TRIONIC T7 Fuel Control System
- Adjustment - Replacement
- Control Module
- Crankshaft position sensor
- Manifold absolute pressure sensor
- Charge air absolute pressure sensor
- Intake air temperature sensor
- Temperature sensor, engine coolant
- Mass air flow sensor
- Throttle body
- Limp-home solenoid
- Resetting Triggered Limp-Home Mechanism
- Relay, Limp-Home Solenoid
- Switch, cruise control
- Brake pedal switch
- Clutch pedal switch
- Charge Air Control Valve
- Checking and adjusting basic charging pressure
- Checking the wastegate
- Turbo bypass control valve
- Fuel pressure regulator
- Checking the fuel pressure regulator
- Fuel pump
- Checking fuel pump capacity
- Relay, fuel pump
- Main relay
- Relay, A/C
- Injectors
- Checking injector flow capacity
- Front oxygen sensor, B235E/R
- Rear oxygen sensor, B235E/R
- EVAP pressure sensor
- EVAP canister purge valve
- EVAP close valve
- Ignition discharge module
- Spark plugs
- Adjusting accelerator pedal cable
- Leak check, fuel pressure, flow capacity and adaptation procedures
- Checking intake system integrity
- Component Location
- Main fuse board 22a in the dashboard
- Brake light switch (29)
- Level sensor, fuel (46)
- Relay, fuel pump (102)
- Clutch switch, cruise control (133)
- Brake switch, cruise control (134)
- Switch, cruise control (141)
- Relay, A/C compressor (156)
- Boost pressure control valve (179a)
- Temperature sensor, coolant (202)
- Mass air flow sensor (205)
- Injector, cylinder 1 (206a)
- Injector, cylinder 2 (206b)
- Injector, cylinder 3 (206c)
- Injector, cylinder 4 (206d)
- Main relay, engine management system (229)
- Transmission range switch 1, automatic (245)
- Heating element, oxygen sensor (271)
- Purge valve, EVAP canister (321)
- Fuel pump motor (323)
- Crankshaft position sensor (345)
- Ignition discharge module (346)
- TC/ABS control module (382)
- Intake air temperature sensor (407)
- Pressure sensor, intake manifold (431)
- Main instrument unit (540)
- ABS control module (547)
- Pressure sensor, EVAP (585)
- Solenoid valve, EVAP shut-off (588)
- Trionic control module, 4-cyl petrol (589)
- Heated oxygen sensor 1 (592Fa)
- Heated oxygen sensor 2 (592Ra)
- Pressure sensor, charge air (603)
- Actuator, throttle body (604)
- Wastegate valve (605)
- Solenoid, limp-home (607)
- Relay, limp-home (640)
- ESP control module (671)
- Sensor, intake air (688)
- Connector H2-43
- Connector H4-2
- Connector H16-6
- Connector H16-7
- Connector H33-1
- Connector H42-5
- Connector H43-1
- Connector H80-1
- Crimp J15, petrol engine harness
- Crimp J16, petrol engine harness
- Crimp J17, petrol engine harness
- Crimp J18, petrol engine harness
- Crimp J20, petrol engine harness
- Crimp J21, petrol engine harness
- Crimp J22, petrol engine harness
- Crimp J23, petrol engine harness
- Crimp J24, petrol engine harness
- Crimp connection J55, instrument harness
- Crimp connection J58, instrument harness
- Crimp connection J60, instrument harness
- Crimp connection J61, instrument harness
- Crimp connection J63, instrument harness
- Crimp connection J83, instrument harness
- Crimp connection J89, instrument harness
- Crimp connection J93, rear harness
- Crimp connection J142, instrument harness
- Crimp J165, instrument harness
- Crimp J169, instrument wiring
- Crimp connection J173, instrument harness
- Grounding point G5
- Grounding point G7, 4-cyl. petrol
- Fault Diagnosis, Fault Codes
- DTC P0100: Mass Air Flow Circuit - No Signal
- DTC P0101: Mass Air Flow Circuit - Performance Problems
- DTC P0102: Mass Air Flow Circuit - Low Input
- DTC P0103: Mass Air Flow Circuit - High Input
- DTC P0106: Manifold Absolute Pressure Sensor Circuit - Performance Problem
- DTC P0107: Manifold Absolute Pressure Sensor Circuit - Open/Short to Ground
- DTC P0108: Manifold Absolute Pressure Sensor Circuit - Short to B+
- DTC P0112: Intake Air Temperature Sensor Circuit - Short to Ground
- DTC P0113: Intake Air Temperature Sensor Circuit - Short to B+/Open Circuit
- DTC P0115: Engine Coolant Temperature Circuit - Performance Problem
- DTC P0116: Engine Coolant Temperature Circuit - Performance Problem
- DTC P0117: Engine Coolant Temperature Sensor Circuit - Short to Ground
- DTC P0118: Engine Coolant Temperature Sensor Circuit - Short to B+/Open circuit
- DTC P0119: Engine Coolant Temperature Circuit - Intermittent Open/Short
- DTC P0125: Excessive Time to Enter Closed Loop Fuel Control
- DTC P0131: O2S Circuit - Low Voltage - Sensor 1
- DTC P0132: O2S Circuit - High Voltage - Sensor 1
- DTC P0133: O2S Circuit - Slow Response - Sensor 1
- DTC P0134: O2S Circuit - No Activity Detected - Sensor 1
- DTC P0137: O2S Circuit - Low Voltage - Sensor 2
- DTC P0138: O2S Circuit - High Voltage - Sensor 2
- DTC P0140: O2S Circuit - No Activity Detected - Sensor 2
- DTC P0171: Long Term Fuel Trim Multiplicative - Max Value, Air/Fuel Too Lean
- DTC P0172: Long Term Fuel Trim Multiplicative - Min Value, Air/Fuel Too Rich
- DTC P0300: Random Misfire Detected
- DTC P0301: Cylinder 1 Misfire Detected
- DTC P0302: Cylinder 2 Misfire Detected
- DTC P0303: Cylinder 3 Misfire Detected
- DTC P0304: Cylinder 4 Misfire Detected
- DTC P0327: Knock Sensor Circuit - Low Input - Bank 1
- DTC P0336: Crankshaft Position Sensor Circuit - Performance Problem
- DTC P0337: Crankshaft Position Sensor - No Input
- DTC P0340: Camshaft Position Sensor Malfunction
- DTC P0420: Three Way Catalytic Converter Malfunction
- DTC P0441: EVAP Purge Valve Malfunction
- DTC P0442: EVAP Small Leakage In System
- DTC P0444: EVAP Purge Valve Circuit - Open/Short To Ground
- DTC P0445: EVAP Purge Valve Circuit - Short To B+
- DTC P0452: EVAP Tank Pressure Sensor Circuit - Short To Ground
- DTC P0453: EVAP Tank Pressure Sensor Circuit - Open/Short To B+
- DTC P0455: EVAP Serious Leakage In System
- DTC P0456: Tank Purging - Very Minor Leak In System
- DTC P0501: Vehicle Speed - Input Signal Outside Limits
- DTC P0502: Vehicle Speed - No Input Signal
- DTC P0506: Idle Speed Control - Idling Speed Too Low
- DTC P0507: Idle Speed Control - Idling Speed Too High
- DTC P0605: Internal Control Module Malfunction
- DTC P1105: Charge Air Absolute Pressure Sensor Circuit - Performance Problem
- DTC P1106: Charge Air Absolute Pressure Sensor Circuit - Performance Problem
- DTC P1107: Charge Air Absolute Pressure Sensor Circuit - Short To Ground/Open
- DTC P1108: Charge Air Absolute Pressure Sensor Circuit - Short to B+
- DTC P1110: Charge Air Bypass Valve Performance Problems
- DTC P1131: O2S Switch Point - Lean - Sensor 1
- DTC P1132: O2S Switch Point - Rich - Sensor 1
- DTC P1133 O2S Circuit Low Voltage - Sensor 1
- DTC P1135: O2S Heater Circuit Current Too Low - Sensor 1
- DTC P1136: O2S Heater Circuit Current Too High - Sensor 1
- DTC P1137: O2S Circuit Low Voltage - Sensor 2
- DTC P1141: O2S Heater Circuit Current Too Low - Sensor 2
- DTC P1142: O2S Heater Circuit Current Too High - Sensor 2
- DTC P1171: Short Term Fuel Trim. Max Value, Air/Fuel Too Lean
- DTC P1172: Short Term Fuel Trim Min. Value - Air/Fuel Too Rich
- DTC P1181: Long Term Fuel Trim Additive Max Value - Air/Fuel Too Lean
- DTC P1182: Long Term Fuel Trim Additive Min. Value - Air/Fuel Too Rich
- DTC P1230: Throttle Position Sensor 1 & 2 Circuit Sum Out-Of-Range - Faulty Signal From Throttle Disc Position Sensor
- DTC P1231: Throttle Position Sensor 1 & 2 Circuit - Sum Out-Of-Range (No Limp Home)
- DTC P1240: Throttle Motor Circuit Shorted
- DTC P1251: Throttle Motor - Full PWM In Closing Direction (Note: May Set If Mechanism Is Not Reseted)
- DTC P1252: Throttle Motor - Full PWM In Open Direction And No Motor Current
- DTC P1253: Throttle Motor - Full PWM In Open Direction During Cranking
- DTC P1260: Throttle Return Spring - Too Low Force (Note: May Set If Mechanism Is Not Reset)
- DTC P1261: Throttle Binding.
- DTC P1263: Throttle Moved Manually When Engine Was Running.
- DTC P1264: Throttle Open When Pedal Is Released.
- DTC P1300: Random Misfire Detected - Catalyst Damaging
- DTC P1301: Cylinder 1 Misfire Detected - Catalyst Damaging
- DTC P1302: Cylinder 2 Misfire Detected - Catalyst Damaging
- DTC P1303: Cylinder 3 Misfire Detected - Catalyst Damaging
- DTC P1304: Cylinder 4 Misfire Detected - Catalyst Damaging
- DTC P1310: Ignition Discharge Module Not Powered - Bank 1
- DTC P1312: Combustion Detection Cyl. 1+2 - Open Circuit/Short to B+
- DTC P1334: Combustion Detection Cyl. 3+4 - Open Circuit/Short to B+
- DTC P1390: Random Misfire Detected - Catalyst Damaging - Fuel Level Low
- DTC P1391: Cylinder 1 Misfire Detected - Catalyst Damaging - Fuel Level Low
- DTC P1392: Cylinder 2 Misfire Detected - Catalyst Damaging - Fuel Level Low
- DTC P1393: Cylinder 3 Misfire Detected - Catalyst Damaging - Fuel Level Low
- DTC P1394: Cylinder 4 Misfire Detected - Catalyst Damaging - Fuel Level Low
- DTC P1441: EVAP Purge Valve & Fuel Level Sensor Malfunction
- DTC P1442: EVAP Small Leakage In System & Fuel Level Sensor Malfunction
- DTC P1444: Canister Close Valve Circuit - Open/Short To Ground
- DTC P1445: Canister Close Valve Circuit - Short To B+
- DTC P1451: EVAP Tank Pressure Sensor - Performance Problem
- DTC P1452: EVAP Tank Pressure Sensor - Value Too Low When Depressurized
- DTC P1453: EVAP Tank Pressure Sensor - Value Too High When Depressurized
- DTC P1455: EVAP Tank Pressure Sensor - Serious Leakage In System & Fuel Level Sensor Malfunction
- DTC P1456: Tank Purging - Leak In System
- DTC P1460: Immobilizer Active (Note: If new T7, MIU or TWICE module, program code in TWICE)
- DTC P1491: EVAP Tank Pressure Sensor Performance Problem & Fuel Level Sensor Malfunction
- DTC P1492: EVAP Tank Pressure Sensor Value Too Low When Depressurized & Fuel Level Sensor Malfunction
- DTC P1493: EVAP Tank Pressure Sensor Value Too High When Depressurized & Fuel Level Sensor Malfunction
- DTC P1530: Pedal Position Sensor 1 & 2 Circuit - Sum Out-Of-Range
- DTC P1531: Pedal Position Sensor 1 & 2 Circuit - Adapted Sum Out-Of-Range
- DTC P1532: Pedal Position Sensor 1 & 2 Circuit - Control Module Inputs Shorted To Each Other
- DTC P1549: Charge Air Malfunction
- DTC P1576: Brake Light Switch Circuit Open/Short To B+
- DTC P1577: Brake Light Switch Circuit Short To Ground
- DTC P1601: Internal Control Module Malfunction
- DTC P1602: Internal Control Module Malfunction
- DTC P1603: Internal Control Module Malfunction
- DTC P1604: Internal Control Module Malfunction
- DTC P1605: Internal Control Module Malfunction
- DTC P1606: Internal Control Module Malfunction
- DTC P1607: Internal Control Module Malfunction
- DTC P1608: Internal Control Module Malfunction
- DTC P1609: Internal Control Module Malfunction
- P1610: Internal Control Module Malfunction
- DTC P1611: Internal Control Module Malfunction
- DTC P1613: Internal Control Module Malfunction
- DTC P1614: Internal Control Module Malfunction
- DTC P1621: Internal Control Module Malfunction
- DTC P1622: No Bus Data From MIU
- DTC P1623: No Bus Data From TCM
- DTC P1624: CHECK ENGINE Request (Bus from TCM)
- DTC P1625: No Bus data From TC/ABS
- DTC P1631: Internal Control Module Malfunction
- DTC P1632: Internal Control Module Malfunction
- DTC P1633: Internal Control Module Malfunction
- DTC P1640: Main Relay Circuit - No Voltage To Control Module Pin 1
- DTC P1641: Fuel Pump Relay - No Voltage To Fuel Pump & O2S Preheating
- DTC P1652: Main Relay Coil Circuit Open/Short To Ground
- DTC P1653: Main Relay Coil Circuit Short to B+
- DTC P1654: Fuel Pump Relay Coil Circuit Open/Short To Ground
- DTC P1655: Fuel Pump Relay Coil Circuit Short To B+
- DTC P1656: A/C Relay Coil Circuit Open/Short To Ground
- DTC P1657: A/C Relay Coil Circuit Short To B+
- DTC P1658: Charge Air Bypass Valve Circuit Open/Short To Ground
- DTC P1659: Charge Air Bypass Valve Circuit Short To B+
- DTC P1662: Charge Air Control Valve Circuit Open/Short To Ground
- DTC P1663: Charge Air Control Valve Circuit Short To B+
- DTC P1670 Limp-Home Relay - Open Circuit Or Short To Ground
- DTC P1671: Limp-Home Relay - Short To B+
- DTC P1676: Injector Circuit - Open/Short To Ground Or B+
- Fault Diagnosis General
- Fault diagnosis strategy for electronic systems
- LEV/OBD II diagnosis
- Fault Handling I, Catalyst Damaging Misfiring
- Fault Handling II, Emission-Related Misfiring Or Fault In Fuel System
- Fault Handling III, Other Emission-Related Components And Function
- Tech 2 menu structure
- Diagnostic trouble code menu
- Menu "Read Values"
- "Activate" menu
- Menu "System Information"
- Checklist for changing turbocharger and engine control module
- Before changing a control module
- Testing for open/short circuits
- Connectors, handling and inspection
- Enhanced ignition discharge module for Trionic 7
- Fault Diagnosis, Symptoms
- Car Will Not Start
- Idling speed low or irregular
- Substantial engine knocking
- Power too low
- Poor driveability, deteriorating performance, irregular or hesitant acceleration
- Engine speed does not go down
- Cruise control not working
- Low Engine Power Output/Little Movement On Turbo Pressure Gauge And Rattling From Turbocharger
- Special Tools
- Tech 2
- 30 14 883 Pressure/vacuum pump
- 83 93 514 Charge pressure gauge
- 83 93 852 Pressure measuring equipment, fuel and oil pressure
- 83 93 886 Diagnostics cable, LH system
- 83 94 538 Circlip tool
- 83 94 546 Fitting tool, fuel line
- 83 94 744 Adapter, fuel pressure testing
- 83 95 675 Test equipment, DI-system
- 83 95 659 Plug kit
- 86 10 867 Ground cable, DI system
- 86 11 170 Test cable, 70-pin
- 86 11 345 Jumper cable (x 2)
- 86 11 352 Measurement cable, male pin (x 4)
- 86 11 386 Test pin, ignition discharge module control
- 86 11 410 Measurement cable, female pin (x 4)
- 86 11 857 Test lamp, red-green
- 86 12 558 Hardware lock SPS (Service Programming)
- 86 12 996 Hardware key for USB port
- Technical Data
- Control module, Trionic T7 (589)
- General data
- Test readings, control module connections
- Crankshaft position sensor (345)
- Manifold absolute pressure sensor (431)
- Charge air absolute pressure sensor (603)
- Intake air temperature sensor (407)
- Coolant temperature sensor (202)
- Mass air flow sensor (205)
- Throttle body (604)
- Limp-home solenoid (607)
- Relay, limp-home solenoid (640)
- Switch, cruise control (141)
- Clutch pedal switch (133)
- Brake pedal switch (134)
- Charge air control valve (179a)
- Control valve, bypass (605)
- Fuel pressure regulator
- Fuel pump (323)
- Relay, fuel pump (102)
- Main relay (229)
- Relay, A/C (156)
- Injectors (206)
- Heated oxygen sensor 1, before catalytic converter (592Fa)
- Heated oxygen sensor 2, after catalytic converter (592Ra)
- EVAP canister purge valve (321)
- EVAP close control valve (588)
- EVAP pressure sensor (585)
- Trionic 7, Mode 06
- Ignition discharge module (346)
- Spark plugs (157)
- Technical Description
- System overview
- Main components
- Brief description
- System diagram - intake, turbo, exhaust - 4-cyl.
- Control module inputs
- Control module bus inputs
- Control module outputs
- Control module bus outputs
- Control module
- Control module power supply
- 5V supply
- Ground
- Crankshaft position sensor
- Mass air flow sensor
- Manifold absolute pressure sensor
- Charge air absolute pressure sensor
- Intake air temperature sensor
- Coolant temperature sensor
- Speed, lead from ABS
- Speed, bus from TC/ABS/ESP
- Bus messages, Trionic T7
- Main relay
- Fuel pump relay
- A/C relay
- Control valve, bypass
- Air mass control, basic function
- Pedal position sensor
- Cruise control
- Air mass limitation
- Notes
- Maximum engine torque
- Manual gearbox, engine torque limitation
- Automatic gearbox, stall limitation
- TCM, engine torque limitation
- Braking
- Traction Control/ESP, engine torque limitation
- Diagnostics
- Knock limitation
- Vehicle speed limitation
- Engine speed limitation
- Turbo speed limitation
- Limitations after system faults
- Overboost function
- Load compensation
- Other air request
- Throttle control
- Turbo control
- Fuel injection, basic function
- Basic quantity, fuel
- Compensation
- Closed loop
- Purging
- Multiplicative adaptation
- Additive adaptation
- Starting fuel
- Injection duration
- Fuel shut-off
- Injectors
- Ignition, basic function
- Idling speed ignition timing
- Catalytic converter heating ignition
- Normal ignition timing
- Knock control
- Starting ignition timing
- Ignition discharge module