Lotus Service Notes Section EMQ

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1 ENGINE MANAGEMENT SECTION EMQ Lotus Techcentre Sub-Section Page Cylinder Numbering 2 Component Function EMQ.1 3 Component Location EMQ.2 5 Diagnostic Trouble Code List EMQ.3 7 Diagnostic Guide EMQ.4 11 CAN Bus Diagnostics; Lotus TechCentre EMQ.5 97 Lotus TechCentre User Guide (lsl602a) EMQ.6 99 Updated 23rd March 2017 Page 1

2 NOTES Cylinder Numbering - viewed from above: RH side of vehicle Front of engine Cylinder Numbering viewed from above Front of engine (auxiliary drive belt end) 1 2 LH RH cylinder 3 cylinder bank (2) 4 bank (1) 6 5 LH side of vehicle em263 Rear of engine Rear of engine (Flywheel end) Firing order: Page 2

3 EMQ.1 - COMPONENT FUNCTION Component Function Mass Air Flow Meter Intake Air Temperature Sensor Engine Coolant Temperature Sensor Throttle Position Sensor Pedal Position Sensor Barometric Pressure Sensor O2 Sensor (Front) Bank 1 O2 Sensor (Front) Bank 2 O2 Sensor (Rear) Bank 1 O2 Sensor (Rear) Bank 2 Engine load detection Air temperature detection Engine coolant temperature detection Determines engine throttle position Determines pedal position requested by driver Barometric pressure detection Measures oxygen content in exhaust before bank 1 primary catalyst Measures oxygen content in exhaust before bank 1 primary catalyst Measures oxygen content in exhaust after bank 1 primary catalyst Measures oxygen content in exhaust after bank 2 primary catalyst Determines crankshaft position Determines bank1 inlet camshaft position Determines bank 2 inlet camshaft position Determines bank 1 exhaust camshaft position Determines bank 2 exhaust camshaft position Determines bank 1 engine detonation Determines bank 2 engine detonation Determines fuel tank level Evaporator temperature detection Determines clutch pedal position Determines brake pedal position Determines driver request for cruise control Actuates engine throttle Crankshaft Position Sensor Camshaft Position Sensor (Inlet) Bank 1 Camshaft Position Sensor (Inlet) Bank 2 Camshaft Position Sensor (Exhaust) Bank 1 Camshaft Position Sensor (Exhaust) Bank 2 Knock Sensor Bank1 Knock Sensor Bank2 Fuel Level Sensor Air Conditioning Evaporator Temperature Sensor Clutch Pedal Position Sensor Brake Pedal Position Switch Cruise Control Multi-function Input Electronic Throttle Control Motor Injector Circuit Cylinder 1 Regulates fuel injected into cylinder 1 Injector Circuit Cylinder 2 Regulates fuel injected into cylinder 2 Injector Circuit Cylinder 3 Regulates fuel injected into cylinder 3 Injector Circuit Cylinder 4 Regulates fuel injected into cylinder 4 Injector Circuit Cylinder 5 Regulates fuel injected into cylinder 5 Injector Circuit Cylinder 6 Regulates fuel injected into cylinder 6 Ignition Circuit Cylinder 1 Actuates spark plug in cylinder 1 Ignition Circuit Cylinder 2 Actuates spark plug in cylinder 2 Ignition Circuit Cylinder 3 Actuates spark plug in cylinder 3 Ignition Circuit Cylinder 4 Actuates spark plug in cylinder 4 Ignition Circuit Cylinder 5 Actuates spark plug in cylinder 5 Ignition Circuit Cylinder 6 Actuates spark plug in cylinder 6 Variable Valve Timing Actuator (Inlet) Bank 1 Variable Valve Timing Actuator (Inlet) Bank 2 Variable Valve Timing Actuator (Exhaust) Bank 1 Variable Valve Timing Actuator (Exhaust) Bank 2 Variable Intake Manifold Actuator Primary Catalyst Bank 1 Primary Catalyst Bank 2 Secondary Catalyst Evaporative Emission Control System Purge Control Valve Actuates bank 1 inlet camshaft timing control Actuates bank 2 inlet camshaft timing control Actuates bank 1 exhaust camshaft timing control Actuates bank 2 exhaust camshaft timing control Actuates variable intake manifold Removes pollutants from exhaust Removes pollutants from exhaust Removes pollutants from exhaust Regulates fuel tank vapour flow into inlet manifold Continued... Page 3

4 Continued... Component Function Fuel Pump Relay Actuates fuel pump Fuel Pressure Sensor (Sport 380 models) Provides fuel pressure information to the ECM Fuel Pump Drive Controller Module (Sport 380 models) Regulates voltage to fuel pump Starter Relay Actuates engine starter motor Cooling Fan 1 Relay Actuates cooling fan 1 Cooling Fan 2 Relay Actuates cooling fan 2 Air Conditioning Control Relay Actuates air conditioning compressor Air Conditioning Control Valve Regulates air conditioning compressor load Coolant Recirculation Pump Actuates coolant recirculation pump Noise Flap Solenoid Actuates air intake flap vacuum control ABS Provides vehicle wheel speed information Battery Provides electrical power Exhaust Bypass Soleniod Allows EP valve to draw vacuum from airbox Transmission Oil Temperature Sensor (Sport 380 models) Activates manual transmission cooler oil pump Updated 23rd March 2017 Page 4

5 EMQ.2 - COMPONENT LOCATION (O 2 ) * * (O 2 ) (O 2 ) (O 2 ) * Ignition coil noise suppression capacitor em239 Page 5

6 em240 Page 6

7 EMQ.3 - DIAGNOSTIC TROUBLE CODE (DTC) LIST Extract below as found in the Exige Owner's Handbook "The engine Malfunction Indicator Lamp (MIL) is provided to warn the driver that the engine management system has detected a fault which may result in increased noxious emissions from the exhaust. In order to minimise emissions and potential engine damage, various operational limitations may automatically be applied. i) If the MIL lights continuously whilst driving, immediately reduce speed and adopt a moderate driving style. Seek Lotus dealer advice without delay and avoid all unnecessary journeys. ii) If the MIL flashes, an engine misfire has been detected which is likely to cause overheat damage to the catalytic converter. Slow down immediately and be prepared to stop. - If the MIL then stops flashing, and is lit continuously, proceed with caution and seek dealer advice. - If the MIL continues to flash, stop the vehicle as soon as it is safe to do so, and switch off the engine. Seek Lotus dealer advice". NOTICE: Continuing to drive the car with a flashing MIL may cause overheat dam age to the catalytic converters and surrounding bodywork. WARNING: Continuing to drive the car with a flashing MIL may cause an engine bay fire. DTC Fault description Page P0011 A Camshaft Position - Timing Over-Advanced or System Performance - Bank 1 12 P0012 A Camshaft Position - Timing Over-Retarded - Bank 1 12 P0014 B Camshaft Position - Timing Over-Advanced or System Performance - Bank 1 12 P0015 B Camshaft Position - Timing Over-Retarded - Bank 1 12 P0016 Crankshaft Position - Camshaft Position Correlation - Bank 1 Sensor A 14 P0017 Crankshaft Position - Camshaft Position Correlation - Bank 1 Sensor B 14 P0018 Crankshaft Position - Camshaft Position Correlation - Bank 2 Sensor A 14 P0019 Crankshaft Position - Camshaft Position Correlation - Bank 2 Sensor B 14 P0021 A Camshaft Position - Timing Over-Advanced or System Performance - Bank 2 12 P0022 A Camshaft Position - Timing Over-Retarded - Bank 2 12 P0024 B Camshaft Position - Timing Over-Advanced or System Performance - Bank 2 12 P0025 B Camshaft Position - Timing Over-Retarded - Bank 2 12 P0076 Intake Valve Control Solenoid Circuit Low - Bank 1 13 P0077 Intake Valve Control Solenoid Circuit High - Bank 1 13 P0079 Exhaust Valve Control Solenoid Circuit Low - Bank 1 13 P0080 Exhaust Valve Control Solenoid Circuit High - Bank 1 13 P0082 Intake Valve Control Solenoid Circuit Low - Bank 2 13 P0083 Intake Valve Control Solenoid Circuit High - Bank 2 13 P0085 Exhaust Valve Control Solenoid Circuit Low - Bank 2 13 P0086 Exhaust Valve Control Solenoid Circuit High - Bank 2 13 P0087 Fuel Rail System/Pressure Too Low 15 P0088 Fuel Rail System/Pressure Too High 15 P0101 Mass or Volume Air Flow Circuit Range/Performance 18 P0102 Mass or Volume Air Flow Circuit Low Input 18 P0103 Mass or Volume Air Flow Circuit High Input 18 P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input 20 P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input 20 P0112 Intake Air Temperature Sensor 1 Circuit Low 21 P0113 Intake Air Temperature Sensor 1 Circuit High 21 P0116 Engine Coolant Temperature Circuit Range/Performance 23 P0117 Engine Coolant Temperature Circuit Low 23 P0118 Engine Coolant Temperature Circuit High 23 P0122 Throttle Position Sensor 'A' Circuit Low 25 Updated 23rd March 2017 Page 7

8 P0123 Throttle Position Sensor 'A' Circuit High 25 P0131 O2 Sensor Circuit Low Voltage (Pre Catalyst) - Bank1 28 P0132 O2 Sensor Circuit High Voltage (Pre Catalyst) - Bank1 28 P0133 O2 Sensor Circuit Slow Response (Pre Catalyst) - Bank1 28 P0134 O2 Sensor Circuit No Activity Detected (Pre Catalyst) - Bank1 28 P0135 O2 Sensor Heater Circuit (Pre Catalyst) - Bank1 28 P0137 O2 Sensor Circuit Low Voltage (Post Catalyst) - Bank1 32 P0138 O2 Sensor Circuit High Voltage (Post Catalyst) - Bank1 32 P0139 O2 Sensor Circuit Slow Response (Post Catalyst) 32 P0140 O2 Sensor Circuit No Activity Detected (Post Catalyst) - Bank1 32 P0141 O2 Sensor Heater Circuit (Post Catalyst) - Bank1 32 P0151 O2 Sensor Circuit Low Voltage (Pre Catalyst) Bank2 28 P0152 O2 Sensor Circuit High Voltage (Pre Catalyst) Bank2 28 P0153 O2 Sensor Circuit Slow Response (Pre Catalyst) Bank2 28 P0154 O2 Sensor Circuit No Activity Detected (Pre Catalyst) Bank2 28 P0155 O2 Sensor Heater Circuit (Pre Catalyst) Bank2 28 P0157 O2 Sensor Circuit Low Voltage (Post Catalyst) Bank2 32 P0158 O2 Sensor Circuit High Voltage (Post Catalyst) Bank2 32 P0159 O2 sensor Circuit Slow Response (Post Catalyst) 32 P0160 O2 Sensor Circuit No Activity Detected (Post Catalyst) Bank2 32 P0161 O2 Sensor Heater Circuit (post Catalyst) Bank2 32 P0171 System Too Lean Bank1 36 P0172 System Too Rich Bank1 36 P0174 System Too Lean Bank2 36 P0175 System Too Rich Bank2 36 P0191 Fuel Rail Pressure Sensor "A" Circuit Range/Performance 38 P0192 Fuel Rail Pressure Sensor "A" Circuit Low 38 P0193 Fuel Rail Pressure Sensor "A" Circuit High 38 P0222 Throttle Position Sensor 'B' Circuit Low 25 P0223 Throttle Position Sensor 'B' Circuit High 25 P025C Fuel Pump Module Control Circuit Low 15 P025D Fuel Pump Module Control Circuit High 15 P0261 Cylinder 1 Injector Circuit Low 40 P0262 Cylinder 1 Injector Circuit High 40 P0264 Cylinder 2 Injector Circuit Low 40 P0265 Cylinder 2 Injector Circuit High 40 P0267 Cylinder 3 Injector Circuit Low 40 P0268 Cylinder 3 Injector Circuit High 40 P0270 Cylinder 4 Injector Circuit Low 40 P0271 Cylinder 4 Injector Circuit High 40 P0273 Cylinder 5 Injector Circuit Low 40 P0274 Cylinder 5 Injector Circuit High 40 P0276 Cylinder 6 Injector Circuit Low 40 P0277 Cylinder 6 Injector Circuit High 40 P0300 Random/Multiple Cylinder Misfire Detected 41 P0301 Cylinder 1 Misfire Detected 41 P0302 Cylinder 2 Misfire Detected 41 P0303 Cylinder 3 Misfire Detected 41 P0304 Cylinder 4 Misfire Detected 41 P0305 Cylinder 5 Misfire Detected 41 P0306 Cylinder 6 Misfire Detected 41 P0327 Knock Sensor 1 Circuit Low 43 P0328 Knock Sensor 1 Circuit High 43 P0332 Knock Sensor 2 Circuit Low 43 P0333 Knock Sensor 2 Circuit High 43 P0335 Crankshaft Position Sensor A Circuit Range/Performance 44 P0341 Camshaft Position Sensor A Circuit Range/Performance (Bank 1) 45 Updated 23rd March 2017 Page 8

9 P0346 Camshaft Position Sensor A Circuit Range/Performance (Bank 2) 45 P0351 Ignition Coil A Primary/Secondary Circuit 46 P0352 Ignition Coil B Primary/Secondary Circuit 46 P0353 Ignition Coil C Primary/Secondary Circuit 46 P0354 Ignition Coil D Primary/Secondary Circuit 46 P0355 Ignition Coil E Primary/Secondary Circuit 46 P0356 Ignition Coil F Primary/Secondary Circuit 46 P0366 Camshaft Position Sensor B Circuit Range/Performance (Bank 1) 45 P0391 Camshaft Position Sensor B Circuit Range/Performance (Bank 2) 45 P0420 Catalyst System Efficiency Below Threshold (Bank 1) 47 P0430 Catalyst System Efficiency Below Threshold (Bank 2) 47 P0444 Evaporative Emission System Purge Control Valve Circuit Open 49 P0445 Evaporative Emission System Purge Control Valve Circuit Shorted 49 P0461 Fuel Level Sensor A Circuit Range/Performance 50 P0462 Fuel Level Sensor A Circuit Low 50 P0463 Fuel Level Sensor A Circuit High 50 P0500 Vehicle Speed Sensor A 53 P0506 Idle Air Control System RPM Lower Than Expected 54 P0507 Idle Air Control System RPM Higher Than Expected 54 P0562 System Voltage Low 57 P0563 System Voltage High 57 P0601 Internal Control Module Memory Checksum Error 60 P0606 ECM/PCM Processor 60 P0610 Variant Code not Programmed 61 P0627 Fuel Pump "A" Control Circuit/Open 15 P0630 VIN not Programmed or Incompatible 63 P0638 Throttle Control Error 64 P0685 ECM Power Relay Control Circuit Open 66 P0700 Transmission Control System (MIL Request) 67 P1104 Safety Processor Throttle Shutdown 75 P1106 Throttle shutdown by BTO 76 P1301 Misfire level causing emissions increase 41 P1302 Misfire level causing catalyst system damage 41 P2100 Throttle Actuator Control Motor Circuit/Open 77 P2102 Throttle Actuator Control Motor Circuit Low 77 P2103 Throttle Actuator Control Motor Circuit High 77 P2104 Throttle Actuator Control System Forced Idle 77 P2105 Throttle Actuator Control System Forced Engine Shutdown 77 P2106 Throttle Actuator Control System Forced Limited Power 77 P2107 Throttle Actuator Control Module Processor 77 P2108 Throttle Actuator Control Module Performance 77 P2119 Throttle Actuator Control Throttle Body Range/Performance 77 P2122 Pedal Position Sensor 1 Circuit Low 82 P2123 Pedal Position Sensor 1 Circuit High 82 P2127 Pedal Position Sensor 2 Circuit Low 82 P2128 Pedal Position Sensor 2 Circuit High 82 P2135 Throttle Position Sensor Voltage Correlation 25 P2138 Pedal Position Sensor Voltage Correlation 82 P2170 Exhaust Pressure Regulator Vent Solenoid Control Circuit Low 85 P2171 Exhaust Pressure Regulator Vent Solenoid Control Circuit High 85 P2173 Throttle Actuator Control System High Airflow Detected 77 P2191 System Too Lean at Higher Load Bank1 86 P2193 System Too Lean at Higher Load Bank2 86 U0109 Lost Communications with Fuel Pump Control Module 15 U0122 Lost Communications with VDCM 91 Updated 23rd March 2017 Page 9

10 Non-MIL Fault codes Extract below as found in the Exige Owner's Handbook "Electrical Fault Tell Tale The Engine Control Module (ECM) is also used to manage various related electrical systems, and is able to detect certain types of fault, which may or may not be apparent to the driver. If such a fault is detected, which has no detrimental effect on exhaust emissions (see MIL tell tale information). This amber tell tale will light for the first 30 seconds after turning on the ignition. Consult your dealer without delay to have the fault diagnosed and rectified". DTC Fault description Page P0480 Fan 1 Control Circuit 52 P0481 Fan 2 Control Circuit 52 P0523 Oil Pressure Sensor Circuit High 55 P0537 A/C Evaporator Temperature Sensor Circuit Low 56 P0538 A/C Evaporator Temperature Sensor Circuit High 56 P0565 Cruise control resume/decelerate signal 58 P0567 Cruise control set/accelerate signal 58 P0568 Cruise control on/off signal 58 P0571 Brake Switch A Circuit 58 P0616 Starter Relay Circuit Low 62 P0617 Starter Relay Circuit High 62 P0646 A/C Clutch Relay Control Circuit Low 65 P0647 A/C Clutch Relay Control Circuit High 65 P0712 Transmission Fluid Temperature Sensor "A" Circuit Low 68 P0713 Transmission Fluid Temperature Sensor "A" Circuit High 68 P0806 Clutch Position Sensor Circuit Range/Performance 71 P0807 Clutch Position Sensor Circuit Low 71 P0808 Clutch Position Sensor Circuit High 71 P0826 Up and Down Shift Switch Circuit 73 P0827 Up and Down Shift Switch Circuit Low 73 P0828 Up and Down Shift Switch Circuit High 73 P0897 Transmission Fluid Deteriorated 68 P1562 Battery Voltage Too Low to Complete Throttle Autozero 58 P1565 Cruise On/Off Switch Intermittent 58 P1567 Cruise Resume/Deceleration Switch Intermittent 58 P1568 Cruise Set/Acceleration Switch Intermittent 58 P1809 Noisy Clutch Pedal Sensor 71 P2602 Coolant Pump Control Circuit Low 87 P2603 Coolant Pump Control Circuit High 87 P2612 A/C Refrigerant Distribution Valve Control Circuit Low 88 P2613 A/C Refrigerant Distribution Valve Control Circuit High 88 P2754 Transmission Fluid Cooler Control Circuit Low 68 P2755 Transmission Fluid Cooler Control Circuit High 68 P2797 Auxiliary Transmission Fluid Pump Performance 68 B1422 A/C Compressor Lock Sensor Circuit 89 U0101 Lost Communications with TCM 90 U0123 Lost Communications with Yaw Rate Sensor Module 93 U0127 Lost Communications with TPMS Module 95 U0141 Lost Communication with Body Control Module "A" 96 U0302 Software Incompatible with TCM 90 U0316 Software Incompatible with VDCM 91 U0416 Invalid Data Received from VDCM 91 U0513 Invalid Data Received from Yaw Rate Sensor Module 93 Updated 23rd March 2017 Page 10

11 When applicable, reference may be made under the 'Notes' heading to a page in the Toyota service manual. This information should be used only for diagnosis and connection detail of the sensor. The Exige S uses a Lotus ECU, the connections for which may be found in circuit diagrams in Section MVa - MVd. Diagnostic Trouble Codes should be read using the Lotus TechCentre. Page 11

12 EMQ.4 - DIAGNOSTIC GUIDE Camshaft Timing Control (VVT) P0011 Camshaft Position Inlet Timing Over-Advanced or System Performance (Bank 1) P0012 Camshaft Position Inlet Timing Over-Retarded (Bank 1) P0014 Camshaft Position Exhaust Timing Over-Advanced or System Performance (Bank 1) P0015 Camshaft Position Exhaust Timing Over Retarded (Bank 1) P0021 Camshaft Position Inlet Timing Over-Advanced or System Performance (Bank 2) P0022 Camshaft Position Inlet Timing Over-Retarded (Bank 2) P0024 Camshaft Position Exhaust Timing Over-Advanced or System Performance (Bank 2) P0025 Camshaft Position Exhaust Timing Over-Retarded (Bank 2) Description The Variable Valve Timing system (VVT) on the intake camshafts and the exhaust camshafts can vary the timing by approximately 35. The camshaft relative position is varied by a system of vanes mounted on the drive end of the camshaft. Each VVT oil control valve modulates a spool valve position in accordance with the drive signal duty cycle, this in turns controls the oil pressure applied to the vanes. A 50% duty cycle applied to the valve will hold the valve current timing by preventing oil flow from the VVT controller housing, a duty cycle less than 50% will retard the valve timing, a duty cycle greater then 50% will advance the valve timing. The ECM regulates this duty cycle based on the feedback signal from the respective camshaft position sensor to optimise the camshaft timing. Component connections Sensor Connector Description ECU Pin ECU Connector 1 Main relay via fuse R VVT Control Valve Inlet (Bank 1) B2 48 Way (Centre) 1 Main relay via fuse R VVT Control Valve Exhaust (Bank 1) A2 48 Way (Centre) 1 Main relay via fuse R VVT Control Valve Inlet (Bank 2) A3 48 Way (Centre) 1 Main relay via fuse R VVT Control Valve Exhaust (Bank 2) A4 48 Way (Centre) Engine running > 30 seconds Coolant temperature > 60 C (140 F) P0116, P0117, P0118 Coolant temperature fault codes VVT error > 8 degrees for time > 5 secs Static valve timing is incorrect VVT camshaft actuator failure VVT control valve stuck open / closed VVT control valve filter Page 12

13 Camshaft Timing Control (VVT) P0076 Intake Valve Control Solenoid Circuit Low (Bank1) P0077 Intake Valve Control Solenoid Circuit High (Bank1) P0079 Exhaust Valve Control Solenoid Circuit Low (Bank1) P0080 Exhaust Valve Control Solenoid Circuit High (Bank1) P0082 Intake Valve Control Solenoid Circuit Low (Bank2) P0083 Intake Valve Control Solenoid Circuit High (Bank2) P0085 Exhaust Valve Control Solenoid Circuit Low (Bank2) P0086 Exhaust Valve Control Solenoid Circuit High (Bank2) Description The Variable Valve Timing system (VVT) on the intake camshafts and the exhaust camshafts can vary the timing by approximately 35. The camshaft relative position is varied by a system of vanes mounted on the drive end of the camshaft. Each VVT oil control valve modulates a spool valve position in accordance with the drive signal duty cycle, this in turns controls the oil pressure applied to the vanes. A 50% duty cycle applied to the valve will hold the valve current timing by preventing oil flow from the VVT controller housing, a duty cycle less than 50% will retard the valve timing, a duty cycle greater then 50% will advance the valve timing. The ECM regulates this duty cycle based on the feedback signal from the respective camshaft position sensor to optimise the camshaft timing. Component connections Sensor Connector Description ECU Pin ECU Connector 1 Main relay via fuse R VVT Control Valve Inlet (Bank 1) B2 48 Way (Centre) 1 Main relay via fuse R VVT Control Valve Exhaust (Bank 1) A2 48 Way (Centre) 1 Main relay via fuse R VVT Control Valve Inlet (Bank 2) A3 48 Way (Centre) 1 Main relay via fuse R VVT Control Valve Exhaust (Bank 2) A4 48 Way (Centre) Engine running P0076, P0079, P0082, P VVT control valve open circuit or short to ground P0077, P0080, P0083, P VVT control valve circuit short to battery voltage ECU output circuit failure VVT control valve The MIL will be illuminated if the faults are present for 2 consecutive trips Page 13

14 Crankshaft Position Camshaft Position Correlation Error P0016 Crankshaft position camshaft position correlation bank 1 sensor A (Inlet) P0017 Crankshaft position camshaft position correlation bank 1 sensor B (Exhaust) P0018 Crankshaft position camshaft position correlation bank 2 sensor A (Inlet) P0019 Crankshaft position camshaft position correlation bank 2 sensor B (Exhaust) Description The crankshaft position sensor is used to identify engine position and speed via a pole wheel mounted on the front end of the crankshaft. The camshaft position sensor is used to determine camshaft position from a three vane reluctor on the rear end of the inlet and exhaust camshaft. Fault codes P0016, P0017, P0018, P0019 indicate a mechanical timing error such as incorrectly set, or 'jumped' cam timing. Engine running (from cranking up to 4 seconds) Camshaft out of phase with crankshaft > 16 degrees Static valve timing is incorrect VVT camshaft actuator failure VVT control valve stuck open / closed VVT control valve filter The MIL will be illuminated if the faults are present for 2 consecutive trips Page 14

15 Fuel Pump Module P0087 Fuel Rail System/Pressure Too Low P0088 Fuel Rail System/Pressure Too High P025C Fuel Pump Module Control Circuit Low P025D Fuel Pump Module Control Circuit High P0627 Fuel Pump "A" Control Circuit/Open U0109 Lost Communications with Fuel Pump Control Module Description: The voltage to the fuel pump is regulated by the fuel pump control module through pulse width modulation (PWM). The fuel pump output duty cycle is a function of the detected fuel pump demand signal from the ECM. The fuel pump demand signal from the ECM is also of PWM type. The fuel pump is incorporated into the fuel tank module, which also includes the fuel level sensor. The fuel pump control module regulates the voltage supplied to the pump to maintain the required fuel pressure indicated by the fuel rail pressure sensor, under control of the ECM. The fuel pump control module also contains internal diagnostics which it returns to the ECM using the fuel pump monitor signal. The fuel pump monitor signal sent to the ECM is also of PWM type. Component connections Fuel Rail Pressure Sensor: Sensor connector Description ECM Pin ECM Connector 1 Ground via ECM K3 48 Way (Right) 2 Fuel rail pressure sensor signal L3 48 Way (Centre) 3 5 volt supply from ECM F4 48 Way (Right) Fuel Pump Control Module: Module connector Description ECM Pin ECM Connector 1 Power from fuel pump relay via fuse R1 2 N/C Fuel pump control from ECM J2 48 Way (Right) 4 Ground Fuel pump supply voltage N/C Fuel pump monitor to ECM G3 48 Way (Right) 8 Fuel pump ground - - via fuel pump relay 2 P0087 / P0088 Engine running for more than 5 seconds Fuel tank level greater than 6 litres Fuel demand less than 80 kg/hr Engine coolant temperature greater than -10ºC (14ºF) Fuel level sensor fault Coolant temperature sensor fault Fuel pump control module fault Deceleration fuel cut off active Page 15

16 P0087 Indicated fuel pressure less than target by 500 mbar (50kPa) for more than 5 seconds P0088 Indicated fuel pressure greater than target by 1000 mbar (100kPa) for more than 5 seconds Fuel pressure sensor failure Fuel control module failure Fuel pump failure Restriction in fuel system The MIL will be illuminated if a fault is present for two consecutive trips. P025C / P025D Ignition on P025C Fuel pump control module open circuit P025C Fuel pump control module shorted to ground P025D Fuel pump control module shorted to 12 volts Fuel pump control module wiring open circuit or shorted to ground or shorted to supply voltage Wiring harness or connector damage Fuel pump control module failure The MIL will be illuminated if a fault is present for two consecutive trips. P0627 Ignition on Battery Voltage > 10 Volts Immobiliser deactivated Fuel pump control module circuit fault present (P025C, P025D) ECM receives error signal from the fuel pump control module which identifies that the fuel pump control module has detected that its connection to the fuel pump is either open circuit, shorted to ground or shorted to the supply voltage. Page 16

17 Fuel pump control module wiring to fuel pump open circuit, shorted to ground or shorted to supply voltage Wiring harness or connector damage Fuel pump failure Fuel pump relay 2 failure The MIL will be illuminated if the fault is present. U0109 Ignition on Battery Voltage > 10 Volts Immobiliser deactivated Fuel pump control module circuit fault present (P025C, P025D) Undefined PWM diagnostic signal received by ECM (i.e. incorrect frequency / pulse width) No PWM diagnostic signal received by ECM Fuel pump control module receiving incorrect demand signal from ECM Wiring harness or connector damage Fuel pump control module failure The MIL will be illuminated if a fault is present for two consecutive trips. Page 17

18 Intake Air Flow P0101 Mass or Volume Air Flow Circuit Range/Performance P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input Description The Mass Air Flow (MAF) sensor is incorporated into the airbox, and measures both intake air flow rate and Intake Air Temperature (IAT). The MAF sensor uses a hot wire exposed to the airflow, which is maintained at a constant temperature by a constant current flow. This is achieved within the sensor unit by varying the voltage applied to the hot wire. This voltage is the output signal from the MAF sensor. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 IAT Signal E3 48 Way (Centre) 2 IAT Ground J3 48 Way (Centre) 3 Main relay via fuse R MAF Ground J4 48 Way (Centre) 5 MAF Signal G1 48 Way (Centre) Sensor characteristics g/second Typical values: g/sec (idle), g/sec (2500rpm elevated idle no load) P0101. Engine running Engine speed >1550rpm Engine speed < 3650rpm Engine coolant temperature > 70ºC (158ºF) Fuel learning enabled P0122, P0123, P0222, P0223 Throttle/Pedal position fault codes Aggressive throttle transients Deceleration fuel cut off active Measured MAF is compared to a predicted MAF based on current engine conditions. Error > 40% for time > 7.5 seconds MAF meter Air induction system Air intake hose connections The MIL will be illuminated if the faults are present for 2 consecutive trips P0102. Page 18

19 Engine running Voltage at ECU < 0.50V for time > 1.5 seconds MAF sensor circuit open MAF sensor circuit short to ground The MIL will be illuminated if the faults are present for 2 consecutive trips P0103. Engine running Engine speed > 6500rpm & throttle position > 95% Voltage at ECU > 4.985V for time > 1.5 seconds MAF sensor circuit short to ECU supply voltage The MIL will be illuminated if the faults are present for 2 consecutive trips Page 19

20 Barometric Pressure P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input Description The barometric pressure sensor is located internally within the ECU, and measures atmospheric pressure. This parameter is required to compensate the mass air flow when the vehicle is operated at higher altitudes. P0107, P0108 Engine running P0107: Voltage at ECU < 1.08V for time > 1.5 seconds P0108: Voltage at ECU > 4.98V for time > 1.5 seconds Sensor failure The MIL will be illuminated if the faults are present for 2 consecutive trips Page 20

21 Intake Air Temperature P0112 Intake Air Temperature Sensor 1 Circuit Low P0113 Intake Air Temperature Sensor 1 Circuit High Description The combined sensor which measures both Mass Air Flow (MAF) and Intake Air Temperature (IAT) is incorporated into the air box. The IAT sensor is a thermistor device which changes resistance with temperature. As air intake temperature decreases the thermistor resistance value increases, and conversely as air temperature increases so the thermistor resistance value decreases. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 IAT Signal E3 48 Way (Centre) 2 IAT Ground J3 48 Way (Centre) 3 Main relay via fuse R MAF Ground J4 48 Way (Centre) 5 MAF Signal G1 48 Way (Centre) Sensor characteristics IAT -20 C (-4 F) kω IAT 20 C (68 F) kω IAT 60 C (140 F) kω P0112 Engine running Voltage at ECM < 0.01V (Inlet air temperature > 119 C (246 F)) for time > 1.5 seconds Signal short circuit Sensor failure The MIL will be illuminated if these faults are present for 2 consecutive trips. P0113 Engine running Voltage at ECM > 4.93V (Inlet air temperature < 39 C ( 38 F)) for time > 1.5 seconds Page 21

22 Signal open circuit Sensor failure The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 22

23 Engine Coolant Temperature P0116 P0117 P0118 Engine Coolant Temperature Circuit Range/Performance Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Description The engine coolant temperature sensor is a thermistor device which changes resistance with temperature. As coolant temperature decreases the thermistor resistance value increases, and conversely as coolant temperature increases so the thermistor resistance value decreases. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Ground C3 48 Way (Centre) 2 Signal G2 48 Way (Centre) Sensor characteristics -20 C (-4 F) = KΩ 20 C (68 F) = KΩ 80 C (176 F) = KΩ 110 C (230 F) = KΩ P0116 Monitor Excess Time to Warm Up: Disable Criteria Excess Time to Warm Up: P0117 / P0118 Engine Coolant Temperature Circuit Low / High Enable Criteria Excess Time to Warm Up: Engine running > 1000 seconds Malfunction Criteria Excess Time to Warm Up: Engine coolant temperature < 40 C (104 F) Monitor Noisy Sensor Check: Disable Criteria Noisy Sensor Check: P0117 / P0118 Engine Coolant Temperature Circuit Low / High Enable Criteria Noisy Sensor Check: Engine running Malfunction Criteria Noisy Sensor Check Engine coolant temperature erratic by more than 30 C (54 F) Sensor wiring Sensor failure Thermostat failure The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 23

24 P0117 Engine running Voltage at ECM < 0.006V (Coolant temperature > 119 C (246 F)) for time > 1.5 seconds Signal short circuit Sensor failure Thermostat failure Cooling system problem The MIL will be illuminated if these faults are present for 2 consecutive trips. P0118 Engine running Voltage at ECM > 4.89V (Coolant temperature < -38 C (-36 F)) for time > 1.5 seconds Signal open circuit Sensor failure The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 24

25 Throttle Position P0122 Throttle Position Sensor 'A' Circuit Low P0123 Throttle Position Sensor 'A' Circuit High P0222 Throttle Position Sensor B Circuit Low P0223 Throttle Position Sensor B Circuit High P2135 Throttle Position Sensor Voltage Correlation Description The throttle position sensor (TPS) is mounted on the throttle body, and detects the opening angle of the throttle valve. The TPS has 2 sensor circuits, each of which transmits a signal, VTA1 and VTA2. VTA1 is used to detect the throttle valve angle and VTA2 is used to detect malfunctions in VTA1. The sensor signal voltages vary between 0 V and 5 V in proportion to the throttle valve opening angle, and are transmitted to the VTA terminals of the ECU. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 ETB A M1 48 Way (Centre) 2 ETB B L2 48 Way (Centre) 3 Ground C4 48 Way (Centre) 4 TPS 1B Signal F3 48 Way (Centre) 5 TPS 1A/B V Ref E4 48 Way (Centre) 6 TPS 1A Signal F2 48 Way (Centre) Sensor characteristics 0% = V ± 5% 100% = V ± 5% P0122. Signal voltage < 0.611V for time > 0.1s Signal short circuit Reference voltage open circuit Reference voltage short to ground Sensor failure The MIL will be illuminated if fault is present. P0123. Page 25

26 Signal voltage > 4.765V for time > 0.1s Signal open circuit Reference voltage open circuit Reference voltage short to ground Sensor failure The MIL will be illuminated if fault is present. P0222. Signal voltage < 2.146V for time > 0.1s Signal short circuit Reference voltage open circuit Reference voltage short to ground Sensor failure The MIL will be illuminated if fault is present. P0223. Signal voltage > 4.985V for time > 0.1s Signal open circuit Reference voltage open circuit Reference voltage short to ground Sensor failure Page 26

27 The MIL will be illuminated if fault is present. Notes: A maximum throttle opening of 15% may be imposed due to a single fault code. In the case of multiple fault codes, a mechanically sprung 7% opening may be applied. P2135 Description The measured throttle position voltages (VTA1 / VTA2) are re-scaled to determine diagnosed throttle openings in percentage terms (0 100%). The diagnosed throttle openings are subsequently used by the ECM to control the throttle actuator to ensure throttle position is correctly maintained. Monitor Correlation Fault: Enable Criteria Correlation Fault: Disable Criteria Correlation Fault: Throttle position sensor 2 > 54% P0122, P0123, P0222, P0223 Throttle position sensor faults Malfunction Criteria Correlation Fault: Diagnosed throttle position difference > 5% for 100ms Monitor Short Circuit Fault: Enable Criteria Short Circuit Fault: Disable Criteria Short Circuit Fault: Malfunction Criteria Short Circuit Fault: Throttle position sensor voltage difference < 0.024V for 100ms Throttle position sensor 1 fault Throttle position sensor 2 fault Short circuit between throttle position sensor signals Throttle position sensor wiring fault The MIL will be illuminated if fault is present. Notes: In the case of a correlation fault being detected a maximum throttle opening of 15% will be imposed. In the case of a short circuit fault being detected a mechanically sprung opening of 7% will be applied. Page 27

28 O2 Sensor (Pre Catalyst) P0131 O2 Sensor 1 Circuit Low Voltage (Bank 1) P0132 O2 Sensor 1 Circuit High Voltage (Bank 1) P0133 O2 Sensor 1 Circuit Slow Response (Bank 1) P0134 O2 Sensor 1 Circuit No Activity Detected (Bank 1) P0135 O2 Sensor 1 Heater Circuit (Bank 1) P0151 O2 Sensor 1 Circuit Low Voltage (Bank 2) P0152 O2 Sensor 1 Circuit High Voltage (Bank 2) P0153 O2 Sensor 1 Circuit Slow Response (Bank 2) P0154 O2 Sensor 1 Circuit No Activity Detected (Bank 2) P0155 O2 Sensor 1 Heater Circuit (Bank 2) Description The oxygen sensors separately monitor the oxygen content in the exhaust gases of each bank of the engine. Each sensor is electrically heated to improve response after start. The sensor consists of a zirconia electrode between two platinum plates. When zirconia comes into contact with oxygen, it becomes an electrical conductor. The exhaust gases pass through louvers in the sensor. One plate is in contact with the outside air and the other plate is in contact with the exhaust gases. The platinum plate in contact with the air is electrically negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically positive. This will cause a difference in electrical potential to develop between the two plates. Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts, depending on the oxygen content of the exhaust gases. Thus when the air/fuel mixture is rich, the oxygen sensor output will be high. If the air/fuel mixture is lean, the oxygen sensor output will be low. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal G3 48 Way (Centre) 2 Bank 1 Ground J2 48 Way (Centre) 3 Bank 1 Heater H3 48 Way (Centre) 4 Bank 1 Main relay via fuse R Bank 2 Signal G4 48 Way (Centre) 2 Bank 2 Ground J2 48 Way (Centre) 3 Bank 2 Heater H4 48 Way (Centre) 4 Bank 2 Main relay via fuse R6 - - Sensor characteristics Normal operating range is mV P0131 (Bank1) or P0151 (Bank2). DFCO (Deceleration Fuel Cut Off) Appropriate engine bank not disabled Engine running Failure Criteria: Sensor voltage < 15mV for time > 30 x 1.5 seconds. Low fuel pressure (Lean mixture) Malfunctioning sensor Page 28

29 External water on sensor Sensor wire shorted to ground The MIL will be illuminated if these faults are present for 2 consecutive trips. P0132 (Bank1) or P0152 (Bank2). Engine running Sensor voltage > 1200mV for time > 30 x 1.5 seconds. High fuel pressure (Rich mixture) Leaking or shorted injector Purge valve fault Oxygen sensor contamination Engine oil contamination Sensor wire shorted to heater voltage The MIL will be illuminated if these faults are present for 2 consecutive trips. P0133 (Bank1) or P0153 (Bank2) Discrete test run once per drive cycle. Monitor completes after 30 oxygen sensor switches have occurred in both switch directions (i.e. rich to lean & lean to rich) or once test enable conditions have been met for 130 seconds. Note lean threshold for oxygen sensor is 322mV, rich threshold for oxygen sensor is 600mV. P0116, P0117, P0118 Coolant temperature sensor faults P0101, P0102, P0103 MAF sensor faults P0335, P0500 Crank or vehicle speed faults P0131, P0132, P0134, P0135 Pre catalyst oxygen sensor faults for Bank1 checks P0151, P0152, P0154, P0155 Pre catalyst oxygen sensor faults for Bank2 checks Aggressive throttle transients Vehicle speed between km/h (158.5 mph) Engine load between % Engine speed between rpm Engine run time > 200 seconds Coolant temperature > 60 C (140 F) Closed loop fuelling enabled Average sensor lean to rich switch time > 220ms & rich to lean switch time > 220ms Average sensor lean to rich switch time > 220ms & the ratio of lean to rich versus rich to lean switch times < 0.5 Page 29

30 Average sensor rich to lean switch time > 130ms & the ratio of lean to rich versus rich to lean switch times > 2.5 No recorded lean to rich or rich to lean sensor switches Sensor connector and wiring should be checked for corrosion and loose connections Sensor contaminated, possibly from fuel, improper use of RTV, engine oil or coolant The MIL will be illuminated if these faults are present for 2 consecutive trips. P0134 (Bank1) or P0154 (Bank2) Monitor Insufficient sensor to enable closed loop fuelling: Discrete test run once per drive cycle. Disable Criteria Insufficient sensor activity to enable closed loop fuelling: Enable Criteria Insufficient sensor to enable closed loop fuelling: Closed loop fuelling delay timer expired (10 200s dependant on engine coolant temperature at engine start) Malfunction Criteria Insufficient sensor to enable closed loop fuelling: Sensor voltage fails to switch above 552mV or below 400mV within a 5 second period. Monitor Insufficient sensor activity once closed loop fuelling activated: Discrete test run once per drive cycle. Disable Criteria Insufficient sensor activity once closed loop fuelling activated: Enable Criteria Insufficient sensor activity once closed loop fuelling activated: Engine run time > 30 seconds Engine is in closed loop fuel control Malfunction Criteria Insufficient sensor activity once closed loop fuelling activated: Set when the sensor fails to switch above 600mV and below 322mV within a 60 second period. Monitor Stuck sensor neutral sensor voltage:. Disable Criteria Stuck sensor neutral sensor voltage: Enable Criteria Stuck sensor neutral sensor voltage: Engine run time > 5 seconds Sensor voltage > 322mV & sensor voltage < 600mV Malfunction Criteria Stuck sensor neutral sensor voltage: Sensor voltage static to within 24mV over a 5 second period. Monitor Stuck sensor lean / rich sensor voltage:. Disable Criteria Stuck sensor lean / rich sensor voltage: Vehicle speed sensor fault (P0500 / U0122) Page 30

31 Enable Criteria Stuck sensor lean / rich sensor voltage: Engine run time > 5 seconds Sensor voltage < 322mV & post catalyst oxygen sensor voltage > 600mV or Sensor voltage > 600mV & post catalyst oxygen sensor voltage < 300mV Engine is in closed loop fuel control Vehicle stationary Malfunction Criteria Stuck sensor lean / rich sensor voltage: Sensor voltage static to within 24mV over a 10 second period. Sensor connector and wiring should be checked for corrosion and loose connections. Gas leak in exhaust system The MIL will be illuminated if these faults are present for 2 consecutive trips. P0135, P0155 Engine run time > 60 seconds Set when the heater output current is greater than 1900mA or less than 250mA for time > 40 x 1.5 seconds. Sensor connector and wiring should be checked for corrosion and loose connections. The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 31

32 O2 Sensor (Post Catalyst) P0137 O2 Sensor Circuit Low Voltage (Bank 1) P0138 O2 Sensor Circuit High Voltage (Bank 1) P0139 O2 Sensor Circuit Slow Response (Bank 1) P0140 O2 Sensor Circuit No Activity Detected (Bank 1) P0141 O2 Sensor Heater Circuit (Bank 1) P0157 O2 Sensor Circuit Low Voltage (Bank 2) P0158 O2 Sensor Circuit High Voltage (Bank 2) P0159 O2 Sensor Circuit Slow Response (Bank 2) P0160 O2 Sensor Circuit No Activity Detected (Bank 2) P0161 O2 Sensor Heater Circuit (Bank 2) Description The oxygen sensors separately monitor the oxygen content in the exhaust gases of each bank of the engine. Each sensor is electrically heated to improve response from start. The sensor consists of a zirconia electrode between two platinum plates. When zirconia comes into contact with oxygen, it becomes an electrical conductor. The exhaust gases passes through louvers in the sensor. One plate is in contact with the outside air and the other plate is in contact with the exhaust gases. The platinum plate in contact with the air is electrically negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically positive. This will cause a difference in electrical potential to develop between the two plates. Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts, depending on the oxygen content of the exhaust gases. Thus when the air/fuel mixture is rich, the oxygen sensor output will be high. If the air/fuel mixture is lean, the oxygen sensor output will be low. When used in conjunction with the pre catalyst oxygen sensor, the post catalyst oxygen sensor can be used to provide an indication of the performance of the catalyst. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal H1 48 Way (Centre) 2 Bank 1 Ground K4 48 Way (Centre) 3 Bank 1 Heater K1 48 Way (Centre) 4 Bank 1 Main relay via fuse R Bank 2 Signal H2 48 Way (Centre) 2 Bank 2 Ground K4 48 Way (Centre) 3 Bank 2 Heater K2 48 Way (Centre) 4 Bank 2 Main relay via fuse R6 - - Sensor characteristics Normal operating range is mV P0137, P0157 Engine running DFCO (Deceleration Fuel Cut Off) Appropriate engine bank not disabled Sensor voltage < 15mV for time > 30 x 1.5 seconds. Page 32

33 Check and rectify any pre catalyst sensor fault code, as they may be causing the fault code to be set Sensor wire shorted to ground Malfunctioning sensor External water on sensor The MIL will be illuminated if these faults are present for 2 consecutive trips. P0138, P0158 Engine running Sensor voltage > 1200mV for time > 30 x 1.5 seconds. Check and rectify any front sensor fault code, as they may be causing the fault code to be set Oxygen sensor contamination Sensor wire shorted to heater voltage The MIL will be illuminated if these faults are present for 2 consecutive trips. P0139, P0159 O2 Sensor, slow response can be defined in two ways; 1) Slow response and 2) Delayed response. 1) Delayed Response This portion of the diagnostic detects if there is a delay in the response of the oxygen sensor signal. The diagnostic will set if the sensor fails to switch rich (sensor voltage > 600mV) within 5 seconds of fuel enrichment or if the sensor fails to switch lean (sensor voltage < 300mV) within 5 seconds of DFCO activation. Discrete test run once per drive cycle. Engine run time > 200 seconds Switch rich only enable criteria: - > 15 g/sec MAF & Pre-catalyst oxygen sensor voltage > 600mV) Switch lean only enable criteria: - DFCO enabled & Pre-catalyst oxygen sensor voltage < 322mV) P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P02777 Injector faults P0300, P0301, P0302, P0303, P0304, P0305, P0306 Misfire faults P1301, P1302 Misfire faults causing emission or catalyst damage P0140, P0141, P0160, P0161 Post catalyst oxygen sensor heater faults Sensor fails to switch lean / rich within 5 seconds Page 33

34 2) Slow Response This portion of the diagnostic detects if the response of the oxygen sensor signal is too slow. The diagnostic will set when the time taken for the sensor to complete a rich to lean switch (600mV to 300mV) or vice versa is greater than the specified threshold for 3 consecutive sensor switches. Discrete test run once per drive cycle. Engine run time > 200 seconds Rich to lean switch only enable criteria: - Post catalyst oxygen sensor voltage > 600mV (i.e. rich) for > 3 seconds prior to initiation of sensor switch Rich to lean switch only enable criteria: - DFCO enabled Lean to rich switch only enable criteria: - Pre catalyst oxygen sensor voltage > 600mV (i.e. rich) for > 1.2 seconds from the point the post catalyst oxygen sensor voltage increases above 300mV (i.e. lean threshold). P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P02777 Injector faults P0300, P0301, P0302, P0303, P0304, P0305, P0306 Misfire faults P1301, P1302 Misfire faults causing emission or catalyst damage P0140, P0141, P0160, P0161 Post catalyst oxygen sensor heater faults 3 consecutive lean to rich or rich to lean switch times > 700 ms. Check and rectify any pre catalyst sensor fault code, as they may be causing the fault code to be set Check exhaust system for potential leaks Catalyst damage/leak/inefficiency Oxygen sensor contamination / damage Partial short circuit of sensor wiring The MIL will be illuminated if a fault is present for 2 consecutive trips. P0140, P0160 Discrete test run once per drive cycle. Engine run time > 30 seconds Closed loop fuel control delay timer expired (nominally 10s, maximum 200s) Set when the sensor fails to switch above 552mV or below 400mV within 60 seconds. Check and rectify any front sensor fault code, as they may be causing the fault code to be set Sensor connector and wiring should be checked for corrosion and loose connections Check exhaust system for potential leaks Page 34

35 The MIL will be illuminated if these faults are present for 2 consecutive trips. P0141, P0161 Engine run time > 60 seconds Set when the heater output current is greater than 1900mA for 40 x 0.5 seconds or less than 250mA for 40 x 1.5 seconds. Sensor connector and wiring should be checked for corrosion and loose connections The MIL will be illuminated if a fault is present for two consecutive trips. Page 35

36 Fuel Control System Too Lean or Rich P0171 System Too Lean (Bank 1) P0172 System Too Rich (Bank 1) P0174 System Too Lean (Bank 2) P0175 System Too Rich (Bank 2) Description The oxygen sensors send signals to the ECU corresponding to the exhaust gas oxygen content, which allows the ECU to maintain a stoichiometric air/fuel ratio under normal driving conditions. The ECU initially does this by making short term fuel corrections of up to ±30% to the calculated fuel demand. This value is subsequently learned by the ECU over time as a long term fuelling correction. If the ECU determines the short term fuelling correction is indicating that a rich fuelling condition exists (i.e. short term fuelling correction is negative / removing fuel), the long term fuelling correction will be reduced (and vice versa), with the aim being that stoichiometric fuelling will be maintained with minimum short term fuelling correction. The ECU learns long term fuelling corrections in three different zones for each engine bank (Zone 1 Low engine load / engine idling, Zone 2 medium engine load, Zone 3 high engine load). The Zone 1 long term fuelling correction is learnt as an injector dead time offset (in micro seconds), where as Zone 2 & Zone 3 corrections are learnt as injector flow rate offsets (in %). Closed loop fuelling active (stoichiometric air fuel ratio requested) Fuel level > 3 litres Engine coolant temperature > 70degC Air intake temperature > 10degC Accumulated mass air flow since engine start > 1500g Altitude < 8000 ft (2438 m), Baro > 756 mbar Evaporative purge system not active Fuel learn zone 1 only enable conditions: - Engine load < 29%, Mass air flow < 13g/s, Engine speed < 1100rpm, Vehicle stationary > 5s, Vehicle in gear > 4s, Idle closed loop control active, Engine idle speed error < 100rpm Fuel learn zone 2 only enable conditions: - Engine load = 30% - 46%, Mass air flow = 20g/s 32g/s Fuel learn zone 3 only enable conditions: - Engine load > 50%, Mass air flow > 34g/s P0011, P0012, P0021, P0022, P0076, P0077, P0082, P0083 Intake valve control solenoid faults P0014, P0015, P0024, P0025, P0079, P0080, P0085, P0086 Exhaust valve control solenoid faults P0016, P0018. P0341, P0346 Inlet camshaft sensor faults P0017, P0019. P0366, P0391 Exhaust camshaft sensor faults P0101, P0102, P0103 Mass air flow sensor faults P0107, P0108 Barometric pressure sensor faults P0112, P0113 Intake air temperature sensor faults P0116, P0117, P0118 Engine coolant temperature sensor faults P0131, P0132, P0133, P0134, P0135, P0151, P0152, P0153, P0154, P0155 Pre catalyst oxygen sensor faults P0191, P0192, P0193 Fuel pressure sensor faults P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P0277 Injector faults P0300, P0301, P0302, P0303, P0304, P0305, P0306 Misfire faults P0351, P0352, P0353, P0354, P0355, P0356 Ignition coil faults P0444, P0445 Evaporative purge valve faults Malfunction Criteria P0171 & P0174: Zone 1 Injector dead time offset < -450μs and either fuel learning active for greater than 300s or fuel learn identified as being mature. Page 36

37 Zone 2 / Zone 3 Injector flow rate offset < -25% and either fuel learning active for greater than 150s or fuel learn identified as being mature. Fuel Pressure too low (restriction in fuel line) Air leak in induction system Water in fuel Exhaust leak / crack before pre-catalyst oxygen sensor Injector fault Sensor connector and wiring for signs of corrosion or loose connections MAF sensor fault Fuel pressure sensor fault Pre-catalyst oxygen sensor fault Evaporative purge valve leak / malfunction Vehicle has previously run out of fuel The MIL will be illuminated if a fault is present for two consecutive trips. Malfunction Criteria P0172, P0175: Zone 1 Injector dead time offset > 450μs and either fuel learning active for greater than 300s or fuel learn identified as being mature. Zone 2 / Zone 3 Injector flow rate offset > 25% and either fuel learning active for greater than 150s or fuel learn identified as being mature. Fuel pressure too high Leaking fuel injector Restriction in the exhaust system or air intake / filter MAF sensor fault Fuel pressure sensor fault Pre-catalyst oxygen sensor fault Evaporative purge valve leak / malfunction Ignition fault The MIL will be illuminated if a fault is present for two consecutive trips. Page 37

38 Fuel Rail Pressure Sensor P0191 Fuel Rail Pressure Sensor "A" Circuit Range/Performance P0192 Fuel Rail Pressure Sensor "A" Circuit Low P0193 Fuel Rail Pressure Sensor "A" Circuit High Description: The Exige Sport 380 fuel system uses a fuel rail pressure sensor to determine the pressure drop across the fuel injectors, and hence is used as part of the calculation for determining the required injector duty cycle. In addition to this, the ECM also uses the sensed fuel pressure as closed loop feedback to modulate the duty cycle of the fuel pump control module, and hence ensure that actual fuel pressure meets demanded fuel pressure. Component connections Sensor connector Description ECM Pin ECM Connector 1 Ground via ECM K3 48 Way (Right) 2 Fuel rail pressure sensor signal B3 48 Way (Right) 3 5 volt supply from ECM F4 48 Way (Right) P0191 Disable Criteria All parts of monitor: P025C, P025D, P0627, U0109 Fuel pump / fuel pump control module fault codes P0192, P0193 Fuel rail pressure sensor circuit fault codes Monitor Stuck Sensor Check: Discrete test run once per drive cycle. Enable Criteria Stuck Sensor Check 1 (Fuel On): Engine running > 5s Deceleration fuel cut off not active Change in fuel pump control correction term > 8% Malfunction Criteria Stuck Sensor Check 1 (Fuel On): Fuel pressure input changed by less than 10kPa (40mV) within 2s of the above conditions being met Enable Criteria Stuck Sensor Check 2 (Fuel Off): Engine running > 5s Deceleration fuel cut off active Fuel on time prior to deceleration fuel cut off activation > 5s Mass air flow at point of deceleration fuel cut off activation > 5 g/s Malfunction Criteria Stuck Sensor Check 2 (Fuel Off): Fuel pressure input changed by less than 10kPa (40mV) within 8s of above conditions being met Monitor Noisy Sensor Check: Enable Criteria Noisy Sensor Check: Engine running Fuelling active on all cylinders Malfunction Criteria Noisy Sensor Check Fuel pressure erratic by more than 40kPa (160mV) for more than 5s Monitor Rationality Check High / Low: Page 38

39 Enable Criteria Rationality Check High: Engine running Lean fuelling error present (P0171 or P0174) or short term fuel adaption terms >= 30% Closed loop fuelling active Fuel mass flow demand < 80kg/hr Malfunction Criteria Rationality Check High: Fuel pump control correction term < -10% for more than 5s Enable Criteria Rationality Check Low: Engine running Rich fuelling error present (P0172 or P0175) or short term fuel adaption terms <= 30% Closed loop fuelling active Fuel mass flow demand < 80kg/hr Malfunction Criteria Rationality Check Low: Fuel pump control correction term > 10% for more than 5s Fuel pressure sensor wiring or connector damage Fuel pressure sensor failure The MIL will be illuminated if the fault is present for two consecutive trips. P0192 / P0193 Engine running P Fuel pressure sensor voltage is less than 0.048V (-1.3kPa) for more than 1.5 seconds P Fuel pressure sensor voltage is greater than 4.985V (1222kPa) for more than 1.5 seconds Fuel pressure sensor disconnected Fuel pressure sensor wiring open circuit, shorted to ground or shorted to supply voltage Fuel pressure sensor wiring or connector damage Fuel pressure sensor failure The MIL will be illuminated if the fault is present for two consecutive trips. Page 39

40 Fuel Injection System P0261 Injector Circuit low voltage Cylinder 1 P0262 Injector Circuit high voltage Cylinder 1 P0264 Injector Circuit low voltage Cylinder 2 P0265 Injector Circuit high voltage Cylinder 2 P0267 Injector Circuit low voltage Cylinder 3 P0268 Injector Circuit high voltage Cylinder 3 P0270 Injector Circuit low voltage Cylinder 4 P0271 Injector Circuit high voltage Cylinder 4 P0273 Injector Circuit low voltage Cylinder 5 P0274 Injector Circuit high voltage Cylinder 5 P0276 Injector Circuit low voltage Cylinder 6 P0277 Injector Circuit high voltage Cylinder 6 Description The ECU has six injector driver circuits, each of which controls an injector. When the engine is running the ECU continuously monitors the injector circuit feedback signals. The monitored feedback signal should be low voltage when the injector is ON and high voltage when the injector is OFF. Component connections Connector Description ECM Pin ECM Connector 1 Main relay via fuse R Injector 1 ground H4 32 Way (Left) 1 Main relay via fuse R Injector 2 ground H3 32 Way (Left) 1 Main relay via fuse R Injector 3 ground H2 32 Way (Left) 1 Main relay via fuse R Injector 4 ground H1 32 Way (Left) 1 Main relay via fuse R Injector 5 ground G4 32 Way (Left) 1 Main relay via fuse R Injector 6 ground G3 32 Way (Left) Engine running Sensor connector or wiring corroded or loose connections The MIL will be illuminated if these faults are present for 2 consecutive trips. Limp home: Limit maximum engine speed to 4000rpm Return the fuel system of the affected bank to open loop fuel control Note - If an injector goes short circuit it is likely that the ECU injector driver will be damaged. Page 40

41 Misfire P0300 Random/Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected P0305 Cylinder 5 Misfire Detected P0306 Cylinder 6 Misfire Detected P1301 Misfire level causing emissions increase P1302 Misfire level causing catalyst system damage Description An engine misfire event can be detected by analysing crank speed variation. Following a combustion event there will be a net acceleration of the crankshaft. Following a misfire event there will be a net deceleration of the crankshaft. The ECM identifies decelerations of the crankshaft by monitoring for changes in the crankshaft time period over a fixed angle of rotation after each firing event. A significant change in this time period, assessed by comparing to the previous period, will be attributed as a misfire on the given firing cylinder. Misfire is assessed over 1000 engine revolutions for misfire level causing emissions increase (P1301) and 200 engine revolutions for misfire level causing catalyst system damage (P1302). If engine misfire reaches a level that would result in engine emissions to exceed regulatory limits, the P1301 diagnostic will set. If the level of misfire is of a level that if it continued, would result in damage to the vehicles catalysts, the P1302 diagnostic will set. If this occurs the ECM will take action to protect the catalysts. This action may include shutting down individual cylinders, shutting down a bank of cylinders, limiting engine speed to 4000rpm or limiting throttle opening. In conjunction with setting a P1301 or P1302 fault code, individual cylinder fault codes will also be set (P0301 P0306). If a cylinder contributes more than 10% of the total misfire, the individual cylinder fault code for that cylinder will be set. If 2 or more cylinders each contribute to more than 10% of the total misfire the random / multiple cylinder misfire fault code will also be set (P0300). Coolant temperature between C ( F) Engine speed between rpm Engine load greater than 14 60% depending on engine speed DFCO enabled (Deceleration Fuel Cut Off) Rough road P0101, P0102, P MAF faults Aggressive throttle transients P1301 Misfire level causing emissions increase Misfire percentage > 2.5% occurs immediately after engine start or cumulatively 4 times over a given drive cycle. P1302 Misfire level causing catalyst system damage Misfire percentage > 10% - 33% depending on engine speed and load P0301 P0306 Individual cylinder percentage misfire > 10% of total engine misfire P0300 will set if 2 or more individual cylinder percentage misfire > 10% of total engine misfire Page 41

42 Limp home modes (P1302 only): Throttle limited Engine speed limited to 4000rpm Affected engine cylinder bank shut down Affected individual cylinders shut down Note the limp home severity is dependent on the severity of the misfire and the number of cylinders affected Injector failure VVT system fault (clearance or timing) Damage to rocker arm assembly MAF sensor fault Connectors and wiring for signs of corrosion or loose connections Spark plug / coil fault Cylinder compression fault PCV system / hoses leak Fuel pressure fault Engine coolant temperature sensor fault Vacuum hose leak ECU P1301 The MIL will be illuminated if a fault is present for two consecutive trips. P1302 The MIL will be illuminated immediately and the ECM will take action to prevent catalyst damage. P0300 P0306 The MIL will be illuminated if a fault is present for two consecutive trips. Notes: The ECM uses two set of misfire learns as part of the misfire diagnostic: - 1.Fuel off misfire learns calculated during DFCO (Deceleration Fuel Cut Off). 2.Fuel on misfire learns calculated once fuel off misfire learns have matured at engine speeds above 5000rpm Page 42

43 Knock Control System P0327 Knock Sensor Circuit Low (Bank 1) P0328 Knock Sensor Circuit High (Bank 1) P0332 Knock Sensor Circuit Low (Bank 2) P0333 Knock Sensor Circuit High (Bank 2) Description The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The piezoelectric element continuously sends a signal to the ECU, when the cylinder block vibrates due to engine knocking, this signal increases. The ECU is able to identify each cylinder. If knock is detected then the ECU will retard the ignition of the relevant cylinder to suppress it. The knock control sensor cannot differentiate between spark knock and other similar sounding noises. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Ground C1 48 Way (Centre) 2 Bank 1 Sensor input D1 48 Way (Centre) 1 Bank 2 Ground C2 48 Way (Centre) 2 Bank 2 Sensor input D2 48 Way (Centre) Engine running P0327 This code is set when the bank 1 knock sensor signal is < V for 3 x 1.5 seconds P0328 This code is set when the bank 1 knock sensor signal is > V for 3 x 1.5 seconds P0332 This code is set when the bank 2 knock sensor signal is < V for 3 x 1.5 seconds P0333 This code is set when the bank 2 knock sensor signal is > V for 3 x 1.5 seconds Abnormal engine noise, i.e. damaged engine or exhaust system contacting vehicle Knock sensor fixing too tight Sensor connector / wiring corroded or loose connections ECU The MIL will be illuminated if a fault is present for two consecutive trips. Page 43

44 Engine Speed / Position Sensors P0335 Crankshaft Position Sensor A Circuit Range/Performance Description Engine speed is calculated by measuring the time between the teeth of the crankshaft sensor trigger disc. The disc has 34 teeth and 2 missing teeth, spaced at 10 degree intervals around the disc. The 2 missing teeth are positioned at 155 degrees before cylinder No.1 TDC. The crankshaft sensor signal is also used to determine misfire events. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor input A4 32 Way (Left) 2 Ground B2 32 Way (Left) Engine running 15 crank errors in succession. This can occur due to no crank signal occurring whilst the camshafts continue to count or if there is a measured consecutive crank error (missing / additional crank pulses recorded). Sensor signal open circuit or short to ground Sensor ground open circuit Sensor failure Crankshaft sensor plate ECU The MIL will be illuminated if this fault is present for two consecutive trips. Notes: If a sensor or sensor circuit failure occurs, the engine will not fire or start. Page 44

45 Engine Speed / Position Sensors P0341 Camshaft Position Sensor A Circuit (Bank 1) P0346 Camshaft Position Sensor A Circuit (Bank 2) P0366 Camshaft Position Sensor B Circuit (Bank 2) P0391 Camshaft Position Sensor B Circuit (Bank 2) Description The camshaft position input to the ECU is used to determine engine phase, enable sequential fuel injection control and to determine camshaft position for VVT control. The inlet camshaft has three teeth spaced 90 apart, which are detected by the electromagnetic sensor. The valve timing setting is measured in the ECU by measuring time from a (fixed position) crankshaft tooth to a (variable position) camshaft tooth. As the engine speed and the position are known from the crankshaft sensor signal, the camshaft position can be calculated. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Inlet Bank 1 Signal A3 32 Way (Left) 2 Inlet Bank 1 Ground B3 32 Way (Left) 3 Supply voltage 5V D1 32 Way (Left) 1 Exhaust Bank 1 Signal D4 32 Way (Left) 2 Exhaust Bank 1 Ground B3 32 Way (Left) 3 Supply voltage 5V D1 32 Way (Left) 1 Inlet Bank 2 Signal A2 32 Way (Left) 2 Inlet Bank 2 Ground B3 32 Way (Left) 3 Supply voltage 5V D1 32 Way (Left) 1 Exhaust Bank 2 Signal D3 32 Way (Left) 2 Exhaust Bank 2 Ground B3 32 Way (Left) 3 Supply voltage 5V D1 32 Way (Left) Engine running Engine speed > 600rpm Engine runtime > 4 seconds 15 revolutions of crankshaft without receiving correct camshaft signal (i.e. incorrect number of camshaft pulses / complete loss of camshaft signal) Sensor circuit fault (open circuit / short to ground) Sensor failure Cam failure Camshaft position plate ECU The MIL will be illuminated if a fault is present for two consecutive trips. Note: Fault code P0341 will also be generated if the vehicle fails security checks on start up. Page 45

46 Ignition System P0351 Ignition Coil A Primary/Secondary Circuit P0352 Ignition Coil B Primary/Secondary Circuit P0353 Ignition Coil C Primary/Secondary Circuit P0354 Ignition Coil D Primary/Secondary Circuit P0355 Ignition Coil E Primary/Secondary Circuit P0356 Ignition Coil F Primary/Secondary Circuit Description A Direct Ignition System (DIS) is used on the engine. The DIS improves the ignition accuracy, reduces highvoltage loss, and enhances the reliability of the ignition system. The DIS is a 1-cylinder system that ignites one cylinder with one ignition coil. The ECU determines the ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the power transistors in the igniter cuts off the current to the primary coil, which induces a spark at the spark plug connected to the secondary coil. The igniter will also send an ignition confirmation signal (IGF) as a fail-safe measure to the ECU. Component connections Connector Pin Description ECU Pin ECU Connector Coil 1 Coil 2 Coil 3 Coil 4 Coil 5 Coil 6 1 Supply Voltage Main relay via fuse R4 for all ignition coils 2 Ignition Coil Feedback D2 D2 D2 D2 D2 D2 32 Way (Left) 3 Coil Output (Logic) F4 F3 F2 F1 E4 E3 32 Way (Left) 4 Ground Cylinder head ground via splice for all ignition coils Engine running No ignition feedback signal to ECM while engine is running for 2 x 1.5 seconds Open or short in IGF1 IGF6 circuits from ignition coil to ECU Coil failure ECU The MIL will be illuminated if a fault is present for two consecutive trips. Page 46

47 Catalyst System Efficiency P0420 Catalyst System Efficiency Below Threshold (Bank 1) P0430 Catalyst System Efficiency Below Threshold (Bank 2) Description The ECU compares the waveform of the oxygen sensors located before and after the catalyst to determine whether or not the catalyst has deteriorated. If the catalyst is functioning normally the pre-catalyst oxygen sensor will be switching between rich and lean whilst the post-catalyst oxygen sensor should also be switching between rich and lean but significantly more slowly. When both the oxygen sensor waveforms change at a similar rate, it indicates that the catalyst performance has deteriorated. The ECU counts the number of pre and post catalyst oxygen sensor switches and divides one by the other to determine a ratio. If this ratio is too high a fault will be indicated. Sensor connections Pre catalyst oxygen sensor Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal G3 48 Way (Centre) 2 Bank 1 Ground J2 48 Way (Centre) 3 Bank 1 Heater Supply H3 48 Way (Centre) 4 Bank 1 Battery Voltage Main relay via fuse R6 1 Bank 2 Signal G4 48 Way (Centre) 2 Bank 2 Ground J2 48 Way (Centre) 3 Bank 2 Heater Supply H4 48 Way (Centre) 4 Bank 2 Battery Voltage Main relay via fuse R6 Post catalyst oxygen sensor Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal H1 48 Way (Centre) 2 Bank 1 Ground K4 48 Way (Centre) 3 Bank 1 Heater Supply K1 48 Way (Centre) 4 Bank 1 Battery Voltage Main relay via fuse R6 1 Bank 2 Signal H2 48 Way (Centre) 2 Bank 2 Ground K4 48 Way (Centre) 3 Bank 2 Heater Supply K2 48 Way (Centre) 4 Bank 2 Battery Voltage Main relay via fuse R6 Discrete test run once per drive cycle. Closed loop fuel control enabled Engine coolant temperature > 60 C (140 F) Barometric pressure > 756 mbar Vehicle speed < 130 km/h (81 mph) MAF > 2 g/sec & MAF < 55 g/sec Air inlet temperature > -10 C (14 F) Accumulated Mass Air > grams depending on coolant temperature Note To complete the catalyst monitor, approximately 1000 pre-catalyst oxygen sensor switches must be completed across the full MAF range of 2 55 g/sec. Page 47

48 P0101, P0102, P0103 P0107, P0108 P0112, P0113 P0116, P0117, P0118 P0131, P0132, P0133, P0134, P0135, P0151, P0152, P0153, P0154, P0155 P0137, P0138, P0139, P0140, P0141, P0157, P0158, P0159, P0160, P0161 P0171, P0172, P0174, P0175 P0300, P0301, P0302, P0303, P0304, P0305, P0306 P0500 MAF sensor faults Barometric pressure sensor faults Inlet air temperature sensor faults Coolant temperature sensor faults Pre-catalyst oxygen sensor faults Post-catalyst oxygen sensor faults Fuelling system faults Misfire faults Vehicle speed sensor fault Catalyst switch ratio > 0.6 (i.e. number of post-catalyst oxygen sensor switches divided by the number of pre-catalyst oxygen sensor switches) Exhaust system leak Oxygen sensor faults Oxygen sensor heater failure Catalyst failure The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 48

49 Evaporative Emission Control Purge, Open / Closed Circuit P0444 Evaporative Emission System Purge Control Valve Circuit Open P0445 Evaporative Emission System Purge Control Valve Circuit Closed Description When the engine is running the ECU continuously monitors the status of the evaporative emission components for open circuit or short. The feedback signal should be low when turned ON and high when turned OFF. The following codes will be set if the above conditions are not met: P0444, P0445. Sensor / component connections Purge Solenoid Connector Pins Description ECU Pin ECU Connector 1 Battery Voltage Main relay via fuse R7 2 Solenoid Output B3 48 Way (Centre) P0444, P0445 Engine running Purge valve request closed (P0444 only) Purge valve request open (P0445 only) Feedback signal error present for 1.5 seconds P0444 Purge valve/wiring open circuit P0445 Purge valve short circuit Diagnostic mask: The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 49

50 Fuel Level Sensor P0461 Fuel Level Sensor A Circuit Range/Performance P0462 Fuel Level Sensor A Circuit Low P0463 Fuel Level Sensor A Circuit High Description When the engine is running the ECU continuously monitors the fuel level sensor feedback signals. Other than for the purpose of the driver being able to determine the fuel level of a vehicle, the fuel level sensor is also used in various OBD monitors. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 2 Fuel level sensor signal A2 48 Way (Right) 3 4 Fuel level sensor ground K3 48 Way (Right) P0461 The monitor contains two portions, stuck sensor and noisy sensor. The stuck sensor portion monitors fuel usage and determines whether the fuel level sensor has responded correctly to this usage to determine if the sensor is stuck. The ECU also monitors the sensor signal at idle after a 20 second de-slosh period to identify if the sensor is noisy. Monitor Noisy Sensor Check: Discrete test run once per drive cycle. Enable Criteria Noisy Sensor Check: Vehicle idling Vehicle stationary for 20 seconds Gear = Neutral or Park or Drive & brake pedal pressed (AT vehicles only) Clutch pedal is either fully depressed or fully engaged (MT vehicles only) Disable Criteria Noisy Sensor Check: Fuel level increase (refuelling event) < 3.3 litres (0.9 US gallons) P0462, P0463 Fuel level sensor circuit faults P0500, U0122 Vehicle speed sensor faults Malfunction Criteria Noisy Sensor Check: Signal fluctuation > 10 litres, 35 times over 7 second period Monitor Stuck Sensor Check: Discrete test run once per drive cycle. Enable Criteria Stuck Sensor Check: Calculated accumulated fuel usage > 18 litres (stuck full, fuel level at test start > 40 litres) Calculated accumulated fuel usage > 15 litres (stuck empty, fuel level at test start < 4 litres) Calculated accumulated fuel usage > 8 litres (stuck midway, fuel level at test start between 4 & 40 litres) Disable Criteria Stuck Sensor Check: P0462, P0463 Fuel level sensor circuit faults Engine run time > 5s Page 50

51 Malfunction Criteria Stuck Sensor Check: Checks for three conditions, stuck when full, stuck when empty or stuck midway. The ECU determines if the sensor is stuck by calculating the amount of fuel used during the test period (this may occur over several drive cycles). If the fuel level does not move by more than 2.6 litres a fault is flagged. Fuel level sensor wiring or connector corroded Fuel level sensor stuck The MIL will be illuminated if these faults are present for 2 consecutive trips. P0462, P0463 Engine Running P0462 Voltage < 0.05V for 3 x 1.5s P0463 Voltage > 4.94V for 3 x 1.5s Sensor open or short circuit Fuel level sensor failure The MIL will be illuminated if these faults are present for 2 consecutive trips. Page 51

52 Engine Cooling Fan Control P0480 Fan 1 Control Circuit P0481 Fan 2 Control Circuit Description Slow Fans ECM engages fan relay 3 and runs both fans in series through the disengaged fan relays 2 & 1. Fast Fans ECM engages fan relays 1 and 2 and runs both of the fans in parallel. ECM diagnosis is only carried out on the fan relays. Component connections Sensor Connector Description ECU Pin ECU Connector Slow Fans F1 48 Way (Right) Fast Fans E2 48 Way (Right) diagnosis of fan relay circuits for short / open circuits Engine running Vehicle speed < 200kph (124.3mph) (P0480 only) Feedback signal error present for 1.5 seconds Wiring harness / electrical connector fault Relay failure ECU fault The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 52

53 Vehicle Speed Sensor P0500 Vehicle Speed Sensor A Description Vehicle speed is received over CAN by the ECU from the VDCM. Monitor Rationality Check: Enable Criteria Rationality Check: Following conditions must occur for 5 seconds Engine speed > 1900rpm and < 5200rpm Engine in deceleration fuel cut off mode. Disable Criteria Rationality Check: U0122 Lost communications with VDCM Malfunction Criteria Rationality Check: Vehicle Speed < 5 kmh at end of 5 second period. 5 consecutive test failures required to fail diagnostic. Monitor VDCM Fault: Enable Criteria VDCM Fault: Engine running Disable Criteria VDCM Fault: U0122 Lost communications with VDCM Malfunction Criteria VDCM Fault: Vehicle speed error signal received via VDCM for 5 x 1.5s VDCM (vehicle dynamics control module) failure Wheel speed sensor failure (check VDCM for reported faults) The MIL will be illuminated if a fault is present for two consecutive trips. Page 53

54 Idle Speed Control P0506 Idle Air Control System RPM Lower Than Expected P0507 Idle Air Control System RPM Higher Than Expected Description The ECM controls the engine idle speed using a combination of spark advance and throttle blade adjustment. If this control cannot attain the desired idle speed a fault is diagnosed. Monitor Idle Speed Error: Enable Criteria Idle Speed Error: Idle closed loop control active Battery voltage between 10 V and 16 V Disable Criteria Idle Speed Error: P0500 / U0122 Vehicle speed sensor faults Malfunction Criteria (P0507) Idle Speed Error: Idle air learn value on upper limit of +1.8g/s Idle speed more than 200 rpm above desired idle speed for more than 5 x 5 seconds. Malfunction Criteria (P0506) Idle Speed Error: Idle air learn value on lower limit of -1.8g/s Idle speed more than 100 rpm below desired idle speed for more than 5 x 5 seconds. Monitor Unable to enter idle closed loop control: Enable Criteria Unable to enter idle closed loop control: Accelerator pedal position < 0.293% Vehicle speed = 0kph Disable Criteria Unable to enter idle closed loop control: P0500 / U0122 Vehicle speed sensor faults Malfunction Criteria (P0507) Unable to enter idle closed loop control: Idle speed more than 304 rpm above desired idle speed for more than 5 x 5 seconds. Induction system air leak Excessive engine load from front end accessory drive system, water pump, power steering, alternator Electronic throttle control fault The MIL will be illuminated if a fault is present for 2 consecutive trips. Notes: There will be a different learn value for AC on and AC off. Either could trigger fault Page 54

55 Engine Oil Pressure Sensor P0523 Engine Oil Pressure Sensor Switch High Description The fault code detects when a warm engine has been switched off and the oil pressure signal remains high Sensor connections Connector Pins Description ECM Pin ECM Connector 1 Sensor signal D3 48 Way (Centre) Engine speed = 0rpm Engine coolant temperature > 70ºC (158ºF) Engine coolant temperature increase since engine start > 20ºC (68ºF) Oil pressure signal > 3.9V for 2 x 1.5 seconds Oil pressure sensor wiring or connector damage Oil pressure sensor failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 55

56 A/C Evaporator temperature sensor P0537 A/C Evaporator temperature sensor circuit low P0538 A/C Evaporator temperature sensor circuit high Description The A/C system incorporates an evaporator temperature sensor for system control. This is a thermistor device that changes resistance with temperature. As the evaporator temperature decreases the thermistor resistance value increases, and conversely as the evaporator temperature increases so the thermistor resistance value decreases. Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor ground K3 48 Way (Right) 2 Sensor signal A3 48 Way (Right) Engine Running P0537 Signal voltage < 0.049V for 1.5 seconds P0538 Signal voltage > 4.399V for 1.5 seconds Thermistor wiring open circuit or shorted Thermistor fault The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 56

57 Battery Voltage P0562 System Voltage Low P0563 System Voltage High P1562 Battery Voltage Too Low To Complete Throttle Autozero Description With a battery and alternator functioning as normal the system voltage for a running engine should be around 14V. The ECM monitors this and will diagnose if the voltage is too high or too low. P0562 / P0563 Engine running P0562 Voltage Too Low < 10V for 10 seconds P0563 Voltage Too High > 16V for 25.5 seconds Alternator fault Battery fault The MIL will be illuminated if a fault is present for two consecutive trips. P1562 Ignition on Throttle autozero currently taking place Battery voltage < 8.0V for 5ms Low battery voltage The MIL will not be illuminated for this fault. The code is for service indication only. Notes: Throttle autozero takes place immediately after engine ECU switches on (i.e. ignition switched on). Page 57

58 Cruise Control P0565 Cruise control on/off signal P0567 Cruise control resume/decel signal P0568 Cruise control set/accel signal P0571 Brake switch A circuit P1565 Cruise On/Off Switch Intermittent P1567 Cruise Resume/Deceleration Switch Intermittent P1568 Cruise Set/Acceleration Switch Intermittent Description Cruise control requests are made using a multi-function switch input directly wired into the engine control unit. From this input the ECM determines the driver request. In addition cruise control is cancelled by the application of either the brake pedal or the clutch pedal (see also P0806, P0807 and P0808). Sensor connections Sensor Connector Description ECU Pin ECU Connector A Cruise control switch input On / Off D2 48 Way (Right) B Cruise control ground K3 48 Way (Right) C Cruise control switch input Resume/Decease C3 48 Way (Right) D Cruise control switch input Set/Increase D3 48 Way (Right) 1 Brake Switch Ground Brake Switch Input C4 48 Way (Right) P0565, P0567, P0568 P0565 Cruise on/off switch pressed signal received continuously for more than 100 seconds P0567 Cruise resume/decel switch pressed signal received continuously for more than 100 seconds P0578 Cruise set/accel switch pressed signal received continuously for more than 100 seconds Cruise switch wiring open circuit or shorted Cruise switch fault ECU input circuit fault The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminate for 30 seconds after engine start if the fault is present. P0571 Enable Criteria Brake Switch Stuck On: Vehicle speed > 10kph (6.2mph) Page 58

59 Accelerator pedal position > 0.88% VDCM CAN communications working (Brake light switch state reported over CAN via VDCM) Disable Criteria Brake Switch Stuck On: Brake light switch fault reported by VDCM Malfunction Criteria Brake Switch Stuck On: Brake switch on > 25.5 seconds whilst brake light switch is indicated off Enable Criteria Brake Switch Stuck Off: VDCM CAN communications working (Brake light switch state reported over CAN via VDCM) Disable Criteria Brake Switch Stuck Off: Brake light switch fault reported by VDCM Malfunction Criteria Brake Switch Stuck Off: Brake switch off > 0.5 seconds whilst brake light switch is indicated on Brake switch wiring open circuit or shorted Brake switch fault Brake switch set incorrectly The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P1565, P1567, P1568 Cruise control not enabled Engine running Engine speed > 0kph Brake pedal pressed (P1567/P1568 only) OR Clutch pedal depressed OR Steering wheel angle > +/- 50deg P0565 Cruise on/off switch pressed signal received more than 20 times over 60 second period P0567 Cruise resume/decel switch pressed signal received more than 20 times over 60 second period P0578 Cruise set/accel switch pressed signal received more than 20 times over 60 second period Intermittent cruise switch wiring fault Cruise switch fault ECU input circuit fault The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminate for 30 seconds after engine start if the fault is present. Page 59

60 ECU Integrity P0601 Internal Control Module Memory Checksum Error P0606 ECM/PCM Processor Description These codes are used by the ECM to check the integrity of the software and calibration data. P0601 checks that on power up that the ECM memory data is the same as when saved at the previous power down. P0606 checks the watchdog timer after a defined period to see if it has reset. If the watchdog timer has not reset then the code has entered an unplanned loop or condition stopping it resetting the timer. P Discrete test runs during ECM initialisation ECM memory checksum stored at previous ECM shutdown does not match current checksum. ECM memory size has changed since previous ECM shutdown. ECM has been reprogrammed Low battery voltage ECM memory corruption The MIL will be illuminated if a fault is present. P Process execution time > 250ms. ECM Fault The MIL will be illuminated if a fault is present. Page 60

61 Variant Code Not Programmed P0610 Variant code not programmed Description The ECM programming process includes the writing to the ECM the vehicle variant code. If a new ECM has been fitted, the relevant vehicle variant code needs to be programmed using the Lotus TechCentre tool. Discrete test runs during ECM initialisation or if the variant code is reprogrammed Disable criteria: Malfunction criteria: Variant code not programmed Variant code does not match that expected by the engine ECM software Potential failure modes Variant code programmed incorrectly ECM memory corruption Diagnostic mask The MIL will be illuminated if fault is present. Page 61

62 Crank Relay P0616 Starter relay voltage low P0617 Starter relay voltage high Description When the ignition key is in the crank position battery voltage is applied to the start request input of the ECM. The ECM will then energise the crank relay, via the immobiliser, to allow the starter motor to be engaged. ECM diagnosis is only carried out on the crank relay. Component connections Relay Connector Description ECU Pin ECU Connector 230 Start Relay Alarm ECU Ignition switch via fuse R Crank relay control G1 48 Way (Right) Vehicle ignition on Engine running (P0616 only) Park or Neutral selected (P AT vehicles only) Feedback signal error present for 1.5 seconds P0616 Crank relay wiring open circuit or shorted to ground P0616 Fuse R16 P0617 Crank relay wiring shorted to 12V Crank relay failure Immobiliser failure ECU output circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 62

63 VIN Not Programmed or Incompatible ECU/PCM P0630 VIN not programmed or incompatible Description The ECM programming process includes the Vehicle Identification Number (VIN). If a new ECM has been fitted this operation is performed using the Lotus TechCentre tool. Discrete test runs during ECM initialisation or if the VIN is reprogrammed VIN not programmed VIN programmed incorrectly The MIL will be illuminated if fault is present. Page 63

64 Throttle Actuator Control Range/Performance P0638 Throttle actuator control range/performance Description The single throttle butterfly valve mounted at the inlet to the intake plenum is operated by a stepper motor under the command of the engine ECU. The valve moves through a range of nearly 90 and should display 100% at full throttle and around 2% at idle. Enable Criteria 1: Engine running Disable Criteria 1: Electronic throttle fault P2135, P0122, P0122, P0222 or P0223 present Throttle in idle limphome condition Throttle demand transient condition Malfunction Criteria 1: TPS error > 3% for 5 x 1.5 seconds Blocked throttle body Damage to throttle actuator The MIL will be illuminated if fault is present. Notes: A mechanically sprung 7% throttle opening may be imposed. Page 64

65 Air Conditioning System P0646 A/C Clutch Relay Control Circuit Low P0647 A/C Clutch Relay Control Circuit High Description The ECM controls the A/C clutch relay in response to the A/C driver request and ECM control logic. Component connections Relay Connector Description ECU Pin ECU Connector B30 Ignition supply via fuse R B85 AC clutch relay control F2 48 Way (Right) B86 Ignition supply via B B87 Power to AC compressor clutch - - B87a Engine running Feedback signal error present for 1.5 seconds P0646 A/C compressor relay wiring open circuit or shorted to ground P0646 Fuse R20 P0647 A/C compressor relay circuit shorted to 12V A/C compressor relay failure ECU output circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 65

66 ECU Power Relay P0685 ECU Power Relay Open Circuit Description The ECU power is controlled by the main power relay. The voltage at ECM pins RM2/RM3/RM4 is compared to the ignition switch input voltage at RB2 to determine if the power relay is open circuit. Because this fault prevents the correct shut down of the ECM, the fault code is only visible whilst the engine is running. Ignition supply voltage > 6V ECU Voltage > (Ignition supply voltage + 3.5V) for 1.5 seconds Fuse R10 Main relay failure (open circuit) The MIL will be illuminated if a fault is present and the engine is running. Page 66

67 Transmission Control System P0700 Transmission Control System (MIL Request) Description Certain faults within the Transmission Control System can have an exhaust emissions impact. When one of these faults is diagnosed by the TCM the MIL is illuminated by the ECM. Engine running Check TCM for fault codes The MIL will be illuminated if a fault is present and the engine is running. Page 67

68 Manual Transmission Cooler System P0712 Transmission Fluid Temperature Sensor "A" Circuit Low P0713 Transmission Fluid Temperature Sensor "A" Circuit High P0897 Transmission Fluid Deteriorated P2754 Transmission Fluid Cooler Control Circuit Low P2755 Transmission Fluid Cooler Control Circuit High P2797 Auxiliary Transmission Fluid Pump Performance Description The manual transmission has an oil cooling circuit which incorporates a temperature sensor and a pump which are used by the ECM to control the transmission oil temperature. The pump is control by the ECM via the oil cooler relay. Component connections Sensor Description ECM Pin ECM Connector 1 Transmission oil temperature sensor signal E2 48 Way (Centre) 2 Ground J3 48 Way (Centre) Splice CE2 Reference voltage via 1kΩ resistor F4 48 Way (Centre) Relay Connector Description ECU Pin ECU Connector A30 Battery voltage via fuse R A85 Oil cooler pump relay control G2 32 Way (Left) A86 Ignition supply via fuse R A87 Power to Oil cooler pump - - A87a P0712, P0713 Engine running P0712 Signal voltage < 0.029V for > 1.5s (transmission oil temperature > 195 C (383 F) P0713 Signal voltage > 4.985V for > 1.5s (transmission oil temperature < -25 C (-13 F) Sensor wiring fault (short / open circuit) Sensor failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P0897 Page 68

69 P0713 Transmission Fluid Temperature Sensor "A" Circuit High Transmission oil temperature > 150 C (302 F) for time > 30s Transmission cooling system obstruction. Transmission cooling pump failure resulting in inadequate transmission cooling. Transmission wear or failure resulting in excessive friction. The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P2754, P2755 Engine running Feedback signal error present for 1.5 seconds P2754 Oil cooler relay wiring open circuit or shorted to ground P2754 Fuse R16 P2755 Oil cooler relay circuit shorted to 12V Oil cooler relay failure ECU output circuit failure Wiring harness or connector damage The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P2797 Discrete test run once per drive cycle. Engine running The following criteria remain true for 160 seconds: - Road speed between km/h (50-80mph) - Transmission oil temperature between C ( F) - Engine coolant temperature between C ( F) P0712 or P0713 Transmission fluid sensor faults Transmission oil temperature rise less than 3 C over 160 second period Page 69

70 Transmission cooler pump failure. Transmission cooling system obstruction. The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 70

71 Clutch position sensor circuit P0806 Clutch position sensor circuit range/performance P0807 Clutch position sensor circuit low P0808 Clutch position sensor circuit high P1809 Noisy Clutch Pedal Sensor Description The clutch position sensor is used to identify the position of the clutch (engaged, disengaged or slipping). This information is used to control features such as fuel cut during gear changes, cruise control deactivation and ensuring any torque increase requests from the ESP system only occur with the clutch engaged. The ECM continuously monitors the clutch position sensor input for malfunctions. Component connections Connector Description ECU Pin ECU Connector A Ground K3 48 Way (Right) B Clutch position sensor signal B1 48 Way (Right) C Reference voltage F4 48 Way (Right) P0806 Discrete test run once per drive cycle. Engine running 15 gear changes taken place Gear >= 3 selected P0807, P0808 Clutch position sensor circuit faults Voltage difference between maximum and minimum clutch position over 15 gear changes less than 1.71V Clutch sensor failure Clutch pedal failure Clutch pedal sensor not fitted correctly to clutch pedal The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P0807, P0808 P0807 Sensor voltage < 0.21V for 1.5a P0808 Sensor voltage > 4.93V for 1.5s Page 71

72 P0807 Clutch sensor wiring open circuit or shorted to ground P0808 Clutch sensor ECU input circuit shorted to 5V or 12V Clutch sensor failure Clutch pedal failure ECU input circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P1809 Ignition ON Manual vehicles only Over a 80ms time period, the clutch position is recorded every 10ms. If over this time period, the clutch position changes by more than 0.244V in a non monotonic manner, the clutch is identified as being noisy. If this continues for a total time of 5 seconds the diagnostic fault will be set. Faulty clutch sensor Faulty clutch sensor connector Intermittent clutch sensor circuit fault The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 72

73 Gear Shift Paddles P0826 Up and Down Shift Switch Circuit P0827 Up and Down Shift Switch Circuit Low P0828 Up and Down Shift Switch Circuit High Description In automatic transmission vehicles gear shift requests can be made using the steering wheel mounted paddles. These switches select a different resistive network to a single ECM input depending on the paddle request. From this input the ECM determines the shift request and passes this to the TCM via CAN. Sensor connections Sensor Connector Description ECM Pin ECM Connector 1 LH paddle (down-shift) Paddle switch input E4 48 Way (Right) 2 LH paddle (down-shift) Paddle switch ground K3 48 Way (Right) 1 RH paddle (up-shift) Paddle switch input E4 48 Way (Right) 2 RH paddle (up-shift) Paddle switch ground K3 48 Way (Right) Sensor characteristics: Up-shift request: 2.737V 3.177V Down-shift request: 2.199V 2.688V Down-shift & Up-shift request: 1.906V 2.053V No shift request: 3.910V 4.154V P0826 Monitor Rationality Check: Enable Criteria Rationality Check: Disable Criteria Rationality Check: Sensor voltage < 0.24V OR > 4.64V (i.e. sensor open / short circuit) Malfunction Criteria Rationality Check: Sensor voltage outside ranges defined above for 1.5s Monitor Stuck Sensor: Enable Criteria Stuck Sensor: Sensor voltage = Up-shift request OR Down-shift request OR Down-shift & Up-shift request Disable Criteria Stuck Sensor: Sensor voltage < 0.24V OR > 4.64V (i.e. sensor open / short circuit) Malfunction Criteria Stuck Sensor: Sensor voltage changes less than +/ V over 100 second period Gear shift paddle switch wiring fault Gear shift paddle switch fault ECM input circuit fault Page 73

74 The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. P0827, P0828 P0827 Sensor voltage < 0.24V for 1.5a P0828 Sensor voltage > 4.64V for 1.5s P0827 Gear shift paddle switch open circuit or shorted to ground P0808 Gear shift paddle switch circuit shorted to 5V or 12V ECM input circuit fault The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 74

75 Safety Processor Throttle Shutdown P1104 Safety Processor Throttle Shutdown The ECM safety processor monitors the vehicles accelerator pedal position and throttle position. For a given accelerator pedal position there is a maximum throttle position that could be expected. If this position is exceeded, the throttle blade is open too far. The ECM safety processor will cut control of the throttle blade forcing it to mechanical limphome, whilst also registering a safety processor throttle shutdown fault. Ignition ON Throttle position to accelerator pedal throttle demand more than 32% offset Throttle position sensor failure Pedal position sensor failure Mechanical failure of throttle The MIL will be illuminated if fault is present. Notes: Throttle will be limited at mechanical limp home. Page 75

76 Brake Throttle Override (BTO) P1106 Throttle shutdown by BTO Description: Brake Throttle Override (BTO) is a function of the ECM that limits the throttle in the case of unintended acceleration. BTO is active when the following conditions are all valid: Vehicle speed > 25 km/h Throttle pedal > 10% Brake pedal is pressed for more than one second. Clutch pedal not operated (heel and toe condition) Ignition ON Throttle exceeds BTO limit by 2% for more than 3 seconds Electronic throttle fault Blocked throttle body Wiring/harness issue at throttle body connector The MIL will be illuminated if fault is present. Notes: Throttle will be limited at mechanical limp home. Page 76

77 Throttle Actuator Control P2100 Throttle Actuator Control Motor Circuit/Open P2102 Throttle Actuator Control Motor Circuit Low P2103 Throttle Actuator Control Motor Circuit High P2104 Throttle Actuator Control System Forced Idle P2105 Throttle Actuator Control System Forced Engine Shutdown P2106 Throttle Actuator Control System Forced Limited Power P2107 Throttle Actuator Control Module Processor P2108 Throttle Actuator Control Module Performance P2119 Throttle Actuator Control Throttle Body Range/Performance P2173 Throttle Actuator Control System High Airflow Detected Connector Description ECU Pin ECU Connector 1 Throttle motor control output (+) M1 48 Way (Centre) 2 Throttle motor control output (-) L2 48 Way (Centre) 3 Throttle position sensor ground C4 48 Way (Centre) 4 Throttle position sensor 1 signal F2 48 Way (Centre) 5 5V reference voltage E4 48 Way (Centre) 6 Throttle position sensor 2 signal F3 48 Way (Centre) Description Throttle position is controlled by the ECM by modulating the voltage to the throttle actuator stepper motor via the ECMs throttle H-bridge drive chip. Feedback of the throttle position is provided via two position sensors which are integrated as part of the throttle assembly. P2100 P2102, P2103, P2104, P2105, P Throttle actuator control faults Feedback signal error present for 500ms. Throttle actuator control motor open circuit The MIL will be illuminated if fault is present. P2102 P2100, P2103, P2104, P2105, P Throttle actuator control faults Feedback signal error present for 500ms. Page 77

78 Throttle actuator control motor short to ground The MIL will be illuminated if fault is present. P2103 P2100, P2102, P2104, P2105, P Throttle actuator control faults Feedback signal error present for 500ms. Throttle actuator control motor short to supply voltage The MIL will be illuminated if fault is present. P2104 Description If a fault is detected which could result in the throttle position being greater than that commanded by the accelerator pedal, control of the throttle actuator is disabled, causing the throttle valve to default to its mechanically sprung setting (approximately 6%). This Forced Idle throttle state provides a fast idle speed which may be used to effect a 'limp home' mechanism. Any of the following faults detected: P0638, P1104, P1106, P2100, P2102, P2103, P2107, P2108, P2119 or P2173 Any of the following fault combinations detected: (P0122 OR P0123) AND (P0222 OR P0223) May be set if a P2135 fault is detected See accompanying fault codes The MIL will be illuminated if fault is present. Note: This code indicates action taken by the ECM, and will always be accompanied by another fault code which has caused this action. Page 78

79 P2105 Description If a fault is detected which could result in engine speed runaway, the ECM throttle state is set to Forced Engine Shutdown which switches off fuel injection in order to stop the engine. Throttle control status = Forced Idle (i.e. P2104 fault code present) MAF > 12g/s for 3 x 0.6s OR Any of the following fault codes detected: P0101, P0102, P0103 MAF sensor fault present Electronic throttle fault Seized throttle actuator Foreign object blocking throttle actuator The MIL will be illuminated if fault is present. Note: This code indicates action taken by the ECM, and will always be accompanied by another fault code which has caused this action. P2106 Description If a fault is detected which could result in engine speed control difficulties, the ECM will enter a throttle state of Forced Limited Power which limits throttle opening to a maximum of 15%. Any of the following faults detected: P0122, P0123, P0222, P0223, P2122, P2123, P2127, P2128, P2135 or P2138 See accompanying fault codes The MIL will be illuminated if fault is present. Note: This code indicates action taken by the ECM, and will always be accompanied by another fault code which has caused this action. Page 79

80 P2107 Description The ECM contains two processors, a main processor and a safety processor. Communications is maintained between these two processors to ensure safety diagnostic functionality of the vehicle is maintained. Cyclic redundancy check error Serial communications lost between main processor and safety processor ECU internal fault Incorrect ECU programming The MIL will be illuminated if fault is present. P2108 P2100, P2102, P2103, P2104, P Throttle actuator control faults Feedback signal error present for 500ms. ECU internal failure Short circuit to throttle actuator The MIL will be illuminated if fault is present. P2119 Description On ECM initialisation, the ECM sequences a throttle autozero in order to define the zero position of the throttle actuator. The ECM attains the zero position of the throttle by forcing the throttle closed. Ignition on Page 80

81 Throttle autozero position outside limits: Throttle position sensor 1 voltage < 0.611V OR >0.797V Throttle autozero routine unable to complete within 1 second: Throttle position sensor 1 voltage not stationary to within 0.01V over 50ms interval Wiring/harness fault at throttle body connector Wiring/harness fault at ECU connector Throttle body dirty Seized throttle actuator Foreign object blocking throttle actuator The MIL will be illuminated if fault is present. P2173 Description The mass air flow reported by the MAF sensor is compared with the mass air flow calculated from the throttle position to determine whether a high MAF condition exists, which could result in engine speed runaway. Engine running P0101, P0102, P0103 MAF sensor fault present Aggressive throttle transients Throttle airflow learn (KAlphaNLearn) > Threshold (25-35% depending on engine speed) MAF sensor airflow Throttle airflow > 54mg Throttle plate damage Seized throttle actuator MAF sensor failure MAF sensor wiring fault Notes: A mechanically sprung 7% throttle opening may be imposed, or the injectors may be shut off to stop the engine Page 81

82 Pedal Position P2122 P2123 P2127 P2128 P2138 Pedal Position Sensor D Circuit Low Pedal Position Sensor D Circuit High Pedal Position Sensor E Circuit Low Pedal Position Sensor E Circuit High Pedal Position Sensor Voltage Correlation Connector Description ECU Pin ECU Connector 1 5V reference voltage E circuit F3 48 Way (Right) 2 5V reference voltage D circuit F3 48 Way (Right) 3 Pedal D position sensor signal B4 48 Way (Right) 4 Pedal D position sensor ground K4 48 Way (Right) 5 Pedal E position sensor ground K4 48 Way (Right) 6 Pedal E position sensor signal A4 48 Way (Right) Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECM. The measured pedal position voltages are re-scaled to determine diagnosed pedal positions in percentage terms (0 100%). The diagnosed pedal positions openings are subsequently used by the ECM to determine demanded throttle position from the driver. Note that the potentiometers operate on 5 volts. P2122/P2123 P2122 Sensor voltage < 0.831V for 100ms P2122 Reference voltage < 2V for 100ms P2123 Sensor voltage > 4.301V for 100ms P2123 Reference voltage > 6V for 100ms Pedal position sensor disconnected Pedal position sensor 1 wiring open circuit, shorted to ground or shorted to supply voltage Pedal position sensor 1 wiring fault or connector damage Pedal position sensor 1 failure Reference voltage wiring fault ECM reference voltage supply failure The MIL will be illuminated if fault is present. Notes: A maximum throttle opening of 15% may be imposed due to a single code. In the case of multiple codes, a mechanically sprung 7% opening may be applied. P2127/P2128 Page 82

83 P2127 Sensor voltage < 0.342V for 100ms P2127 Reference voltage < 2V for 100ms P2128 Sensor voltage > 2.322V for 100ms P2128 Reference voltage > 6V for 100ms Pedal position sensor disconnected Pedal position sensor 2 wiring open circuit, shorted to ground or shorted to supply voltage Pedal position sensor 2 wiring fault or connector damage Pedal position sensor 2 failure Reference voltage wiring fault ECM reference voltage supply failure The MIL will be illuminated if fault is present. Notes: A maximum throttle opening of 15% may be imposed due to a single code. In the case of multiple codes, a mechanically sprung 7% opening may be applied. P2138 Monitor Correlation Fault: Enable Criteria Correlation Fault: Disable Criteria Correlation Fault: P2122, P2123, P2127, P2128 Pedal position sensor faults Malfunction Criteria Correlation Fault: Diagnosed pedal position difference > 8% for 100ms Monitor Short Circuit Fault: Enable Criteria Short Circuit Fault: Disable Criteria Short Circuit Fault: Malfunction Criteria Short Circuit Fault: Pedal position sensor voltage difference < 0.024V for 100ms Pedal position sensor 1 fault Pedal position sensor 2 fault Short circuit between pedal position sensor signals Pedal position sensor wiring fault Page 83

84 The MIL will be illuminated if fault is present. Notes: A maximum throttle opening of 15% may be imposed. Page 84

85 Exhaust Pressure Regulator Vent Solenoid P2170 P2171 Exhaust Pressure Regulator Vent Solenoid Control Circuit Low Exhaust Pressure Regulator Vent Solenoid Control Circuit High Description: The exhaust pressure regulator vent solenoid is used to control a vacuum to the exhaust valve in the silencer and in so doing controls the state of the exhaust valve (open / closed). When the solenoid is active (i.e. in Sport / Race mode, at high loads / engine speeds or immediately after engine after start up) the exhaust valve in the silencer will be open. The diagnostic is an electrical check of the vent solenoid and does not check the actual physical position of the exhaust valve. The exhaust valve has been designed to fail open; however detection of any fault will impose a lower engine speed limit for engine safety. Connector Pins Description ECU Pin ECU Connector 1 Battery Voltage - main relay via fuse R Solenoid Output B1 48 Way (Centre) Engine running Feedback signal error present for 1.5s. P2170 Electrical harness fault open circuit or short circuit to ground P2171 Electrical harness fault short circuit to 5V Exhaust pressure regulator vent solenoid failure The MIL will be illuminated if a fault is present for two consecutive trips. Page 85

86 System Too Lean at Higher Load P2191 System Too Lean at Higher Load (Bank 1) P2193 System Too Lean at Higher Load (Bank 2) Description The oxygen sensor sends a signal to the ECU corresponding to the exhaust gas oxygen content enabling the ECU to maintain a 14.7:1 air/fuel ratio under normal driving conditions. At higher loads when the system is required to run richer than 14.7:1 air/fuel ratio, the oxygen sensor should return a signal greater than 600mV. If either of the oxygen sensor voltages are less than 600mV when the ECU requires the engine to be running rich the above codes are set for the respective banks. Engine coolant > 70 C Engine not in deceleration fuel cut Engine load > 40% AFR demand richer than 13.0:1 (lambda 0.9) Disable Criteria P2191/P2193: P0101, P0102, P0103 MAF sensor faults P0106, P0107, P0108 Barometric pressure sensor faults P0111, P0112, P0113 Intake air temperature sensor faults P0116, P0117, P0118 Engine coolant temperature sensor faults P0441, P0444, P0445 Evaporative purge valve faults P0261, P0262, P0264, P0265, P0267, P0268 P0270, P0271, P0273, P0274, P0276, P0277 Injector faults Disable Criteria P2191 only: P0131, P0132, P0133, P0134, P0135 Oxygen sensor faults P0301, P0303, P0305 Misfire faults Disable Criteria P2193 only: P0151, P0152, P0153, P0154, P0155 Oxygen sensor faults P0302, P0304, P0306 Misfire faults Pre-catalyst oxygen sensor voltage < 600mV for 2s. Fuel Pressure too low (restriction in fuel line) Cylinder misfire Air leak in induction system Water in fuel Exhaust leak / crack before pre-catalyst oxygen sensor Oxygen sensor connector / wiring fault (corrosion or loose connections) MAF sensor fault The MIL will be illuminated if fault is present for two consecutive trips. Page 86

87 Coolant Recirculation Pump P2602 P2603 Coolant Pump Control Circuit Low Coolant Pump Control Circuit High Description During a hot shutdown of the engine (engine coolant temperature > 108degC (226degF)), the recirculation pump will be activated to continue to pump coolant around the engine. The recirculation pump will also run in cold ambient conditions to aid heater performance. Component connections Connector Description ECU Pin ECU Connector 1 Battery Voltage - Main relay via fuse R Recirculation pump output M1 48 Way (Right) P continuous P engine running Feedback signal error present for 1.5s. P2602 Pump wiring open circuit or shorted to ground P2602 Fuse R5 failure P2603 Pump circuit, ECM side, shorted to battery voltage Pump failure ECU output circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 87

88 A/C Refrigerant Distribution Valve P2612 P2613 A/C Refrigerant Distribution Valve Control Circuit Low A/C Refrigerant Distribution Valve Control Circuit High Description: The A/C refrigerant flow is regulated by the ECM using the distribution valve to control the evaporator to the required temperature and prevent freezing. Component connections: Connector Description ECM Pin ECM Connector 1 Control valve output K3 48 Way (Centre) 2 Battery Voltage - Main relay via fuse R7 - - Engine running Feedback signal error present for 1.5s. P2612 Valve wiring open circuit or shorted to ground P2612 Fuse R5 failure P2613 Valve circuit, ECM side, shorted to battery voltage Distribution valve failure ECM output circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 88

89 A/C Compressor Lock Sensor Circuit B1422 A/C Compressor Lock Sensor Circuit Description: The ECM monitors the A/C compressor speed. If this speed is not within a calculated expect range based on current engine speed, the ECM will turn off the A/C compressor clutch. This is to prevent belt damage due to slippage. Component connections: Connector Description ECM Pin ECM Connector 1 A/C compressor speed sensor signal C1 32 Way (Left) 2 A/C compressor speed sensor ground B1 32 Way (Left) Engine speed > 1200rpm A/C system active P0537, P0538 A/C evaporator temperature sensor faults P0646, P0647 A/C compressor clutch faults P2612, P2613 A/C distribution valve faults A/C compressor speed error > 10% for 4s A/C compressor clutch mechanism slipping or seized A/C compressor drive belt slipping A/C compressor speed sensor wiring fault A/C compressor speed sensor failure ECM input circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 89

90 Communications with TCM U0101 U0302 Lost Communications with TCM Software Incompatible with TCM Description: The ECM communicates with the Transmission Control Module (TCM) via the CAN bus. If these CAN bus communications are interrupted the ECM will register a diagnostic code. The ECM also checks that its software set matches the TCM software set to ensure compatibility. U0101 Engine running CAN message not received for 50ms Reprogramming of TCM CAN wiring fault TCM failure / loss of power to TCM CAN bus corruption by another module on CAN bus The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. U0302 Ignition on U0101 Lost communications with TCM ECM / TCM software IDs do not match Incorrect programming of ECM/TCM Incorrect variant coding of ECM The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 90

91 Communications with VDCM U0122 U0316 U0416 Lost Communications with VDCM Software Incompatible with VDCM Invalid Data Received From VDCM Description: The ECM communicates with the Vehicle Dynamic Control Module (VDCM) via the CAN bus. If these CAN bus communications are interrupted the ECM will register a diagnostic code. The ECM also performs checks to confirm compatibility between the ECM & VDCM. U0122 Engine running CAN message not received for 9s Reprogramming of VDCM CAN wiring fault VDCM failure / loss of power to VDCM CAN bus corruption by another module on the CAN bus The MIL will be illuminated if fault is present. U0316 Ignition on U0101 Lost communications with TCM ECM / VDCM variant codes do not match Incorrect programming of ECM / VDCM Incorrect variant coding of ECM / VDCM The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 91

92 U0416 Five consecutive CAN messages received from ABS module with invalid checksum. Five consecutive CAN messages received from ABS module with invalid live counter. ABS module failure Incorrect ABS module fitted ABS module flashed with incorrect software CAN BUS failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 92

93 Communications with Yaw Rate Sensor Module U0123 U0513 Lost Communications with Yaw Rate Sensor Module Invalid Data Received from Yaw Rate Sensor Module Description: The Yaw Rate Sensor signal is used by the ECM within the Gear Shift Indication (GSI) function. The Yaw Rate Sensor communicates with the ECM via the CAN bus. If these CAN bus communications are interrupted the ECM will register a diagnostic code. U0123 Ignition on > 0.5s CAN message not received for 50ms CAN wiring fault Yaw Rate Sensor module failure / Loss of power to Yaw Rate Sensor module CAN bus corruption by another module on the CAN bus The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. U0513 Monitor Error Signal: Enable Criteria Error Signal: Ignition on > 0.5s Disable Criteria Error Signal: Malfunction Criteria Error Signal: Yaw Rate Sensor error message received for 50ms Monitor Rationality: Enable Criteria Rationality: Ignition on > 0.5s Engine not running Vehicle stationary Disable Criteria Rationality: U0123 Lost communications with Yaw Rate Sensor module U0122, P0500 Vehicle speed faults Page 93

94 Malfunction Criteria Rationality: Lateral acceleration > 0.3g for 3s Yaw Rate Sensor module fault Yaw Rate Sensor module incorrectly fitted The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 94

95 Communications with TPMS U0127 Lost Communications with TPMS Module Description: The ECM communicates with the Tyre Pressure Monitoring System (TPMS) module via the CAN bus acting as a gateway between the TPMS module and the instrument pack. If these CAN bus communications are interrupted the ECM will register a diagnostic code. Ignition on > 0.5s CAN message not received for 150ms CAN wiring fault TPMS module failure / loss of power to TPMS module CAN bus corruption by another module on CAN bus The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 95

96 Communications with BCM U0141 Lost Communication with Body Control Module "A" Description: The ECM sends a signal to the front headlights which states whether the engine is running or not. This signal is used to control the illumination of the daytime running lamps. Component connections: LH / RH Daytime Running / Side Lamps Connector Description ECM Pin ECM Connector 2 Switch pack Side lamp output Battery voltage Ignition switch via fuse F Engine running signal output G2 48 Way (Right) 10 Ground - - Engine running Feedback signal error present for 1.5s. Engine running signal output wiring open circuit, shorted to ground or shorted to battery voltage Daytime running lamp failure ECM output circuit failure The service light will be illuminated for 30 seconds at the point the fault occurs, and then illuminated for 30 seconds after engine start if the fault is present. Page 96

97 EMQ.5 - CAN BUS DIAGNOSTICS; LOTUS TECHCENTRE Controller Area Network (CAN) is an electronic standard to allow high speed communication between modules and controllers, via a serial data bus. The bus is a circuit linking the modules to the controller, consisting of a pair of cables, twisted together to reduce electromagnetic interference, and carrying a square wave voltage signal corresponding to '0's and '1's, coded in such a way as to identify and prioritise the individual messages. On the Exige S, CAN based systems include; engine management, anti-lock braking and related features, tyre pressure monitoring, instrument pack, and onboard diagnostics. A 'stand alone' lap top PC loaded with 'Lotus Techcentre' software allows the CAN based serial data to be read. A Vehicle Communication Device (T000T1472F) introduced for the Europa model is used to connect the vehicle to the laptop Lotus Techcentre. Engine programming, live data display and systems diagnosis are all carried out via the Lotus Techcentre. The minimum specification of the laptop computer for installation of the Lotus Techcentre is as follows: Processer 1.70 Ghz; 1 GB RAM; 40 GB HDD; CDRW DVD ROM; WIN XP PRO or VISTA; USB interface; Ethernet or Wireless LAN Note that this laptop should be dedicated soley to the Lotus Techcentre, with no other software installed. This diagnostic software is designed primarily for use by trained Lotus technicians, and is available as a CD under part number T000T1510F (version 4) or later supercessions. A monthly (Lotus Dealers) or annual (non-lotus dealers) licence and support fee will also be levied, providing access to Lotus TechCentre Technical Support phoneline on , and on lotus.support.uk@omitec.com Also required is a unique 18 character licence/registration key without which Techcentre will not function. This key is non transferable to other PC s. TechCentre Connection The DLC is located on the back of the scuttle crossbeam above the outboard side of the driver's footwell. Data Link Connector (DLC) em242 Page 97

98 Power for the VCD is taken from the vehicle battery via the DLC and when powered a blue tell tale on the unit will light. Should updated firmware be available for the VCD (usually downloaded as part of an online update) TechCentre will automatically update the VCD and display a message to confirm. The VCD, under part number T000T1472F is supplied in a black plastic carry case containing the following: VCD 16 Pin Yellow connector lead (VCD to Vehicle) USB lead (VCD to PC) USB extension lead (VCD to PC) not illustrated Yellow connector lead Vehicle Communication Device (VCD) Stand alone laptop PC Lotus Techcentre Data Link Connector (DLC) USB connector lead em241 Use of TechCentre Instructions for using the TechCentre are available in the Technical Information section displayed on programme start up. For further information see the LSL602a Lotus TechCentre User Guide shown on the following pages. The user guide can also be downloaded as a separate publication from the Lotus Dealer Portal at: dealers>aftersales>techcentre & Production Program Information. Page 98

99 EMQ.6 - LOTUS TECHCENTRE USER GUIDE (lsl602a) LOTUS TECHCENTRE BASIC USERS GUIDE lsl602a Page 99

100 INTRODUCTION Version 4. T000T1510F Controller Area Network (CAN) is an electronic standard to allow high speed communication between modules and controllers, via a serial data bus. The bus is a circuit linking the modules to the controller, consisting of a pair of cables, twisted together to reduce electromagnetic interference, and carrying a square wave voltage signal corresponding to '0's and '1's, coded in such a way as to identify and prioritise the individual messages. On all or most of the current Lotus range, CAN based systems include; engine management system, ABS, instrument cluster and tyre pressure monitoring system. Please note SRS is serial comms on K-Line A Vehicle Communication Device (T000T1472F) is used to connect the vehicle to the laptop installed with the Lotus Techcentre Software (contained on the disc T000T1510F). Engine programming, live data display, diagnostics of engine, ABS, airbag systems etc is accessed through this software. Also required is a unique 18 character licence/registration key without which Techcentre will not function. This key is non transferable to other PC s. The minimum specification of the laptop computer for installation of the Lotus Techcentre is as follows: Processor 1.70 GHz; 1 GB RAM; 40 GB HDD; CDRW DVD ROM; WIN XP PRO OR VISTA; USB interface; Ethernet or Wireless LAN Note that this laptop should ideally be dedicated totally to the Lotus Techcentre, with no other software. This Diagnostic software was primarily designed for use by trained Lotus technicians. The Lotus Techcentre unique telephone number for Technical Support is The address is lotus.support.uk@omitec.com when an is sent you automatically receive a confirmation response with a unique tracking number. Page 100

101 TECHCENTRE CONNECTIVITY Model Type of Electronic Control Unit Engine ECU Communication compatible Reprogrammable EMS ABS SRS TPMS IP 08 MY on Pre 08 Elise 2004 on Y Y Y Y N Y N* Exige 2004 on Y Y Y Y N Y N* Europa 2006 on N Y Y N/A N N N on Y Y N/A N/A N Y N* Evora 2009 on Y Y Y Y Y Y N/A Esprit V8 Y Y N N N N N Key: EMS : Engine Management System ABS : Brakes (Anti-lock Braking System) SRS : Airbags (Supplemental Restraint System ) TPMS : Tyre Pressure Monitoring System IP : Instrument Cluster Note: Currently Techcentre is only able to re-program engine ECU s for 08MY on. *A new communication cable will be available in the near future to provide management program downloads to pre 08 MY Toyota powertrain*. Excluding Europa. Refer to above table. Techcentre has no connectivity to Elise/Exige range and variants fitted with MG/Rover powertrain. Limited diagnostics is available on V8 Esprit. No communication is available to Europa powertrain. Communication to the above mentioned vehicles is via the Lotus Scan 3 tool. Part numbers: T000T1467F UK/EU T000T1456F USA Page 101

102 VEHICLE CONNECTION Yellow Plug 16 Pin Connector Blue Power Indicator VCD USB Lead Connection of the Techcentre is via a dedicated connector socket known as the Data Link Connector (DLC) which is located within the footwell of vehicles. Power for the VCD is taken from the DLC and when powered a blue light will illuminate. Should updated firmware be available for the VCD (usually downloaded as part of online update) Techcentre will automatically update the VCD and display a message to confirm. Vehicle Communication Device T000T1472F (VCD) is supplied in a black plastic carry case containing the following: VCD 16 Pin Yellow connector plug (VCD to Vehicle) USB lead (VCD to PC) USB extension lead (VCD to PC) not illustrated Page 102

103 CONTENTS Page 1. START UP Page 2. VIN ENTRY/MODEL SELECTION Page 3. TYPE & MARKET Page 4. MODEL YEAR/ECU SELECTION Page 5. TAB CATEGORIES. EMS/PERFORMANCE INFORMATION Page 6. FAULT CODES/LIVE DATA Page 7. LIVEDATA CONTINUED Pages LIVE DATA RECORDING & PLAYBACK Page 13. TECHNICAL INFORMATION/SETTINGS Page 14. ACTUATOR TESTS Page 15. OBD TEST RESULTS/VEHICLE INFORMATION Page 16. GUIDED ROUTINES Page 17. ECU REPROGRAMMING Page 18. ECU REPROGRAMMING CONTINUED Page VEHICLE CONFIGURATION (EVORA) Page 22. ABS TAB CATEGORIES Page 23. SRS TAB CATEGORIES Page 24. TPMS TAB CATEGORIES Page 25. IP TAB CATEGORIES Page 103

104 Basic users guide After software installation is complete these 2 icons will be displayed on your desktop. Periodically, approx every 7-10 days, click on Lotus Update Client. exe to ensure latest version/software is loaded. To start Techcentre click on Lotus TechCentre Icon and start up screen will appear followed by home screen as below. 1 Page 104

105 Enter VIN number or click on icon to read VIN from ECU If no Vin is entered you will need to select vehicle from menu displayed. 2 Page 105

106 Select type from list Select market from list 3 Page 106

107 Select model year from list Select system from list 4 Page 107

108 Only tabs that are highlighted can be read. Tabs that are greyed out will not function usually due to the fact that they are not applicable to ECU system selected. Tab will change colour from grey/green to orange to show this tab is active. Tab Categories Performance Information: Displays recorded performance data such as, engine speed Vehicle speed, temperatures etc and also total engine run time. To read this data, click on magnifying glass icon. To save this data, click on floppy disc icon. The window below will pop up showing destination of saved information. 5 Page 108

109 Tab Categories Fault Codes: Displays any fault codes stored in the control unit. To read this data, click on magnifying glass icon. To erase codes, click on eraser icon. Screen tab displays the following: Fault manager: Displays codes. Full Fault List: Full list of codes relevant to this control unit. Fault Diagnosis: Not yet enabled. Freeze Frame: Data recorded when code triggered. Live Data: Displays live data streamed into and out of the control unit. Click on tab and screen below is displayed. 6 Page 109

110 Live Data: Continued. Select and highlight desired item/items. Click on + to add to remove. Values are displayed numerically. To view as graph click here. Start/Pause recording Stop recording 7 Page 110

111 1 Recording Live Data in Techcentre V ) Select EMS Module > Live Data 2) Select items to view / record 3) Click record Data 4) Data can be viewed as graphs if desired 5) Click stop to finish recording 6) On screen prompt - select yes to save data 7) Enter an appropriate file name, click ok 8 Page 111

112 Playback of Live Data in Techcentre V4 The correct model must be selected in Techcentre to playback live data recorded. If connected to an incorrect vehicle type or playing back data on bench, disconnect the VCD from Laptop. Open Techcentre click look up vehicle details and manually select desired model from which data was recorded. Click on EMS > Live Data Click on Saved Data (Located on lower left of screen) 9 Page 112

113 Playback of Live Data in Techcentre V ) Select data to playback in LH pane 2) Click open file (items will appear in RH pane) 3) Click play to playback 4) Data can be viewed as graphs if desired 5) Click Stop to finish playback 10 Page 113

114 Transfer of recorded Live Data in Techcentre V4 Recorded Live Data is stored in the following directory:- Note: you must select the correct user from document and settings, this is the logged into the laptop when the data was recorded. C:\Documents and Settings\User\ApplicationData\Omitec\Techcentre\RealTimeMod Recorded Live Data is stored in folders as shown above In order to transfer live data the ENTIRE FOLDER (xxxxxxx-xxxx-xxxxxxxxxxxxxxxx) which contains the saved data is required. Right click in RealTimeModel folder and select view details, use the date modified field to help identify where your data is stored. (aim to improve folder location in future). If you cannot locate the file use the windows search function. Select the RealTimeModel folder as the folder to search in and enter the vehicle VIN number as filename. Double click the folder and check if the desired is contained within. 11 Page 114

115 Transfer of recorded Live Data in Techcentre V4 (2) Folder will contain the individual recorded files in CSV format as shown below. Once the data file to transfer is successfully located, return to its containing folde shown below and archive (zip) the ENTIRE FOLDER (xxxxxxx-xxxx-xxxx-xxxxxx file to Lotus for analysis. Best practice to help manage file size and non relevant data being transferred, copy the ENTIRE FOLDER to another location on the laptop, delete CSV files that are not required and then zip. 12 Page 115

116 Technical Information: Contains Lotus Service Bulletins etc. Click on folder and list will be displayed All files are PDF format and searchable Settings: Identifies Software Version and all release notes which are PDF format. 13 Page 116

117 Actuator Tests: Tests function and circuit integrity to highlighted items. Select and highlight desired item/items by clicking on + and remove with -. Toggle desired item on/off by clicking on words or slider 14 Page 117

118 OBD Test Results: Shows results for emission related sensors. Select and highlight desired item separately to show test result. Result can be printed out if desired by clicking on printer icon in top right corner. Vehicle Information: Look in vehicle information for ECU software level, serial number etc. 15 Page 118

119 Guided Routines: These are step by step instructions to perform certain operations for example, ECU renewal. 1. Click on required tab. 2. Click on forward button. 3. Follow on screen instructions. 4. Exit 16 Page 119

120 ECU Reprogramming: Follow these step by step instructions to reprogram ECU. Progress display 2. This message will be displayed. 1. Click on this icon to start programming. Note: If history is not recorded it may affect future warranty claims! 3. Followed by printer info. 17 Page 120

121 ECU Reprogramming: Continued. Warning! Pay attention to this message as re-programming will wipe previous software. 4. Click OK to continue Follow on screen instructions. To confirm calibration ID is correct check in vehicle information as detailed on page Page 121

122 Vehicle Configuration: Only applicable to Evora. EMS (Engine) Engine Ecu fitted to Evora will require configuring depending on variant/model. From the table displayed select applicable configuration relevant to model. Click on this to read current configuration. Click on this to write new configuration. Note: (Above illustration does not show full list.) 19 Page 122

123 Vehicle Configuration: Only applicable to Evora. Variant coding via guided routines Click on this to write Variant code. Click on this and ensure ignition is on. 20 Page 123

124 Variant coding via guided routines Continued. Enter 16 digit variant Code here. Verify Yes or No. Click to continue. Variant coding is now complete. Exit guided routines and check vehicle configuration 21 Page 124

125 ABS ABS Tab categories Fault Codes: Reads and clears stored fault codes. Full fault code list included. Live Data: Displays data and sensor reading in numeric and graphical format. Actuator Tests: Activates circuits and related hardware. Guided Routines: Brake Bleed. Steering Angle Sensor Calibration. ECU Renewal. Vehicle Configuration Evora Only: Configures ABS ECU e.g. TCS, ESP,HBA etc. Vehicle Information: Displays Hardware version, Software version, Serial number etc Page 125

126 SRS SRS Tab categories Fault Codes: Reads and clears stored fault codes. Full fault code list included. Live Data: Displays data and sensor reading in numeric and graphical format. Guided Routines: Configuration-Reprogram. ECU Renewal. Vehicle Information: Displays Hardware version, Software version, Serial number etc. Actuator Tests: Activates lamp circuits. (Not on all Models) Memory Read: (Not on all Models) Page 126

127 TPMS Fault Codes: Reads and clears stored fault codes. Full fault code list included. Live Data: Displays sensor reading in numeric and graphical format. Guided Routines: Pressure sensor & ECU Renewal. TPMS Tab categories Page 127

128 IP (Instrument Cluster) Actuator Tests: Activates Speedo. IP Tab categories Guided Routines: Write Odo value to new instrument cluster. Vehicle Configuration Evora Only: Writes configuration to new instrument cluster Page 128

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