again Refer to «Checking other diagnostic trouble codes (DTCs)»(ref-430984-S11175800462011101900000) Cancel fault-tracing for this fault. FAULT NOT FOUND: Troubleshooting has been completed.

The control module has previously detected a leak in the tank system but the fault is no longer active. The fault may be due to leakage in the fuel tank, fuel filler pipe, fuel tank filler cap, evaporative emission system (EVAP) canister, EVAP canister purge valve, leak diagnostic unit or in the hoses between these components.

Other information

1. To check the fuel tank system for leakage, see «Test pressurizing the tank system»(ref-430981-S12713956662011101900000)
2. For the location of components: For 5 cylinder turbocharged engines -2001, see «Location of components»(ref-430982-S15631897472011101900000) For 5 cylinder turbocharged engines 2002, see «Location of components, engine compartment»(ref-430982-S26522438492011101900000) For 5 cylinder turbocharged engines 2003-, see «Location of components, engine compartment»(ref-430982-S36428841102011101900000) For B5254T4 2004-, see «Location of components, engine compartment»(ref-430982-S37883263132011101900000) .
3. To replace the leak diagnostic unit, see «Leak diagnostic pump, replacing»(ref-451850-S04505719982012020900000) .

1. Continue Refer to «Verification»(ref-430984-S24942925162011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
2. Ignition on
3. Activate the quick test of the fuel tank system
4. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble code (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 is not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
5. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND" If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. Other information For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) .

Is the test result "NO FAULT FOUND" for both the leak diagnostic unit and the fuel tank system?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S16857338762011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

HINT: After carrying out the repair, check that the fault has been remedied.

1. Switch off the ignition to ensure that the status of the quick test for the fuel tank system is "NOT COMPLETED". The test cannot be started if the status is "COMPLETED"
2. Ignition on
3. Activate the quick test of the fuel tank system
4. Read off the battery voltage, the status of the quick test of the fuel tank system and the status of the test phase. Check the parameters according to the conditions for starting the quick test of the fuel tank system. NOTE: The following conditions must be met in order for the quick test of the fuel tank system to be run correctly. Conditions for starting the quick test of the fuel tank system Diagnostic trouble code (DTC) ECM-4000, ECM-4007, ECM-4010, or ECM-4024 is not stored Engine off, ignition on The battery voltage must be 11-14 V The status of the test phase must be "NOT RUNNING". The status of the quick test for the fuel tank system must be "NOT COMPLETED". NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 10 minutes, depending on the quantity of fuel in the fuel tank. Connect a battery charger if necessary.
5. Active the quick test for the fuel tank system by clicking the start button. Click the stop button to cancel the test. Check that the quick test has started by reading off the status of the test phase. The test has started when the status of the test phase is "REFERENCE 1". Wait until the test is complete. When the test is completed, the status of the test phase must be "NOT RUNNING" and the status of the quick test for the fuel tank system must be "COMPLETED". If no faults are detected after the quick test of the fuel tank system, the test result for the leak diagnostic module and the fuel tank system will be "NO FAULT FOUND" If a fault is detected after the quick test of the fuel tank system is complete, the test result for the fuel tank system or leak diagnostic unit will be "FAULT FOUND" with the fault type, depending on the fault. Other information For further information about leak diagnostics, see «LEAK DIAGNOSTICS (CERTAIN MARKETS ONLY)»(ref-430978-S11435012312012011700000) For information about test phases, see «TEST PHASES»(ref-430978-S06054681342012011700000) .

Is the test result "NO FAULT FOUND" for both the leak diagnostic unit and the fuel tank system?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S16857338762011101900000)

See Fault-tracing

Signal missing

See Signal missing

Signal too high

See Signal too high

1. Ignition on. Activate the valve in the leak diagnostic unit to check whether the fault is permanent or intermittent. The valve clicks when it is activated. The fault is permanent if the valve does not activate. The fault is intermittent if the valve activates.

1. Continue Refer to «Checking components and wiring»(ref-430984-S14140094842011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition on
2. Activate the valve in the leak diagnostic unit. The valve should click. Check that the function is OK.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S24396809812011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Signal missing

See Signal too high

Signal too low

See Signal too low

Checking software

HINT: For vehicles of model year 2003-2008, the software in engine control module (ECM) should be checked before fault tracing of the fault relating to the leak from the tank system is carried out.

Scheme 647

Scheme 648

1. Ignition on. Click on the VCT2000 symbol to start the read out and check the software version in the Engine control module (ECM). NOTE: More instructions follow together with the read out.

Has the latest software been downloaded to the control module?

1. YES Refer to «Perform quick-test tank system»(ref-430984-S14738763462011101900000)
2. NO ANOTHER TEST

Scheme 649

1. Activate the test by pressing on the symbol for VCT2000.
2. Read off initial parameters and check them according to start conditions for performing the test.
3. Press the button "Start" to start the quick-test.
4. Check that the test has started. Parameters run status shall go to "In progress" and the test phase shall go to "Reference". NOTE: If the test does not start, check that the start conditions are fulfilled. When the reference phase is finished, check of the tank system starts. The pressure in the tank starts to increase. Within 15 minutes the Engine control module (ECM) makes a decision as to whether there is leakage in the tank system or not. The test is finished.
5. Check parameters for test result and follow relevant instructions below. NOTE: Estimated leakage shall be used to get an idea of the proximity to the diagnostic trouble code limit. If the estimated leakage is very near the diagnostic trouble code limit, troubleshooting should probably be performed despite the Tank system, test result shows "No leakage found", especially if diagnostic trouble code for leakage has been stored earlier. NOTE: Use diagnostic trouble code counter to see the frequency of the problem. Also use frozen values to get an idea if external conditions may have affected the result. Compare with current conditions in the workshop. Conditions for starting the quick test of the fuel tank system No DTCs related to EVAP purge valve or ambient air pressure sensor set. Battery voltage 11-15 V. Atmospheric pressure higher than 750 hPa, appr. 2500 m (8200 ft). Fuel level 0-85 %. Ambient air temperature 4-35 °C (39-95 °F). NOTE: The battery voltage must be correct throughout the entire test. The test can take up to 15 minutes, depending on the quantity of fuel in the fuel tank. It is highly recommended to use the constant voltage charger, Midtronics PSC-550, during the test. Other information See «Description of parameters, quick test of the fuel tank system»(ref-430984-S32597385962012011700000) See «Test phases, quick test fuel tank system»(ref-430984-S09796869212012011700000) See «Location of components, engine compartment»(ref-430982-S37883263132011101900000) See «Fuel tank system, check»(ref-430981-S24807502402011101900000) See «Test pressurizing the tank system»(ref-430981-S12713956662011101900000) Select alternative according to relevant test results: DMTL, test result = "Problem found" Refer to «DMTL, test result = "Problem found"»(ref-430984-S38781533392011101900000) Tank system, test result = "No leakage found" Refer to «Tank system, test result = "No leakage found"»(ref-430984-S30494026842011101900000) Tank system, test result = "Minor leakage found" Refer to «Tank system, test result = "Minor leakage found"»(ref-430984-S09667326332011101900000) Tank system, test result = "Major leakage found" Refer to «Tank system, test result = "Major leakage found"»(ref-430984-S14344480572011101900000) DMTL, test result and Tank system, test result = "Unknown" Refer to «DMTL, test result and Tank system, test result = "Unknown"»(ref-430984-S12027836932011101900000) Cancel fault-tracing. FAULT NOT FOUND: Troubleshooting has been completed.

ECU-power: supply (V)

The value indicates the voltage supply from the system relay to the engine control module (ECM).

Atmospheric pressure (Pa)

The value indicates the ambient pressure. The Engine control module (ECM) receives a signal from the atmospheric pressure sensor.

HINT: The sensor is integrated in the Engine control module (ECM).

Fuel level (l)

The value shows the fuel level in the tank. The Engine control module (ECM) receives a signal from fuel level sensor.

HINT: The sensor is connected to the Central electronic module (CEM) and information is sent to the Engine control module (ECM) via CAN.

Ambient temperature (°C)

The value indicates the ambient temperature. The Engine control module (ECM) receives a signal from the outside temperature sensor.

HINT: The sensor is connected to the Central electronic module (CEM) and information is sent to the Engine control module (ECM) via CAN.

Fuel tank pressure (Pa)

The value indicates the calculated tank pressure. The Engine control module (ECM) calculates the average pressure with the help of the measured power consumption on the leak diagnostic unit's pump. The pressure will rise from 0 Pa to approx. 4500 Pa during the test.

HINT: The calculated pressure can differ from the measured pressure by 15 %. This is normal.

Estimated leak (mm)

The value shows the diameter of the leak. The Engine control module (ECM) calculates the diameter with the help of measurements made during testing.

HINT: The parameter should be used to get an understanding of how close to the diagnostic trouble code limit the system is. If the estimated size of the leak is very close to the diagnostic trouble code limit, fault tracing should probably be carried out despite the test result for the tank system showing "No leakage found", especially if the diagnostic trouble code (DTC) for leakage was initially generated.

Reference

Reference phase for leakage, and operating check of the leak diagnostic unit (DMTL), is in progress.

If no fault is detected during this phase, the check for major leakage starts.

If a fault is detected during this phase the test is stopped and the parameter "DMTL, test status" shows "Fault Found". The diagnostic trouble code (DTC) for the detect fault is stored in the Engine control module (ECM).

Major leak

Investigation of the fuel tank system in progress.

If no fault is detected during this phase, the check for minor leakage starts.

If leakage is detected during this phase the test is stopped and the parameter "Tank system test result" shows "Major leak found". The diagnostic trouble code (DTC) is stored in the Engine control module (ECM).

Minor leak

Investigation of the fuel tank system in progress.

If leakage is detected during this phase the test is stopped and the parameter "Tank system test result" shows "Minor leak found". The diagnostic trouble code (DTC) is stored in the Engine control module (ECM).

Not-in: progress

Leakage diagnosis not in progress. Quick-test tank system has not started, has been finished, or has been blocked.

HINT: For vehicles of model year 2003-2008, the software in engine control module (ECM) should be checked before fault tracing of the fault relating to the leak from the tank system is carried out.

1. Ignition on. Click on the VCT2000 symbol to start the read out and check the software version in the Engine control module (ECM). NOTE: More instructions follow together with the read out.

Has the latest software been downloaded to the control module?

1. YES Refer to «Perform quick-test tank system»(ref-430984-S03587984552011101900000)
2. NO ANOTHER TEST

HINT: For vehicles of model year 2003-2008, the software in engine control module (ECM) should be checked before fault tracing of the fault relating to the leak from the tank system is carried out.

1. Ignition on. Click on the VCT2000 symbol to start the read out and check the software version in the Engine control module (ECM). NOTE: More instructions follow together with the read out.

Has the latest software been downloaded to the control module?

1. YES See «Perform quick-test tank system»(ref-430984-S06725575452012011700000)
2. NO ANOTHER TEST

See Fault-tracing

See Fault-tracing

See Fault-tracing

See Fault-tracing information

Leakage

See Leakage

See Fault-tracing information

Information

No fault-tracing has been developed for this diagnostic trouble code (DTC). A diagnostic trouble code for CAN communication can also be generated in the Central Electronic Module (CEM). This diagnostic trouble code shall not be cleared until the trouble code in the central electronic module (CEM) and in other affected control modules has been remedied and cleared. Therefore, first read the diagnostic trouble codes in the Central Electronic Module (CEM) and other affected control modules, perform fault tracing and remedy as necessary. This diagnostic trouble code (DTC) can then be erased.

Other information

1. See «General information about fault-tracing in the CAN network»(ref-430984-S22921379972011101900000)

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

The control module has previously registered a fault. The fault is now no longer present.

1. Continue Refer to «Information»(ref-430984-S39253766692011101900000)

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

See Intermittent fault

Checking for air leakage in the intake system

Check for air leakage. See Check for air leaks in the intake system .

Remedy as necessary.

Scheme 650

Was there any air leakage?

1. YES Refer to «Verification»(ref-430984-S08079637622011101900000)
2. NO Refer to «Checking for air leakage in the exhaust system»(ref-430984-S11845508132011101900000)

Preparations

Check that all hoses are undamaged and are in place with their hose clips tightened.

Connecting

Remove fresh air hose from mass air flow (MAF) sensor.

Install tool 9995545 with pressure regulator 9995544 on fresh air hose and tighten hose clamp.

Use hose clip to seal crankcase ventilation hose.

Remove oil filler cap.

Remove the lower hose from the canister purge (CP) valve.

Scheme 651

Connect the compressed air hose and adjust the regulator to obtain a pressure of maximum 0.3 bar .

A gentle hissing sound can be heard from the oil filler opening. This is due to the opening of an intake valve and the leakage of cylinder pressure past the piston rings.

If a leak is suspected spray a soap solution onto the area.

Small bubbles are permissible between throttle body (TB) and intake hose (if made of plastic). No bubbles are permissible with rubber hose.

Check for air leakage from canister purge (CP) valve. No leakage is permissible.

Checking for air leakage in the exhaust system

Check for air leakage. See Checking for air leakage in the exhaust system .

Remedy as necessary.

Scheme 652

Was there any air leakage?

1. YES Refer to «Verification»(ref-430984-S08079637622011101900000)
2. NO Refer to «Checking fuel and residual pressures»(ref-430972-S11080112202011101900000)

1. For 1999 model year cars, see «Checking for air leakage in the exhaust system (1999)»(ref-430984-S17375392432012011700000)
2. For 2000- model year cars, see «Checking for air leakage in the exhaust system (2000-)»(ref-430984-S36001845882012011700000) .

Checking for air leakage in the exhaust system (2000-)

Special tools

9995544

9997085

Note. The illustrations in this service information are used for different model years and / or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 653

Remove

1. the nut where the three-way catalytic converter (TWC) and exhaust system separate
2. the gasket. Separate the exhaust system from the three-way catalytic converter (TWC).

Installing tool

Scheme 654

Install

1. The tool (1) «9997085»(ref-403953-S05162907402011061000000) using a new gasket
2. pressure regulator «9995544»(ref-403953-S05241159092011061000000) on tool «9997085»(ref-403953-S05162907402011061000000) . Adjust the pressure to 0.4 bar .

Cleaning and checking

Check the exhaust system by spraying a soap solution on all joints and connections between the cylinder head and the rear heated oxygen sensor (HO2S). Only very small and slow bubbles are permissible.

Finishing

Remove

1. pressure regulator «9995544»(ref-403953-S05241159092011061000000)
2. tool «9997085»(ref-403953-S05162907402011061000000) .

Installing components

1. a new gasket where the exhaust system and three-way catalytic converter (TWC) divide
2. a new nut for the exhaust system. Tighten.

Start the engine. Check for leaks where the three-way catalytic converter (TWC) and the exhaust system divide.

Checking for air leakage in the exhaust system (1999)

Special tools

9995544

9995546

Engagement

Install tool 9995546 and pressure regulator 9995544 on the exhaust system.

Adjust the pressure to 0.4 bar . Depending on the condition of the exhaust system a lower pressure may be necessary.

Scheme 655

Check the exhaust system. Spray a soap solution on all joints and connections between the cylinder head and the rear heated oxygen sensor (HO2S).

Only very small and slow bubbles are permissible.

Checking fuel and residual pressures

Check the fuel pressure and residual pressure. See Checking fuel and residual pressures .

Remedy as necessary.

Scheme 656

Was the pressure OK?

1. YES Refer to «Checking the compression»(ref-430984-S01047098102011101900000)
2. NO Refer to «Verification»(ref-430984-S08079637622011101900000)

Checking the compression

Test the compression. See Compression test .

Remedy as necessary.

Scheme 657

Is the compression OK?

1. YES Refer to «Replacing the component»(ref-430984-S39668957152011101900000)
2. NO Refer to «Verification»(ref-430984-S08079637622011101900000)

Install

Install

1. the spark plugs. Tightening torque 30 Nm (22 lb. ft) .
2. the ignition coils. Tightening torque 10 Nm (7.4 lb. ft) .

Scheme 658

1. the cover over the ignition coils. Tightening torque 8 Nm (6 lb. ft) .
2. the upper camshaft belt cover. Tightening torque 8 Nm (6 lb. ft) .
3. the disassembled connectors.

Applies only to turbocharged engines

Install the charge air pipe.

Remove the seals.

Tighten the mountings and hose clamps.

Scheme 659

Erase diagnostic trouble codes (DTCs)

Start the engine and check that it functions normally.

Use VIDA to vehicle communication to check which diagnostic trouble codes (DTCs) have been stored.

Erase the diagnostic trouble codes (DTCs).

Check the engine compartment and wipe it clean.

1. Try a new three-way catalytic converter (TWC): For B5xx4T -2004, see «Replacing the three-way catalytic converter (TWC)»(ref-430985-S24257827642011101900000) For B5xx4T 2005-, see «Three-way catalytic converter (TWC), replacing»(ref-430985-S00339593432011101900000) .

1. Continue Refer to «Verification»(ref-430984-S08079637622011101900000)

HINT: After carrying out the repair, check that the fault has been remedied as follows

Scheme 660

Scheme 661

1. Ignition off.
2. Replace connector, components etc.
3. Test drive car according to «Verifying repairs»(ref-430972-S31879278172011101900000) . NOTE: After test driving the engine should not be turned off. Information in the control module is erased. Connect VCT 2000 to the data link connector (DLC). Read off the status of the diagnostic trouble code (DTC). The text NOT READY is displayed if the diagnosis is still on-going. This indicates that the test drive was too short.

Is FAULT NOT REGISTERED displayed?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S24752813422011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Permanent fault

See Permanent fault

When the fault is no longer present, no fault-tracing for an intermittent fault is required.

Scheme 662

Signal missing. Intermittent fault

See Signal missing. Intermittent fault

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Start the engine.
4. Air conditioning (A/C) switch on
5. Start the blower fan Check that the pressure increases in the air conditioning (A/C) system when the air conditioning (A/C) compressor engages. Also check if cold air blows into the passenger compartment when at the coolest setting. NOTE: The air conditioning (A/C) pressure is given in volts for values. For 5-cylinder turbocharged engines and 6-cylinder engines 2001, see «Component specifications»(ref-430975-S12681654262011101900000) . For 5-cylinder turbocharged engines and 6-cylinder engines 2002, see «Component specifications»(ref-430975-S24294221072011101900000) . For 5 cylinder turbocharged engines and 6 cylinder engines 2003-, see «Component specifications»(ref-430975-S37637200832011101900000) . For B5254T4 2004-, see «Component specifications»(ref-430975-S19541977602011101900000) . For 5-cylinder normally aspirated engines 1999-, see «Component specifications»(ref-451848-S36406831262012020900000)

Does the pressure in air conditioning (A/C) system change?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S12218798072011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Signal missing. Permanent fault

See Signal missing. Permanent fault

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

Signal too high. Intermittent fault

See Signal too high. Intermittent fault

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Start the engine.
4. Air conditioning (A/C) switch on
5. Start the blower fan Check that the pressure increases in the air conditioning (A/C) system when the air conditioning (A/C) compressor engages. Also check if cold air blows into the passenger compartment when at the coolest setting. NOTE: The air conditioning (A/C) pressure is given in volts for values. For 5-cylinder turbocharged engines and 6-cylinder engines 2001, see «Component specifications»(ref-430975-S12681654262011101900000) . For 5-cylinder turbocharged engines and 6-cylinder engines 2002, see «Component specifications»(ref-430975-S24294221072011101900000) . For 5 cylinder turbocharged engines and 6 cylinder engines 2003-, see «Component specifications»(ref-430975-S37637200832011101900000) . For B5254T4 2004-, see «Component specifications»(ref-430975-S19541977602011101900000) . For 5-cylinder normally aspirated engines 1999-, see «Component specifications»(ref-451848-S36406831262012020900000)

Does the pressure in air conditioning (A/C) system change?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S12383487932011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Signal too high. Permanent fault

See Signal too high. Permanent fault

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

Signal too low. Intermittent fault

See Signal too low. Intermittent fault

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Start the engine.
4. Air conditioning (A/C) switch on
5. Start the blower fan Check that the pressure increases in the air conditioning (A/C) system when the air conditioning (A/C) compressor engages. Also check if cold air blows into the passenger compartment when at the coolest setting. NOTE: The air conditioning (A/C) pressure is given in volts for values. For 5-cylinder turbocharged engines and 6-cylinder engines 2001, see «Component specifications»(ref-430975-S12681654262011101900000) . For 5-cylinder turbocharged engines and 6-cylinder engines 2002, see «Component specifications»(ref-430975-S24294221072011101900000) . For 5 cylinder turbocharged engines and 6 cylinder engines 2003-, see «Component specifications»(ref-430975-S37637200832011101900000) . For B5254T4 2004-, see «Component specifications»(ref-430975-S19541977602011101900000) . For 5-cylinder normally aspirated engines 1999-, see «Component specifications»(ref-451848-S36406831262012020900000)

Does the pressure in air conditioning (A/C) system change?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S25446669902011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Signal too low. Permanent fault

See Signal too low. Permanent fault

Check that the engine speed (RPM) sensor is correctly installed.

Check the engine speed (RPM) sensor. Check that it is not damaged or dirty.

HINT: The diagnostic trouble code (DTC) can be caused by damage in the flywheel / carrier plate. Look for damage to the flywheel / carrier plate.

Other information

1. For B5xx4T -2001, see «Replacing the engine speed (RPM) sensor»(ref-430961-S04288859222011101900000)
2. For B5xx4T 2002-, does not apply to B5244T5, see «Replacing the engine speed (RPM) sensor»(ref-430961-S41057985512011101900000)
3. For B5244T5 2005-, see «Engine speed (RPM) sensor, replacing»(ref-430984-S26474169192012011700000) .

1. Continue Refer to «Verification»(ref-430984-S35834715532011101900000)

Engine speed (RPM) sensor, replacing

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 663

Remove the hose clamp from the mass air flow (MAF) sensor. Disconnect the connector from the mass air flow (MAF) sensor.

Remove

1. the 3 x screws for the fresh air intake (1) in the front cover plate
2. the 3 x screws for the air cleaner (ACL)
3. the air cleaner (ACL) (2) assembly.

Unhook the control valve from the air cleaner (ACL) housing.

Scheme 664

Remove the nut for the engine speed (RPM) sensor

Disconnect the connector for the sensor.

Lift out the sensor from the holder.

Installing the engine speed (RPM) sensor

Install

1. the sensor in the holder
2. a new nut. Tighten. Connect the connector for the sensor.

Installing the air cleaner (ACL)

Install

1. the air cleaner (ACL) (2) assembly. Tighten the screws. Unhook the control valve on the air cleaner (ACL) housing
2. the screws for the fresh air intake (1) in the front cover plate. Tighten the screws.

Connect the connector to the mass air flow (MAF) sensor. Tighten the hose clamp.

Start the engine and check the function.

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Start the engine
4. Read off the diagnostic status and fault status for the diagnostic trouble code (DTC) by selecting the relevant diagnostic trouble code (DTC) from the list. Increase the engine speed a number of times until the diagnostic is "Complete". Check the fault status for the diagnostic trouble code (DTC) when the diagnostic is "Complete". If the function is correct, the fault status must be "No fault found" when the diagnostic is complete. HINT: In some cases several functions of the component will be diagnosed. The affects the amount of time taken to run the diagnostic.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S14533814052011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Start the engine
4. Read off the diagnostic status and fault status for the diagnostic trouble code (DTC) by selecting the relevant diagnostic trouble code (DTC) from the list. Increase the engine speed a number of times until the diagnostic is "Complete". Check the fault status for the diagnostic trouble code (DTC) when the diagnostic is "Complete". If the function is correct, the fault status must be "No fault found" when the diagnostic is complete. HINT: In some cases several functions of the component will be diagnosed. The affects the amount of time taken to run the diagnostic.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S15718641812011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Start the engine
4. Read off the diagnostic status and fault status for the diagnostic trouble code (DTC) by selecting the relevant diagnostic trouble code (DTC) from the list. Increase the engine speed a number of times until the diagnostic is "Complete". Check the fault status for the diagnostic trouble code (DTC) when the diagnostic is "Complete". If the function is correct, the fault status must be "No fault found" when the diagnostic is complete. HINT: In some cases several functions of the component will be diagnosed. The affects the amount of time taken to run the diagnostic.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S40251114332011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Check that the engine speed (RPM) sensor is correctly installed.

Check the engine speed (RPM) sensor connector. Check for intermittent contact resistance and oxidation.

HINT: The engine speed (RPM) sensor and its wiring are sensitive to interference from surrounding cables, the starter motor cable for example, or similar high amperage cables.

Interference can cause difficulty in starting the engine, prevent the engine from starting at all or cause the tachometer to flicker during start attempts etc.

Causes of interference can be

1. nearby cables, such as an incorrectly routed cable for the starter motor
2. incorrectly tightened bolted joints securing the transmission to the engine.

Checking power cable

Check for incorrectly routed cables (routed too close to the engine speed (RPM) sensor).

Checking bolted joints

When removing and installing the transmission it is important that all the bolts for the engine are correctly tightened. Incorrectly tightened bolts can cause poor ground connection and interfere with the engine speed (RPM) sensor. Check that all the bolts from the transmission to the engine are correctly tightened.

Checking the wiring

Check the signal cable between the engine speed (RPM) sensor terminal #1 and engine control module (ECM) terminal #A48 (#A48) and between the engine speed (RPM) sensor terminal #2 and engine control module (ECM) terminal #A66 (#B6). Check for an intermittent short-circuit to supply voltage. Check for an intermittent short-circuit to ground. Check for an intermittent open-circuit.

Other information

1. See «Checking wiring and terminals»(ref-430909-S26456997912011101900000)
2. For B5xx4T -2001, see «Replacing the engine speed (RPM) sensor»(ref-430961-S04288859222011101900000)
3. For B5xx4T 2002-, does not apply to B5244T5, see «Replacing the engine speed (RPM) sensor»(ref-430961-S41057985512011101900000)
4. For B5244T5 2005-, see «Engine speed (RPM) sensor, replacing»(ref-430984-S26474169192012011700000) .

Remedy as necessary.

Scheme 665

Scheme 666

1. Continue Refer to «Verification»(ref-430984-S20679724632011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Start the engine
4. Read off the diagnostic status and fault status for the diagnostic trouble code (DTC) by selecting the relevant diagnostic trouble code (DTC) from the list. Increase the engine speed a number of times until the diagnostic is "Complete". Check the fault status for the diagnostic trouble code (DTC) when the diagnostic is "Complete". If the function is correct, the fault status must be "No fault found" when the diagnostic is complete. HINT: In some cases several functions of the component will be diagnosed. The affects the amount of time taken to run the diagnostic.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S22738321642011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

No fault-tracing has been developed for this diagnostic trouble code (DTC). A diagnostic trouble code (DTC) for this fault is stored in the transmission control module (TCM) first and then in the engine control module (ECM). This diagnostic trouble code (DTC) can not be erased before the diagnostic trouble code (DTC) in the transmission control module (TCM) has been erased and remedied.

First read off the diagnostic trouble codes (DTCs) in the transmission control module (TCM). Fault-trace and remedy as required. This diagnostic trouble code (DTC) can then be erased.

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

Check that the engine speed (RPM) sensor is correctly installed.

Check the engine speed (RPM) sensor connector. Check for intermittent contact resistance and oxidation.

The engine speed (RPM) sensor is sensitive to interference from surrounding power cables, the starter motor cable for example, or similar high amperage cables. This occurs when starting the engine for example.

Interference can cause difficulty in starting the engine, the engine does not start at all, the tachometer flickers at start attempts etc.

Causes of interference can be

1. surrounding power cables, for example an incorrectly routed starter motor cable
2. incorrectly routed transmission bolted joints for the engine.

Checking the power cable

Check for incorrectly routed power cables (routed too close to the engine speed (RPM) sensor).

Checking the bolted joints

When removing and installing the transmission it is important that all the bolts for the engine are correctly tightened. Incorrectly tightened bolts can cause poor ground connection and interfere with the engine speed (RPM) sensor. Check that all the bolts from the transmission to the engine are correctly tightened.

Checking the wiring

Check the signal cable between the engine speed (RPM) sensor terminal #1 and engine control module (ECM) terminal #A48 (#A48) and between the engine speed (RPM) sensor terminal #2 and engine control module (ECM) terminal #A66 (#B6). Check for an intermittent short-circuit to supply voltage. Check for an intermittent short-circuit to ground. Check for an intermittent open-circuit.

Other information

1. See «Checking wiring and terminals»(ref-430909-S26456997912011101900000)
2. For B5xx4T -2001, see «Replacing the engine speed (RPM) sensor»(ref-430961-S04288859222011101900000)
3. For B5xx4T 2002-, does not apply to B5244T5, see «Replacing the engine speed (RPM) sensor»(ref-430961-S41057985512011101900000)
4. For B5244T5 2005-, see «Engine speed (RPM) sensor, replacing»(ref-430984-S26474169192012011700000) .

Remedy as necessary

1. Continue Refer to «Verification»(ref-430984-S39881338732011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Start the engine. Allow the engine to idle. There is a fault if the engine does not start
2. Read off the diagnostic status and the fault status for diagnostic trouble code (DTC) ECM-5200. Check that the fault status is "NO FAULT FOUND" when the diagnostic status is COMPLETED. If the fault status is "FAULT FOUND" when the diagnostic status is COMPLETED there is a fault.

Does the engine start and is the fault status "NO FAULT FOUND"?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S36554466482011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Faulty signal

See Faulty signal

Checking interference to the engine speed (RPM) sensor

Check the engine speed (RPM) sensor connector. Check for contact resistance and oxidation.

The engine speed (RPM) sensor is sensitive to interference from surrounding power cables, the starter motor cable for example, or similar high amperage cables. This occurs when starting the engine for example.

Interference can cause difficulty in starting the engine, the engine does not start at all, the tachometer flickers at start attempts etc.

Causes of interference can be

1. surrounding power cables, for example an incorrectly routed starter motor cable
2. incorrectly routed transmission bolted joints for the engine.

Checking the power cable

Check for incorrectly routed power cables (routed too close to the engine speed (RPM) sensor).

Checking the bolted joints

When removing and installing the transmission it is important that all the bolts for the engine are correctly tightened. Incorrectly tightened bolts can cause poor ground connection and interfere with the engine speed (RPM) sensor. Check that all the bolts from the transmission to the engine are correctly tightened.

Other information

1. See «Checking wiring and terminals»(ref-430909-S26456997912011101900000)
2. For B5xx4T -2001, see «Replacing the engine speed (RPM) sensor»(ref-430961-S04288859222011101900000)
3. For B5xx4T 2002-, does not apply to B5244T5, see «Replacing the engine speed (RPM) sensor»(ref-430961-S41057985512011101900000)
4. For B5244T5 2005-, see «Engine speed (RPM) sensor, replacing»(ref-430984-S26474169192012011700000) .

Remedy as necessary

1. Continue Refer to «Verification»(ref-430984-S13112355222011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Start the engine. Allow the engine to idle. There is a fault if the engine does not start
2. Read off the diagnostic status and the fault status for diagnostic trouble code (DTC) ECM-5200. Check that the fault status is "NO FAULT FOUND" when the diagnostic status is COMPLETED. If the fault status is "FAULT FOUND" when the diagnostic status is COMPLETED there is a fault.

Does the engine start and is the fault status "NO FAULT FOUND"?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S32589318962011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Signal missing

Checking interference

The engine speed (RPM) sensor is sensitive to interference from surrounding power cables, the starter motor cable for example, or similar high amperage cables. This occurs when starting the engine for example.

Interference can cause difficulty in starting the engine, the engine does not start at all, the tachometer flickers at start attempts etc.

Causes of interference can be

1. surrounding power cables, for example an incorrectly routed starter motor cable
2. incorrectly routed transmission bolted joints for the engine.

Checking the power cable

Check for incorrectly routed power cables (routed too close to the engine speed (RPM) sensor).

Checking the bolted joints

When removing and installing the transmission it is important that all the bolts for the engine are correctly tightened. Incorrectly tightened bolts can cause poor ground connection and interfere with the engine speed (RPM) sensor. Check that all the bolts from the transmission to the engine are correctly tightened.

Remedy as necessary

Check the engine speed (RPM) sensor connector. Check for intermittent contact resistance and oxidation.

Other information

1. For B5xx4T -2001, see «Replacing the engine speed (RPM) sensor»(ref-430961-S04288859222011101900000)
2. For B5xx4T 2002-, does not apply to B5244T5, see «Replacing the engine speed (RPM) sensor»(ref-430961-S41057985512011101900000)
3. For B5244T5 2005-, see «Engine speed (RPM) sensor, replacing»(ref-430984-S26474169192012011700000) .

1. Continue Refer to «Verification»(ref-430984-S41005983162011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Start the engine. Allow the engine to idle. There is a fault if the engine does not start
2. Read off the diagnostic status and the fault status for diagnostic trouble code (DTC) ECM-5200. Check that the fault status is "NO FAULT FOUND" when the diagnostic status is COMPLETED. If the fault status is "FAULT FOUND" when the diagnostic status is COMPLETED there is a fault.

Does the engine start and is the fault status "NO FAULT FOUND"?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S09302111222011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Signal too high

Check that the engine speed (RPM) sensor is correctly installed.

Check the engine speed (RPM) sensor. Check that it is not damaged or dirty.

Check the flywheel for damage.

Other information

1. For B5xx4T -2001, see «Replacing the engine speed (RPM) sensor»(ref-430961-S04288859222011101900000)
2. For B5xx4T 2002-, does not apply to B5244T5, see «Replacing the engine speed (RPM) sensor»(ref-430961-S41057985512011101900000)
3. For B5244T5 2005-, see «Engine speed (RPM) sensor, replacing»(ref-430984-S26474169192012011700000) .

1. Continue Refer to «Verification»(ref-430984-S33923945962011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Start the engine. Allow the engine to idle. There is a fault if the engine does not start
2. Read off the diagnostic status and the fault status for diagnostic trouble code (DTC) ECM-5200. Check that the fault status is "NO FAULT FOUND" when the diagnostic status is COMPLETED. If the fault status is "FAULT FOUND" when the diagnostic status is COMPLETED there is a fault.

Does the engine start and is the fault status "NO FAULT FOUND"?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S18487082592011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Signal too low

See Fault-tracing information

See Signal missing. Permanent fault

See Signal too high. Permanent fault

See Signal too low. Permanent fault

Programming/replacing the engine control module (ECM)

1. Ignition off. The engine control module (ECM) has registered an internal fault or a fault in the software. Try downloading new software into the control module. To download new software or replace the engine control module (ECM), see: See «Engine control module (ECM), replacing»(ref-430961-S10976842282011101900000) . If software cannot be downloaded or new software does not solve the problem, replace the engine control module (ECM) and download the relevant software to the new control module. NOTE: After downloading new software or replacing the engine control module (ECM), the throttle unit must be adapted according to VIDA Vehicle communication: "Throttle unit adaptation". Remedy as necessary.

1. Continue Refer to «Information»(ref-430984-S14695254602011101900000)

In case of this defect, troubleshooting is not followed by verification.

The information can be displayed again or the fault-tracing for this fault can be interrupted.

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

See Fault-tracing information

1. Ignition on
2. Read off the oil level sensor signal. Check that all three values for oil level, oil temperature and oil grade are between 17-83%. The fault is intermittent at the moment if all the values are OK.

1. Continue Refer to «Checking connectors and wiring»(ref-430984-S35402768192011101900000)

Oil-level: sensor, replacing

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Removing the oil level sensor

Remove the splash guard under the engine. Only applies to cars with automatic transmissions.

Position the container under the engine oil trough.

Remove the oil plug.

Drain the engine oil. It is easier to drain the oil if the engine is at operating temperature.

Scheme 667

Remove

1. the screws for the sensor. Disconnect the connector for the sensor
2. the sensor.

Installing the oil level sensor

Note. For tightening torques, see Tightening torque .

Install

1. the sensor
2. screws for the sensor. Tighten. Connect the connector to the sensor
3. the oil plug.

Fill with engine oil. Run the engine to operating temperature. Check for any oil leakage.

Install the splashguard under the engine. Only applies to cars with automatic transmissions.

Check the oil level. Top up if required.

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Ignition on
4. Read off the oil level sensor signal. Check that all three values for oil level, oil temperature and oil grade are between 17-83%. The fault has been remedied if all the values are OK.

Are these values OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S19056588112011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

1. Ignition on
2. Read off the oil level sensor signal. Check that all three values for oil level, oil temperature and oil grade are between 17-83%. The fault is intermittent at the moment if all the values are OK.

1. Continue Refer to «Checking the wiring»(ref-430984-S38989679032011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Ignition on
4. Read off the oil level sensor signal. Check that all three values for oil level, oil temperature and oil grade are between 17-83%. The fault has been remedied if all the values are OK.

Are these values OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S09876047612011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

1. Ignition on
2. Read off the oil level sensor signal. Check that all three values for oil level, oil temperature and oil grade are between 17-83%. The fault is intermittent at the moment if all the values are OK.

1. Continue Refer to «Checking the wiring»(ref-430984-S28051972512011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Ignition on
4. Read off the oil level sensor signal. Check that all three values for oil level, oil temperature and oil grade are between 17-83%. The fault has been remedied if all the values are OK.

Are these values OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S20596222672011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking for oil leakage and replacing the component

Note. If diagnostic trouble codes (DTCs) ECM-540X and ECM-550X are stored at the same time, codes ECM-540X must be remedied first.

1. Checking the engine for oil leakage
2. Also check the oil level sensor connector. Check for loose connections, contact resistance or oxidation. HINT: This diagnostic trouble code (DTC) may be stored if the engine oil is significantly mixed with fuel or coolant for example. Try a new oil level sensor if no fault is found and the fault is permanent. Remedy as necessary. Other information: To connect the breakout box, see «Connecting the breakout box»(ref-430911-S30587875092011101900000) For information about signals: For 5 cylinder turbocharged engines -2001, see «Signal specification»(ref-430975-S34273110602011101900000) For 5 cylinder turbocharged engines 2002, see «Signal specification»(ref-430975-S11230688812011101900000) For B5254T2 -2004, see «Signal description»(ref-430975-S13000059482011101900000) For B5204T5, B5234T3, B5234T7 and B5244T3 -2004, see «SIGNAL SPECIFICATION (B5204T5, B5234T3, B5234T7 AND B5244T3 -2004)»(ref-430978-S25137021352012011700000) For B5254T4 2004, see «SIGNAL SPECIFICATION (B5254T4 2004)»(ref-430978-S06851592402012011700000) For 5 cylinder turbocharged engines 2005-, see «Signal specification»(ref-430975-S24350024032011101900000) . To access or replace the oil level sensor, see «Oil level sensor, replacing»(ref-430984-S35610398162012011700000) See «Checking wiring and terminals»(ref-430909-S26456997912011101900000)

1. Continue Refer to «Verification»(ref-430984-S31307949762011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reinstall the connectors, components etc.
3. Start the engine. Allow the engine to idle for 1 minute. Increase the engine speed (RPM) to approximately 5100 RPM for at least 1 second. The car must then be driven at a speed of more than 50 km/h. NOTE: The above instructions must be followed and carried out in the specified order.
4. Read off the status of the diagnostic trouble code (DTC). The fault has been remedied if status of the diagnostic trouble code (DTC) is intermittent.

Is the status of the diagnostic trouble code (DTC) intermittent?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S01777505292011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking the oil level and replacing the component

Note. If diagnostic trouble codes (DTCs) ECM-540X and ECM-550X are stored at the same time, codes ECM-540X must be remedied first.

1. Check that the oil level in the engine is not too low. Ensure that the level is correct. HINT: This diagnostic trouble code (DTC) may be stored if the engine oil is significantly mixed with fuel or coolant for example. Try a new oil level sensor if no fault is found and the fault is permanent. Remedy as necessary. Other information: To connect the breakout box / access the control module, see «Connecting the breakout box»(ref-430911-S30587875092011101900000) For information about signals: For 5 cylinder turbocharged engines -2001, see «Signal specification»(ref-430975-S34273110602011101900000) For 5 cylinder turbocharged engines 2002, see «Signal specification»(ref-430975-S11230688812011101900000) For B5254T2 -2004, see «Signal description»(ref-430975-S13000059482011101900000) For B5204T5, B5234T3, B5234T7 and B5244T3 -2004, see «SIGNAL SPECIFICATION (B5204T5, B5234T3, B5234T7 AND B5244T3 -2004)»(ref-430978-S25137021352012011700000) For B5254T4 2004, see «SIGNAL SPECIFICATION (B5254T4 2004)»(ref-430978-S06851592402012011700000) For 5 cylinder turbocharged engines 2005-, see «Signal specification»(ref-430975-S24350024032011101900000) . See «Oil level sensor, replacing»(ref-430984-S35610398162012011700000) See «Checking wiring and terminals»(ref-430909-S26456997912011101900000) .

1. Continue Refer to «Verification»(ref-430984-S24177156672011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Start the engine and allow to idle for approximately 1 minute
4. Read off the status of the diagnostic trouble code (DTC). The fault has been remedied if status of the diagnostic trouble code (DTC) is intermittent.

Is the status of the diagnostic trouble code (DTC) intermittent?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S35588783762011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

See Signal missing. Intermittent fault

Checking the connector

1. Ignition off
2. Check the air conditioning (A/C) relay connector. Check for contact resistance and oxidation
3. Reinstall the components, reconnect the connectors etc.
4. Ignition on
5. Activate the air conditioning (A/C) relay. A " clicking sound" should be heard when the air conditioning (A/C) relay is activated. If the air conditioning (A/C) relay is now OK, the cause of the fault was loose connections in the connector. Other information For information about signals: For 5 cylinder turbocharged engines -2001, see «Signal specification»(ref-430975-S34273110602011101900000) For 5 cylinder turbocharged engines 2002, see «Signal specification»(ref-430975-S11230688812011101900000) For B5254T2 -2004, see «Signal description»(ref-430975-S13000059482011101900000) For B5204T5, B5234T3, B5234T7 and B5244T3 -2004, see «SIGNAL SPECIFICATION (B5204T5, B5234T3, B5234T7 AND B5244T3 -2004)»(ref-430978-S25137021352012011700000) For B5254T4 2004, see «SIGNAL SPECIFICATION (B5254T4 2004)»(ref-430978-S06851592402012011700000) For 5 cylinder turbocharged engines 2005-, see «Signal specification»(ref-430975-S24350024032011101900000) . See «Checking wiring and terminals»(ref-430909-S26456997912011101900000) .

Does the air conditioning (A/C) relay function?

1. YES OKAY: Troubleshooting has been completed.
2. NO Refer to «Checking components and wiring»(ref-430984-S29342422472011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reconnect connectors, reinstall components
3. Ignition on.
4. Activate air conditioning (A/C) relay. An "clicking sound" should be heard from the air conditioning (A/C) relay when it is activated.

Does the air conditioning (A/C) relay function?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S13789522452011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Signal missing. Permanent fault

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

See Signal too high. Intermittent fault

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reconnect connectors, reinstall components
3. Ignition on.
4. Activate air conditioning (A/C) relay. An "clicking sound" should be heard from the air conditioning (A/C) relay when it is activated.

Does the air conditioning (A/C) relay function?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S32205990052011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Signal too high. Permanent fault

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

See Signal too low. Intermittent fault

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reconnect connectors, reinstall components
3. Ignition on.
4. Activate air conditioning (A/C) relay. An "clicking sound" should be heard from the air conditioning (A/C) relay when it is activated.

Does the air conditioning (A/C) relay function?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S22551642212011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

See Signal too low. Permanent fault

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

Checking connector

1. Ignition off.
2. Check turbocharger (TC) control valve connector for contact resistance and oxidation according to «Contact resistance and oxidation»(ref-451698-S00298544662012020900000) .
3. Reinstall components, reconnect connectors etc.
4. Ignition on.
5. Activate turbocharger (TC) control valve.
6. A click should be heard from the turbocharger (TC) control valve. If the function is OK the cause of the fault was loose connections in the connector. Other information To access/replace the turbocharger (TC) control valve, see «Replacing the turbocharger (TC) control valve»(ref-430985-S41822906312011101900000)

Is the function OK?

1. YES OKAY: Troubleshooting has been completed.
2. NO Refer to «Checking component and wiring»(ref-430984-S30644699022011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Ignition on.
4. Activate turbocharger (TC) control valve
5. A click should be heard from the turbocharger (TC) control valve.
6. Check that the function is OK.

Is function OK ?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S05611625362011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Ignition on.
4. Activate turbocharger (TC) control valve
5. A click should be heard from the turbocharger (TC) control valve.
6. Check that the function is OK.

Is function OK ?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S23378096892011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Ignition on.
4. Activate turbocharger (TC) control valve
5. A click should be heard from the turbocharger (TC) control valve.
6. Check that the function is OK.

Is function OK ?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S09686430452011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking hoses and the turbocharger (TC) control valve

Check the hoses between the pressure servo for the boost pressure control (BPC) valve and the turbocharger (TC) control valve. Check that the hoses are not trapped, blocked or damaged.

Check the hoses between the turbocharger (TC) control valve and the charge air pipe (between the turbocharger (TC) and the charge air cooler (CAC)). Check that the hoses are not trapped, blocked or damaged.

Check the turbocharger (TC) control valve by activating it. The turbocharger (TC) control valve must click when it is activated.

Check the setting of the pressure servo for the boost pressure control (BPC) valve. Check the boost pressure control (BPC) valve. Check that the pressure servo and the boost pressure control (BPC) valve are functioning correctly and are not sticking

See Wastegate valve, adjusting

See Pressure regulator, checking/adjusting

Other information

1. See «Replacing the turbocharger (TC) control valve»(ref-430985-S41822906312011101900000) .

1. Continue Refer to «Verification»(ref-430984-S22932515982011101900000)

Pressure regulator, checking/adjusting

Special tools

9995646

9995544

Preparation

To simplify the following text, the terms turbo1 and turbo2 are used.

turbo1 is for cylinders 1,2,3. turbo2 is for cylinders 4, 5, 6.

Note. Always check / set both the pressure regulators.

Scheme 668

Remove

1. the screw for the engine stabilizer brace mounting on the engine
2. the cross stay between the suspension turrets
3. the plastic charge air pipe. Place to one side
4. the plastic intake pipe. Put it to one side.

Remove the pressure regulator hoses at the T piece

Position the turbo1 pressure regulator hose so that it can be reached from underneath the car later on.

Scheme 669

Raise the car.

Remove the lower splash guard.

Pull down the hose from the pressure regulator.

Remove the split pin from the lever.

Lift off the push rod.

Scheme 670

Connect

1. manometer «9995646»(ref-403953-S17881977312011061000000) to the pressure regulator hose
2. pressure regulator «9995544»(ref-403953-S05241159092011061000000) to the manometer.

Note. When taking readings the manometer must always hang vertically from its hook. This is to ensure that the correct values are obtained. Set the three-way junction handle to the middle position.

Screw out the adjustment screw for the pressure regulator completely.

Connect compressed air to pressure regulator.

Screw in the adjustment screw for the pressure regulator so that the manometer displays the value applicable to the relevant engine, according to the table below.

The three-way junction connector has a vent (drilled hole) where it connects to the pressure regulator to facilitate setting the correct pressure.

Scheme 671

Push the boost pressure control (BPC) valve lever towards the turbocharger (TC) housing. The boost pressure control (BPC) valve should be closed.

Check that the push rod locates on the lever lug.

If necessary, adjust the push rod until it locates.

Note. The boost pressure control (BPC) valve spindle must be mounted on the lever when the lock-nut is adjusted. The diaphragm in the pressure regulator will be damaged if the push rod is twisted.

Install the split pin on the lever.

Tighten the locknut on the lever.

Remove the test equipment.

Insert the hose upwards following previous routing.

Install the lower splash guard.

Lower the car.

Scheme 672

Remove

1. the turbocharger (TC) intake pipe
2. the charge air pipe from the turbocharger (TC)
3. the heat deflector plate over the turbocharger (TC).

Checking and adjusting push rod

1. Check and adjust the push rod. See «Checking and adjusting push rod»(ref-430984-S35368744012012011700000) .

Install the split pin on the lever.

Tighten the locknut on the lever.

Remove the test equipment.

Install

1. the heat deflector plate over the turbocharger (TC). Tighten to 25 Nm
2. the charge air and intake pipes to the turbocharger (TC). Align against the plastic pipes and tighten.

Lower the car.

1. the engine stabilizer brace between the suspension turrets. Tighten the screws at the suspension turret. Tighten to 50 Nm
2. the screw for the engine stabilizer brace mounting on the engine. Tighten to 80 Nm .

Press the plastic pipes into place and tighten the clamps.

1. the mounting screws for plastic pipes and tighten
2. the hoses from the pressure regulators to the T piece.

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Test drive the vehicle on the road. Ensure that high boost pressure is reached (high load) so that the engine control module (ECM) can run the diagnostic
4. Connect VCT2000 to the data link connector (DLC) without switching off the engine. NOTE: If the engine is switched off, the stored fault status will be erased and the test drive will have to be repeated. Read off the diagnostic status and fault status for the diagnostic trouble code (DTC) by selecting the relevant diagnostic trouble code (DTC) from the list. Check the fault status for the diagnostic trouble code (DTC) when the diagnostic is "Complete". If the function is correct, the fault status must be "No fault found" when the diagnostic is complete.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S28239414472011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Scheme 673

1. Ignition off.

Check the intake system for air leakage and loose charge-air pipe.

See Air leakage in the intake system, checking

Does the problem persist?

1. YES Refer to «Checking hoses and the turbocharger (TC) control valve»(ref-430984-S30355877022011101900000)
2. NO Refer to «Verification»(ref-430984-S19345535802011101900000)

Check the turbocharger (TC) control valve by activating it. The turbocharger (TC) control valve must click when it is activated.

Check the setting of the pressure servo for the boost pressure control (BPC) valve. Check the boost pressure control (BPC) valve. Check that the pressure servo and the boost pressure control (BPC) valve are functioning correctly and are not sticking: Wastegate valve, adjusting

Other information

1. See «Replacing the turbocharger (TC) control valve»(ref-430985-S41822906312011101900000)
2. See «Quick check, turbocharger (TC)»(ref-430964-S14970156512011101900000)
3. See «Turbocharger (TC), replacing»(ref-430985-S34618679542011101900000)

1. Continue Refer to «Verification»(ref-430984-S19345535802011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reconnect the connectors, reinstall components etc.
3. Test drive the vehicle on the road. Ensure that high boost pressure is reached (high load) so that the engine control module (ECM) can run the diagnostic
4. Connect VCT2000 to the data link connector (DLC) without switching off the engine. NOTE: If the engine is switched off, the stored fault status will be erased and the test drive will have to be repeated. Read off the diagnostic status and fault status for the diagnostic trouble code (DTC) by selecting the relevant diagnostic trouble code (DTC) from the list. Check the fault status for the diagnostic trouble code (DTC) when the diagnostic is "Complete". If the function is correct, the fault status must be "No fault found" when the diagnostic is complete.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S32732928492011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Replacing a component

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. Replace the engine cooling fan (FC) control module if the engine cooling fan (FC) cannot be activated at all speeds and no faults have been found on wiring and connections. Remedy as necessary. Other information: See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000)

1. Continue Refer to «Verification»(ref-430984-S14975926202011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reinstall the connectors, components etc.
3. Ignition on. Activate the engine cooling fan (FC). Check all 6 speeds of the engine cooling fan (FC).

Is the engine cooling fan (FC) working?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S08566356642011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking the component

1. Ignition off.
2. Check that the engine cooling fan (FC) blade rotates easily. Check that nothing is obstructing the engine cooling fan (FC) blade.
3. Remedy as necessary.
4. Ignition on.
5. Check all speeds of the engine cooling fan (FC). Activate the engine cooling fan (FC) by clicking the VCT2000 symbol.

1. Continue Refer to «Checking the component and wiring»(ref-430984-S04412486772011101900000)

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. Replace the engine cooling fan (FC) control module if the engine cooling fan (FC) cannot be activated at all speeds and no faults have been found on wiring and connections. Remedy as necessary. Other information: See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000)

1. Continue Refer to «Verification»(ref-430984-S11979226192011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reinstall the connectors, components etc.
3. Ignition on. Activate the engine cooling fan (FC). Check all 6 speeds of the engine cooling fan (FC).

Is the engine cooling fan (FC) working?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S35689376252011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

1. Ignition off.
2. Check that the fan blade rotates easily. Check that nothing is obstructing the fan
3. Remedy as necessary
4. Ignition on
5. Check all speeds of the engine cooling fan (FC). Activate the engine cooling fan (FC) by clicking the VCT2000 symbol.

1. Continue Refer to «Checking the component and wiring»(ref-430984-S09855020102011101900000)

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. Replace the engine cooling fan (FC) control module if the engine cooling fan (FC) cannot be activated at all speeds and no faults have been found on wiring and connections. Remedy as necessary. Other information: See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000)

1. Continue Refer to «Verification»(ref-430984-S21904922402011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reinstall the connectors, components etc.
3. Ignition on. Activate the engine cooling fan (FC). Check all 6 speeds of the engine cooling fan (FC).

Is the engine cooling fan (FC) working?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S10946547692011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

1. Ignition off.
2. Check that the engine cooling fan (FC) blade rotates easily. Check that nothing is obstructing the engine cooling fan (FC) blade.
3. Remedy as necessary.
4. Ignition on.
5. Check all speeds of the engine cooling fan (FC). Activate the engine cooling fan (FC) by clicking the VCT2000 symbol.

1. Continue Refer to «Checking components and wiring»(ref-430984-S23641876462011101900000)

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. Replace the engine cooling fan (FC) control module if the engine cooling fan (FC) cannot be activated at all speeds and no faults have been found on wiring and connections. Remedy as necessary. Other information: See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000)

1. Continue Refer to «Verification»(ref-430984-S01101272422011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off
2. Reinstall the connectors, components etc.
3. Ignition on. Activate the engine cooling fan (FC). Check all 6 speeds of the engine cooling fan (FC).

Is the engine cooling fan (FC) working?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S05954121902011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

Faulty signal. Intermittent fault

See Faulty signal. Intermittent fault

1. Ignition off.
2. Check that the fan blade rotates easily. Check that nothing is obstructing the fan.
3. Remedy as necessary.
4. Ignition on.
5. Check all speeds of the engine cooling fan (FC). Activate the engine cooling fan (FC) by clicking the VCT2000 symbol.

1. Continue Refer to «Checking component»(ref-430984-S41794093912011101900000)

Checking component

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. If the engine cooling fan (FC) cannot be activated at any speed: Check the fuse, power supply cable and ground lead for the engine cooling fan (FC). Check the connector and wiring between the engine control module (ECM) and engine cooling fan (FC) module. Check for damage. Check for an open circuit. Check for a short circuit. If the engine cooling fan (FC) can be activated at one or more speeds: Check the connectors to the engine cooling fan (FC) control module and Engine Control Module (ECM). Check for damage to pins and connections. Also check other connectors and connections that connect cables between Engine Control Module (ECM) and the control module for electric cooling fan. Check the wiring between the engine control module (ECM) and the engine cooling fan (FC) module. Check for damage. Remedy as necessary. Other information: See «Connecting the breakout box»(ref-430911-S30587875092011101900000) For information about signals: For 5 cylinder turbocharged engines -2001, see «Signal specification»(ref-430975-S34273110602011101900000) For 5 cylinder turbocharged engines 2002, see «Signal specification»(ref-430975-S11230688812011101900000) For B5254T2 -2004, see «Signal description»(ref-430975-S13000059482011101900000) For B5204T5, B5234T3, B5234T7 and B5244T3 -2004, see «SIGNAL SPECIFICATION (B5204T5, B5234T3, B5234T7 AND B5244T3 -2004)»(ref-430978-S25137021352012011700000) For B5254T4 2004, see «SIGNAL SPECIFICATION (B5254T4 2004)»(ref-430978-S06851592402012011700000) For 5 cylinder turbocharged engines 2005-, see «Signal specification»(ref-430975-S24350024032011101900000) . See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000) For information about the cable routing, see the relevant Wiring Diagram. See «Checking wiring and terminals»(ref-430909-S26456997912011101900000)

Was a fault detected?

1. YES Refer to «Verification»(ref-430984-S36972301512011101900000)
2. NO Refer to «Replacing a component»(ref-430984-S36550008472011101900000)

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. Replace the engine cooling fan (FC) control module if the engine cooling fan (FC) cannot be activated at all speeds and no faults have been found on wiring and connections. Remedy as necessary. Other information: See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000)

1. Continue Refer to «Verification»(ref-430984-S36972301512011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall the connectors, components etc.
3. Ignition on. Activate the engine cooling fan (FC). Check that all the 3 engine cooling fan (FC) speeds function.

Is the engine cooling fan (FC) working?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S42202069622011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Faulty signal. Permanent fault

See Faulty signal. Permanent fault

HINT: Diagnostic trouble code (DTC) may be caused by a damaged fuse. If the engine does not start, check the fuse for the power supply to the camshaft reset valve.

1. Start the engine
2. Read off the value for the camshaft shift angle and the desired value for the camshaft shift angle
3. Active the quick test of camshaft control by clicking the start button
4. Increase the engine speed (RPM) to approximately 2500 RPM and keep the engine running at this speed. When the engine speed (RPM) increases, the control module will start the quick test to control the shift angle of the camshaft to the different target values. There is a fault if the control module does not operate the camshaft shift angle to the different target values. During the quick test, check that the shift angle of the camshaft (actual value) corresponds to the target values to an accuracy of 10°. If the shift angle of the camshaft (target value) does not change, or if the actual value does not correspond to the target value, the function is faulty. Deviation between the values can be read off in the lower display. Carry out the check for approximately 15 seconds at an engine speed (RPM) of 2500 RPM. The test is completed when the shift angle of the camshaft returns to 0°. To restart the test, let the engine return to idle speed, then increase the engine speed to approximately 2500 RPM. The fault is intermittent if the function is OK. NOTE: The test is active until the ignition is switched off. Switch off the ignition before the vehicle is delivered to the customer.

1. Continue Refer to «Checking components»(ref-430984-S06516081962011101900000)

Check the level and quality of the engine oil. Check for contaminants in particular.

Check the engine oil pressure.

Remove the camshaft reset valve. Check the oil ducts for the cylinder head for the camshaft reset valve (intake) for blockages and dirt.

HINT: The fault can be caused by contaminants in the camshaft reset valve. Try cleaning the valve.

Remedy as necessary.

Try a new intake camshaft reset valve if the above remedy does not solve the fault.

HINT: The fault may also have been caused by an internal fault in the variable valve timing unit. The variable valve timing unit may be damaged if the above fault-tracing and corrective action do not remedy the fault.

Other information

1. See «Checking oil pressure»(ref-430986-S02276284322011101900000)
2. See «VVT solenoid, inspection and cleaning»(ref-430984-S39324502642012011800000)
3. See «Replacing the variable valve timing solenoid»(ref-430984-S05164088622012011800000)
4. For B5xx4T -2001, see «Camshaft seal/variable valve timing (VVT) unit, replacing»(ref-430989-S26890464062011101900000)
5. For B5xx4T 2002-, see «Camshaft seal/variable valve timing (VVT) unit, replacing»(ref-430989-S14448442782011101900000) .
6. For B5254T4, see «Camshaft seals / variable valve timing (VVT) unit, replacing»(ref-451860-S27792738602012020900000)

1. Continue Refer to «Verification»(ref-430984-S15886051252011101900000)

Scheme 674

Remove VVT solenoid from camshaft cover.

Blow through center hole with compressed air.

Air should emerge from inner hole (1) nearest coil.

Scheme 675

Connect power to solenoid. Solenoid should click.

Blow through center hole with compressed air.

Air should emerge from outer hole (2) if solenoid and plunger are functioning properly.

Scheme 676

Remove solenoid from aluminum housing.

Scheme 677

Remove

1. snap ring (1)
2. washer (2), spring (3) and plunger (4).

Inspect and clean all parts.

Blow out aluminum housing.

Oil parts with engine oil.

Reassemble solenoid.

Check operation as described in operations 1 and 2.

Reinstall solenoid in car using new seal.

Replacing the variable valve timing solenoid

Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Scheme 678

Applies only to B6xx4T

Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and the turbocharger (TC).

Put them to one side.

Slacken off the clamp for the intake manifold at the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the manifold towards the firewall.

Scheme 679

Remove the upper timing belt cover.

Note. Clean the area around the variable valve timing (VVT) solenoid thoroughly to avoid contaminated oil entering the ducts / the variable valve timing (VVT) unit.

Remove

1. the connector for the check valve
2. the screws holding the valve
3. the control valve and the gasket.

Installing the variable valve timing solenoid

Clean the gasket faces. Note the cleanliness requirements above.

Install a new gasket.

Install

1. a new check valve Tighten the control valve crosswise. Tighten to 10 Nm
2. the connector
3. the upper timing belt cover.

Applies only to B6xx4T

Turn back the intake manifold for the turbocharger (TC) for cylinders 1, 2, 3 and tighten the clamp.

Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC).

Tighten the hose clamps.

HINT: After carrying out the repair, check that the fault has been remedied.

1. Start the engine
2. Read off the value for the camshaft shift angle and the desired value for the camshaft shift angle
3. Active the quick test of camshaft control by clicking the start button
4. Increase the engine speed (RPM) to approximately 2500 RPM and keep the engine running at this speed. When the engine speed (RPM) increases, the control module will start the quick test to control the shift angle of the camshaft to the different target values. There is a fault if the control module does not operate the camshaft shift angle to the different target values. During the quick test, check that the shift angle of the camshaft (actual value) corresponds to the target values to an accuracy of 10°. If the shift angle of the camshaft (target value) does not change, or if the actual value does not correspond to the target value, the function is faulty. Deviation between the values can be read off in the lower display. Carry out the check for approximately 15 seconds at an engine speed (RPM) of 2500 RPM. The test is completed when the shift angle of the camshaft returns to 0°. To restart the test, let the engine return to idle speed, then increase the engine speed to approximately 2500 RPM. NOTE: The test is active until the ignition is switched off. Switch off the ignition before the car is delivered to the customer.

Is the function OK?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S27271377132011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

If the fault is intermittent, do not verify fault-tracing if the fault does not recur.

It is possible to view the information again, or leave fault-tracing for this diagnostic trouble code (DTC).

See Signal missing. Intermittent fault

1. Ignition off.
2. Check that the fan blade rotates easily. Check that nothing is obstructing the fan.
3. Remedy as necessary.
4. Ignition on.
5. Check all speeds of the engine cooling fan (FC). Activate the engine cooling fan (FC) by clicking the VCT2000 symbol.

1. Continue Refer to «Checking components and wiring»(ref-430984-S38115326812011101900000)

Replacing engine cooling fan control module

1. Ignition off. CAUTION: Avoid touching the pins in the control module and the corresponding connector on the cable harness. There is a risk of static discharge which could damage the control module. Discharge yourself and tools to be used by holding the tool's metal part and touching a body part on the car just before starting to work. Replace the engine cooling fan (FC) control module if the engine cooling fan (FC) cannot be activated at all speeds and no faults have been found on wiring and connections. Remedy as necessary. Other information See «Engine cooling fan (FC), replacing»(ref-430971-S21904131862011101900000)

1. Continue Refer to «Verification»(ref-430984-S24775246002011101900000)

HINT: After carrying out the repair, check that the fault has been remedied.

1. Ignition off.
2. Reinstall connectors, components etc.
3. Ignition on. Activate the engine cooling fan (FC). Check that all 3 engine cooling fan (FC) speeds function.

Is the engine cooling fan (FC) working?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-430984-S09216324282011101900000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.