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Diagnosis and Testing|Removal and Installation > < Fuel Fired Booster Heater

Transit.Tourneo Connect 2002.5 (06.2002-)

Auxiliary Heating - Electric Booster Heater Transit/Tourneo Connect 2002.5 (06/2002-)
Diagnosis and Testing

Refer to Wiring Diagrams Section 412-02B, for schematic and connector information.

Special Tool(s)

Terminal Probe Kit

418-S035

Worldwide Diagnostic System (WDS)

418-F224
General Equipment
Digital multimeter
Clip-on ammeter (DC)

Inspection and Checking

  1. VERIFY customer concern.
  1. Visually CHECK for any obvious mechanical or electrical damage.

Visual Inspection

Mechanical Electrical
  • Coolant level
  • Electric booster heater mounting
  • Fuses
  • Wiring harness
  • Connectors
  1. RECTIFY any obvious causes for a concern found during the visual inspection before performing any further tests. CHECK the operation of the system.
  1. If the concern persists after the visual inspection, CARRY OUT a fault diagnosis on the powertrain control module (PCM) and the charging system with WDS and RECTIFY any displayed faults in accordance with the fault description. CHECK the operation of the system.
  1. For vehicles without any stored faults, PROCEED in accordance with the Symptom Chart.
  1. Following checking or elimination of the fault and after completion of operations, the fault memories of all vehicle modules must be READ OUT and any stored faults must be DELETED. READ OUT all fault memories again following a road test.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Electric booster heater inoperative / partly inoperative
*
Fuse(s)
*
Circuit(s)
*
Intake air temperature signal
*
Glow plug heating relay, stage 1
*
Glow plug heating relay, stage 2
*
Electric booster heater
*
Powertrain control module (PCM)
*
GO to Pinpoint Test A.

System Check

PINPOINT TEST A : ELECTRIC BOOSTER HEATER INOPERATIVE / PARTLY INOPERATIVE
NOTE:
NOTE:The electric booster heater only works when the engine is running, the battery is being charged by the generator, the ambient temperature is below 8°C and the coolant temperature has not yet exceeded 75°C.
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE ELECTRIC BOOSTER HEATER
1
Ignition switch in position III.

2
Measure the current in circuits 15-RD23 (GN/BK) and 15-RD22 (GN/RD) at the electric booster heater using the clip-on ammeter.

Is a current measured?
Yes
GO to A2.
No
GO to A3.
A2: CHECK 1ST STAGE OF ELECTRIC BOOSTER HEATER CIRCUIT

1
Measure the current in circuit 15-RD22 (GN/RD) at the electric booster heater using the clip-on ammeter.

Is a current of more than 10 A measured?
Yes
GO to A15.
No
GO to A6.
A3: CHECK THE ELECTRIC BOOSTER HEATER GLOW PLUG
1
Ignition switch in position 0.

2
Measure the resistance between the electric booster heater, connector C965, circuit 15-RD22 (GN/RD), component side and electric booster heater housing.

Is a resistance of less than 1.2 Ohm registered?
Yes
GO to A4.
No
RENEW the electric booster heater. CHECK the operation of the system.
A4: CHECK THE ELECTRIC BOOSTER HEATER GROUND CONNECTION

1
Measure the resistance between the electric booster heater, connector C968, circuit 31-RD22 (BK), component side and ground.

Is a resistance of less than 1 Ohm registered?
Yes
GO to A5.
No
LOCATE and REPAIR the break in circuit 31-RD22 (BK) between the electric booster heater and ground connection G57 using the Wiring Diagrams. CHECK the operation of the system.
A5: CHECK THE SIGNAL FROM THE INTAKE AIR TEMPERATURE SENSOR
NOTE:
NOTE:The intake air temperature sensor is integrated in the mass air flow sensor (engine management).
1
Connect the diagnostic tool.
2
Ignition switch in position II.
3
Check the intake air temperature signal using the WDS.

Is the intake air temperature signal OK, i.e. is the indicated temperature value plausible?
Yes
Check the powertrain control module (PCM) and RENEW as necessary. CHECK the operation of the system.
No
For further information, refer to REFER to Section  303-14 Electronic Engine Controls.
A6: CHECK FUSE F11
1
Ignition switch in position 0.
2
CHECK fuse F11 (BJB).

Is the fuse OK?
Yes
GO to A7.
No
RENEW fuse F11 (20 A). CHECK the operation of the system. If the fuse blows again, LOCATE and REPAIR the short to ground using the Wiring Diagrams.
A7: CHECK THE VOLTAGE AT FUSE F11
1
Connect fuse F11 (BJB).
2
Measure the voltage between fuse F11 (20 A) and ground.

Does the meter display battery voltage?
Yes
GO to A8.
No
REPAIR the voltage supply to fuse F11 using the Wiring Diagrams. CHECK the operation of the system.
A8: CHECK VOLTAGE AT GLOW PLUG HEATING RELAY, STAGE 1
1
Disconnect glow plug heating relay, stage 1 C1013.

2
Measure the voltage between glow plug heating relay, stage 1, socket C1013, pin 3, circuit 30-RH24 (RD), wiring harness side and ground.

Does the meter display battery voltage?
Yes
GO to A9.
No
LOCATE and REPAIR the break in circuit 30-RH24 (RD) between the glow plug heating relay, stage 1 and fuse F11 using the Wiring Diagrams. CHECK the operation of the system.
A9: CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY, STAGE 1
1
Ignition switch in position II.

2
Measure the voltage between glow plug heating relay, stage 1, socket C1013, pin 1, circuit 15-RH23 (GN/RD), wiring harness side and ground.

Does the meter display battery voltage?
Yes
GO to A10.
No
LOCATE and REPAIR the break in circuit 15-RH23 (GN/RD) between glow plug heating relay, stage 1, and soldered connection S117 using the Wiring Diagrams. CHECK the operation of the system.
A10: CHECK FOR OPEN CIRCUIT BETWEEN GLOW PLUG HEATING RELAY, STAGE 1, AND THE ELECTRIC BOOSTER HEATER.
1
Ignition switch in position 0.

2
Measure the resistance between glow plug heating relay, stage 1, socket C1013, pin 5, circuit 15-RH22 (GN/RD), wiring harness side and ground.

Is a resistance of less than 1.2 Ohm registered?
Yes
GO to A12.
No
GO to A11.
A11: CHECK THE ELECTRIC BOOSTER HEATER

1
Measure the resistance between the electric booster heater, connector C965, circuit 15-RD22 (GN/RD), component side and ground.

Is a resistance of less than 1.2 Ohm registered?
Yes
LOCATE and REPAIR the break in circuit 15-RD22 (GN/RD) between glow plug heating relay, stage 1, and the electric booster heater using the Wiring Diagrams. CHECK the operation of the system.
No
RENEW the electric booster heater. CHECK the operation of the system.
A12: CHECK GLOW PLUG HEATING RELAY, STAGE 1
1
Check glow plug heating relay 1, in accordance with the component test at the end of this section.

Is the glow plug heating relay, stage 1 OK?
Yes
Vehicles with 104 pin EEC: GO to A13.
Vehicles with 121 pin EEC: GO to A14.
No
RENEW glow plug heating relay, stage 1. CHECK the operation of the system.
A13: CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY, STAGE 1 - VEHICLES WITH 104 PIN EEC
1
Disconnect PCM C415.

2
Measure resistance between glow plug heating relay, stage 1, socket C1013, pin 2, circuit 31S-RH23 (BK/OG), wiring harness side and PCM, connector C415, pin 98, circuit 31S-RH23 (BK/OG), wiring harness side.

Is a resistance of less than 2 Ohm registered?
Yes
CHECK the PCM and RENEW as necessary. CHECK the operation of the system.
No
LOCATE and REPAIR the break in circuit 31S-RH23 (BK/OG) between the PCM and the glow plug heating relay, stage 1, using the Wiring Diagrams. CHECK the operation of the system.
A14: CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY, STAGE 1 - VEHICLES WITH 121 PIN EEC
1
Disconnect PCM C414.

2
Measure resistance between glow plug heating relay, stage 1, socket C1013, pin 2, circuit 31S-RH23 (BK/OG), wiring harness side and PCM, connector C414, pin 61, circuit 31S-RH23 (BK/OG), wiring harness side.

Is a resistance of less than 2 Ohm registered?
Yes
CHECK the PCM and RENEW as necessary. CHECK the operation of the system.
No
LOCATE and REPAIR the break in circuit 31S-RH23 (BK/OG) between the PCM and the glow plug heating relay, stage 1, using the Wiring Diagrams. CHECK the operation of the system.
A15: CHECK FUSE F18
1
Ignition switch in position 0.
2
CHECK fuse F18 (BJB).

Is the fuse OK?
Yes
GO to A16.
No
RENEW fuse F18 (40 A). CHECK the operation of the system. If the fuse blows again, LOCATE and REPAIR the short to ground using the Wiring Diagrams.
A16: CHECK THE VOLTAGE AT FUSE F18
1
Connect fuse F18 (BJB).
2
Measure the voltage between fuse F18 (40 A) and ground.

Does the meter display battery voltage?
Yes
GO to A17.
No
REPAIR the voltage supply to fuse F18 using the Wiring Diagrams. CHECK the operation of the system.
A17: CHECK VOLTAGE AT GLOW PLUG HEATING RELAY, STAGE 2
1
Disconnect glow plug heating relay, stage 2 C1010.

2
Measure the voltage between glow plug heating relay, stage 2, socket C1010, pin 3, circuit 30-RH26 (RD), wiring harness side and ground.

Does the meter display battery voltage?
Yes
GO to A18.
No
LOCATE and REPAIR the break in circuit 30-RH26 (RD) between the glow plug heating relay, stage 2 and fuse F18 using the Wiring Diagrams. CHECK the operation of the system.
A18: CHECK CONTROL VOLTAGE AT GLOW PLUG HEATING RELAY, STAGE 2
1
Ignition switch in position II.

2
Measure the voltage between glow plug heating relay, stage 2, socket C1010, pin 1, circuit 15-RH25 (GN/BK), wiring harness side and ground.

Does the meter display battery voltage?
Yes
GO to A19.
No
LOCATE and REPAIR the break in circuit 15-RH25 (GN/BK) between glow plug heating relay, stage 2, and soldered connection S117 using the Wiring Diagrams. CHECK the operation of the system.
A19: CHECK FOR OPEN CIRCUIT BETWEEN GLOW PLUG HEATING RELAY, STAGE 2, AND THE ELECTRIC BOOSTER HEATER.
1
Ignition switch in position 0.

2
Measure the resistance between glow plug heating relay, stage 2, socket C1010, pin 5, circuit 15-RH23 (GN/BK), wiring harness side and ground.

Is a resistance of less than 0.8 Ohm registered?
Yes
GO to A22.
No
GO to A20.
A20: CHECK THE ELECTRIC BOOSTER HEATER
1
Disconnect electric booster heater C966.
2
Disconnect electric booster heater C967.

3
Measure the resistance between the electric booster heater, connector C966, circuit 15-RD23 (GN/BK), component side and ground.

Is a resistance of less than 1.2 Ohm registered?
Yes
GO to A21.
No
RENEW the electric booster heater. CHECK the operation of the system.
A21: CHECK THE ELECTRIC BOOSTER HEATER

1
Measure the resistance between electric booster heater, connector C967, component side and ground.

Is a resistance of less than 1.2 Ohm registered?
Yes
LOCATE and REPAIR the break in circuit 15-RD23 (GN/BK) between glow plug heating relay, stage 2 and the electric booster heater (or bridge at electric booster heater) using the Wiring Diagrams. CHECK the operation of the system.
No
RENEW the electric booster heater. CHECK the operation of the system.
A22: CHECK GLOW PLUG HEATING RELAY, STAGE 2
1
Check glow plug heating relay 2, in accordance with the component test at the end of this section.

Is the glow plug heating relay, stage 2 OK?
Yes
Vehicles with 104 pin EEC: GO to A23.
Vehicles with 121 pin EEC: GO to A24.
No
RENEW glow plug heating relay, stage 2 CHECK the operation of the system.
A23: CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY, STAGE 2 - VEHICLES WITH 104 PIN EEC
1
Disconnect PCM C415.

2
Measure resistance between glow plug heating relay, stage 2, socket C1010, pin 2, circuit 31S-RH25 (BK/GN), wiring harness side and PCM, connector C415, pin 75, circuit 31S-RH25 (BK/GN), wiring harness side.

Is a resistance of less than 2 Ohm registered?
Yes
CHECK the PCM and RENEW as necessary. CHECK the operation of the system.
No
LOCATE and REPAIR the break in circuit 31S-RH25 (BK/GN) between the PCM and the glow plug heating relay, stage 2, using the Wiring Diagrams. CHECK the operation of the system.
A24: CHECK FOR OPEN CIRCUIT BETWEEN PCM AND GLOW PLUG HEATING RELAY, STAGE 2 - VEHICLES WITH 121 PIN EEC
1
Disconnect PCM C414.

2
Measure resistance between glow plug heating relay, stage 2, socket C1010, pin 2, circuit 31S-RH25 (BK/GN), wiring harness side and PCM, connector C414, pin 62, circuit 31S-RH25 (BK/GN), wiring harness side.

Is a resistance of less than 2 Ohm registered?
Yes
CHECK the PCM and RENEW as necessary. CHECK the operation of the system.
No
LOCATE and REPAIR the break in circuit 31S-RH25 (BK/GN) between the PCM and the glow plug heating relay, stage 2, using the Wiring Diagrams. CHECK the operation of the system.

Component Tests

Glow plug heating relay, stage 1

  1. Check the normally open contact in the unswitched state.
    • Measure the resistance at the relay, between pin 3 and pin 5, component side.
    • Is a resistance of more than 10 kOhms measured?

        • 1. If yes, go to 2.

        2. If no, RENEW the relay.

  1. Check the normally open contact in the switched state.
    • Using a fused test cable (1 A), connect pin 1 of the relay, component side, to the battery positive terminal.
    • Using a test cable, connect pin 2 of the relay, component side, to the battery negative terminal.
    • Measure the resistance at the relay, between pin 3 and pin 5, component side.
    • Is a resistance of less than 2 Ohm registered?

        • 1. If yes, then the relay is OK.

        2. If no, RENEW the relay.

Glow plug heating relay, stage 2

  1. Check the normally open contact in the unswitched state.
    • Measure the resistance at the relay, between pin 3 and pin 5, component side.
    • Is a resistance of more than 10 kOhms measured?

        • 1. If yes, go to 2.

        2. If no, RENEW the relay.

  1. Check the normally open contact in the switched state.
    • Using a fused test cable (1 A), connect pin 1 of the relay, component side, to the battery positive terminal.
    • Using a test cable, connect pin 2 of the relay, component side, to the battery negative terminal.
    • Measure the resistance at the relay, between pin 3 and pin 5, component side.
    • Is a resistance of less than 2 Ohm registered?

        • 1. If yes, then the relay is OK.

        2. If no, RENEW the relay.

Diagnosis and Testing|Removal and Installation > < Fuel Fired Booster Heater