TRIONIC T7 Fuel Control System
- Repair Instructions
- 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
- 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
- Procedure Upon Control Module Replacement And During SPS Of Trionic T7 Biopower E85
- Ignition Discharge Module
- Spark Plugs
- Adjusting The Accelerator Pedal Cable
- Leak Check, Fuel Pressure, Flow Capacity And Adaptation Procedures
- Checking Intake System Integrity
- Description & Operation
- System Overview
- Main Components
- Brief Description
- Brief Description, BioPower
- Fuel Properties, E85
- 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, Bus From 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
- BioPower
- Manual gearbox, engine torque limitation
- Automatic gearbox, stall limitation
- TCM, engine torque limitation
- Braking
- Traction Control / ESP, engine torque limitation
- Diagnosis
- 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
- Ethanol Adaptation
- Injectors
- Ignition, Basic Function
- Idling Speed Ignition Timing
- Catalytic Converter Heating Ignition
- Normal Ignition Timing
- Knock Control
- Starting Ignition Timing
- Ignition Discharge Module
- Component Locator
- 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)
- Motor, Fuel Pump (323)
- Crankshaft Position Sensor (345)
- Ignition Discharge Module (346)
- Intake Air Temperature Sensor (407)
- Pressure Sensor, Intake Manifold (431)
- Main Instrument Unit (540)
- 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)
- Unit, Fuel Pump (689)
- Connector H4-2
- Connector H10-4
- Connector H16-6
- Connector H16-7
- Connector H24-1
- Connector H24-2
- 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 J118, Instrument Harness
- Crimp Connection J142, Instrument Harness
- Crimp J165, Instrument Harness
- Crimp J169, Instrument Wiring
- Grounding Point G5
- Grounding Point G7, Petrol
- Specifications
- 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)
- Special Tools & Equipment
- 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
- Diagnostic Information & Procedures
- 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
- "Read Values" Menu
- "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 checking
- Enhanced ignition discharge module for Trionic 7
- Measures after changing a control module
- Fault Diagnosis, Fault Codes
- Notes
- P0100; Mass Air Flow Circuit. No Signal
- P0101; Mass Air Flow Circuit. Performance Problems
- P0102; Mass Air Flow Circuit. Low Input
- P0103; Mass Air Flow Circuit. High Input
- P0106; Manifold Absolute Pressure Sensor Circuit. Performance Problem
- P0107; Manifold Absolute Pressure Sensor Circuit. Open / Short to Ground
- P0108; Manifold Absolute Pressure Sensor Circuit. Short to B+
- P0111; Intake Air Temperature Sensor, Performance Problem
- P0112; Intake Air Temperature Sensor Circuit. Short to Ground
- P0113; Intake Air Temperature Sensor Circuit. Short to B+ / Open Circuit
- P0114; Engine Coolant and Intake Air Temperature, Plausibility Fault
- P0115; Engine Coolant Temperature Circuit. Performance Problem
- P0116; Engine Coolant Temperature Circuit. Performance Problem
- P0117; Engine Coolant Temperature Sensor Circuit. Short to Ground
- P0118; Engine Coolant Temperature Sensor Circuit. Short to B+ / Open circuit
- P0119; Engine Coolant Temperature Circuit. Intermittent Open / Short
- P0125; Excessive Time to Enter Closed Loop Fuel Control
- P0126; Engine Coolant Temperature Circuit Problem
- P0131; O2S Circuit. Low Voltage. Sensor 1
- P0132; O2S Circuit. High Voltage. Sensor 1
- P0133; O2S Circuit. Slow Response. Sensor 1
- P0134; O2S Circuit. No Activity Detected. Sensor 1
- P0137; O2S Circuit. Low Voltage. Sensor 2
- P0138; O2S Circuit. High Voltage. Sensor 2
- P0140; O2S Circuit. No Activity Detected. Sensor 2
- P0171; Long Term Fuel Trim Multiplicative. Max Value, Air/Fuel too Lean
- P0172; Long Term Fuel Trim Multiplicative. Min Value, Air/Fuel too Rich
- P0300; Random Misfire Detected
- P0301; Cylinder 1 Misfire Detected
- P0302; Cylinder 2 Misfire Detected
- P0303; Cylinder 3 Misfire Detected
- P0304; Cylinder 4 Misfire Detected
- P0327; Knock Sensor Circuit. Low Input, Bank 1
- P0336; Crankshaft Position Sensor Circuit. Performance Problem
- P0337; Crankshaft Position Sensor. No Input
- P0340; Camshaft Position Sensor. Malfunction
- P0420; Three Way Catalytic Converter. Malfunction
- P0441; EVAP Purge Valve. Malfunction
- P0442; EVAP. Small Leakage in System
- P0444; EVAP Purge Valve Circuit. Open / Short to Ground
- P0445; EVAP Purge Valve Circuit. Short to B+
- P0452; EVAP Tank Pressure Sensor Circuit. Short to Ground
- P0453; EVAP Tank Pressure Sensor Circuit. Open / Short to B+
- P0455; EVAP. Serious Leakage in System
- P0456; Tank purging, Very minor leak in system
- P0501; Vehicle Speed. Input signal outside limits
- P0502; Vehicle Speed. No input signal
- P0506; Idle Speed Control. Idling Speed too Low
- P0507; Idle Speed Control. Idling Speed too High
- P0605; Internal Control Module. Malfunction
- P1105; Charge Air Absolute Pressure Sensor Circuit. Performance Problem
- P1106; Charge Air Absolute Pressure Sensor Circuit. Performance Problem
- P1107; Charge Air Absolute Pressure Sensor Circuit. Short to Ground / Open
- P1108; Charge Air Absolute Pressure Sensor Circuit. Short to B+
- P1110; Charge Air Bypass Valve. Performance Problems
- P1131; O2S. Switch point - lean. Sensor 1
- P1132; O2S. Switch point - rich. Sensor 1
- P1133; O2S Circuit. Low Voltage. Sensor 1
- P1135; O2S Heater Circuit. Current too Low, Sensor 1
- P1136; O2S Heater Circuit. Current too High, Sensor 1
- P1137; O2S Circuit. Low Voltage. Sensor 2
- P1141; O2S Heater Circuit. Current too Low, Sensor 2
- P1142; O2S Heater Circuit. Current too High, Sensor 2
- P1171; Short Term Fuel Trim. Max Value, Air/Fuel too Lean
- P1172; Short Term Fuel Trim. Min Value, Air/Fuel too Rich
- P1181; Long Term Fuel Trim Additive. Max Value, Air/Fuel too Lean
- P1182; Long Term Fuel Trim Additive. Min Value, Air/Fuel too Rich
- P1230; Throttle Position Sensor 1 and 2 Circuit. Sum Out of Range. (Faulty signal from throttle disc position sensor)
- P1231; Throttle Position Sensor 1 and 2 Circuit. Sum Out of Range (No Limp Home)
- P1240; Throttle Motor Circuit. Shorted
- P1251; Throttle Motor. Full PWM in Closing Direction. NOTE. May set if Mechanism is not Reseted
- P1252; Throttle Motor. Full PWM in Open Direction and no Motor Current
- P1253; Throttle Motor. Full PWM in Open Direction During Cranking
- P1260; Throttle Return Spring. Too Low Force. NOTE. May set if Mechanism is not Reseted
- P1261; Throttle Binding
- P1263; Throttle moved manually when engine was running
- P1264; Throttle Open when Pedal is Released
- P1300; Random Misfire Detected. Catalyst Damaging
- P1301; Cylinder 1 Misfire Detected. Catalyst Damaging
- P1302; Cylinder 2 Misfire Detected. Catalyst Damaging
- P1303; Cylinder 3 Misfire Detected. Catalyst Damaging
- P1304; Cylinder 4 Misfire Detected. Catalyst Damaging
- P1310; Ignition Discharge Module. Not Powered, Bank 1
- P1312; Combustion Detection Cyl. 1+2. Open Circuit / Short to B+
- P1334; Combustion Detection Cyl. 3+4. Open Circuit / Short to B+
- P1390; Random Misfire Detected. Catalyst Damaging. Fuel Level Low
- P1391; Cylinder 1 Misfire Detected. Catalyst Damaging. Fuel Level Low
- P1392; Cylinder 2 Misfire Detected. Catalyst Damaging. Fuel Level Low
- P1393; Cylinder 3 Misfire Detected. Catalyst Damaging. Fuel Level Low
- P1394; Cylinder 4 Misfire Detected. Catalyst Damaging. Fuel Level Low
- P1441; EVAP Purge valve. Malfunction and malfunctional fuel level sensor
- P1442; EVAP Small Leakage in System and malfunctional fuel level sensor
- P1444; Canister Close Valve Circuit. Open / Short to Ground
- P1445; Canister Close Valve Circuit. Short to B+
- P1451; EVAP Tank Pressure Sensor. Performance Problem
- P1452; EVAP Tank Pressure Sensor. Value too low when Depressurized
- P1453; EVAP Tank Pressure Sensor. Value too high when Depressurized
- P1455; EVAP Tank Pressure Sensor. Serious Leakage in system and malfunctional fuel level sensor
- P1456; EVAP Small Leakage in System and malfunctional fuel level sensor
- P1460; Immobilizer Active. NOTE. If new T7, MIU or TWICE module, program code in TWICE
- P1491; EVAP Tank Pressure Sensor. Performance Problem and malfunctional fuel level sensor
- P1492; EVAP Tank Pressure Sens. Value too low when Depressurised and malfunctional fuel level sen
- P1493; EVAP Tank Pressure Sens. Value too high when Depressurised and malfunctional fuel level se
- P1530; Pedal Position Sensor 1 and 2 Circuit. Sum Out of Range
- P1531; Pedal Position Sensor 1 and 2 Circuit. Adapted Sum Out of Range
- P1532; Pedal Position Sensor 1 and 2 Circuit. Control Module Inputs Shorted to Each other
- P1549; Charge Air. Malfunction
- P1576; Brake Light Switch Circuit. Open / Short to B+
- P1577; Brake Light Switch Circuit. Short to Ground
- P1601; Internal Control Module. Malfunction
- P1602; Internal Control Module. Malfunction
- P1603; Internal Control Module. Malfunction
- P1604; Internal Control Module. Malfunction
- P1605; Internal Control Module. Malfunction
- P1606; Internal Control Module. Malfunction
- P1607
- P1608; Internal Control Module. Malfunction
- P1609; Internal Control Module. Malfunction
- P1610; Internal Control Module. Malfunction
- P1611; Internal Control Module. Malfunction
- P1613; Internal Control Module. Malfunction
- P1614; Internal Control Module. Malfunction
- P1621; Internal Control Module. Malfunction
- P1622; No Bus Data From MIU. See Fault Tracing 3:5 Bus and Diagnostic Communication
- P1623; No Bus Data From TCM. See Fault Tracing 3:5 Bus and Diagnostic Communication
- P1624; CHECK ENGINE. Request (Bus from TCM)
- P1625; No Bus data From TC/ABS. See Fault Tracing 3:5 Bus and Diagnostic Communication
- P1631; Internal Control Module. Malfunction
- P1632; Internal Control Module. Malfunction
- P1633; Internal Control Module. Malfunction
- P1640; Main Relay Circuit. No Voltage to Control Module pin 1
- P1641; Fuel Pump Relay. No Voltage to Fuel Pump and O2S Preheating
- P1652; Main Relay Coil Circuit. Open / Short to Ground
- P1653; Main Relay Coil Circuit. Short to B+
- P1654; Fuel Pump Relay Coil Circuit. Open / Short to Ground
- P1655; Fuel Pump Relay Coil Circuit. Short to B+
- P1656; A/C Relay Coil Circuit. Open / Short to Ground
- P1657; A/C Relay Coil Circuit. Short to B+
- P1658; Charge Air Bypass Valve Circuit. Open / Short to Ground
- P1659; Charge Air Bypass Valve Circuit. Short to B+
- P1662; Charge Air Control Valve Circuit. Open / Short to Ground
- P1663; Charge Air Control Valve Circuit. Short to B+
- P1670; Limp-home relay, open circuit or short to ground
- P1671; Limp-home relay, short to B+
- P1676; Injector Circuit. Open / Short to Ground or B+
- 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 the turbo pressure gauge and rattling from the turbocharger
- Long starting time, uneven idling speed after cold start (BioPower)
- Idling speed too low, starting problems BioPower
- Cold start and driveability problems, BioPower
- Fault Diagnosis, General
- Schematic and Routing Diagrams