October 30: LEMON manuals on a temporary server, it is slow and having issues, download the manuals you need! Later in November we will switch back to the fast server.
TRIONIC T7 Fuel Control System Expand All (for easy ctrl-f) Collapse All Repair Instructions 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 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 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, 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 Schematic and Routing Diagrams