I own a 1994 Citroen AX, 954cc fitted with single-point petrol injection controlled by a Bosch Mono-Motronic MA3.0 Electronic Control Unit/Module (ECU or ECM). It recently began to run badly, particularly when driving at speed on long journeys. The ECU kept giving fault code
51, indicating a faulty Oxygen Sensor (Lambda Sensor). It was replaced with a universal 4-wire zirconia sensor from eBay, but the problem persisted. This was then replaced with the correct Bosch sensor, only for the problem to reoccur. The exhaust was checked for leaks and the bolts tightened on the exhaust manifold, to no avail. The throttle body was then removed and Hylomar silicone gasketing compound applied to both sides of the top and bottom gaskets, again without success. Finally the inlet manifold was examined, which appeared sound. However it was removed (requiring the radiator fluid to be drained and the throttle body to be removed again), the old rubber cement rubbed off and replaced with Hylomar on both surfaces (it=92s easier to apply a thin coat with a finger rather than with the nozzle supplied). To my amazement, the problem vanished! (Rubber based compounds may be prone to perishing over long periods and high temperatures, while silicone is not.)
The ECU now gives fault code 14 only, causing the engine to run badly, indicating a faulty Coolant Temperature Sensor (Citroen Part No. 24246 =96 =A322). A new sensor (thermistor) still generates the same fault code and the wiring is okay. It could be an ECU fault, although it occurs on two other ECUs. Bosch charge =A3360 for a replacement unit and there is no documentation available! So I suspected that the multi-plug may have a bad contact =96 computer PCBs have had gold plated contacts for years but the motor industry doesn=92t like reliable cars! To overcome this problem, wires have to be soldered onto the internal contacts of the multi-plug socket. First remove the ECUs plastic cover, the multi- plug and the four retaining 8mm bolts. Once indoors, remove the five T15 torx screws. The top plate may need levering off as it is sealed with silicone sealant. Two thin insulated wires are soldered onto pins
25 and 26 (CTS and sensor return =96 polarity not important). (Pin 20 is on top at the cable end but do a continuity check between the multi- plug pins and the sensor connector to be sure you have pins 25 and
26.) It should be possible to close the top plate over the thin insulated wires without damage. The lead to the sensor plug is cut and a new cable soldered in and sealed at either end with heat shrink tubing - the original wiring loom is inaccessible so the bare ends are also covered with heat shrink insulation, which is more durable than tape. The new cable should be routed behind the block alongside the wiring loom. No more 14 fault codes!
The other problem on the Citroen AX is the throttle potentiometer which wears out (fault code 21), and is only available with the throttle body (Citroen Part No. 1920X4) at around =A3300! Bosch do an exchange unit for around =A3170 (Bosch Part No. 0 986 438 671) + =A33 odd for a 5 pack of gaskets (Bosch Part No. 3 431 015 900). But Bosch won=92t sell you the potentiometer as a separate part. Happily the potentiometers have now appeared on eBay as =93Throttle Position Sensor for Citroen, Peugeot 3437022=94 priced at =A320! The position of the original potentiometer should be marked before removing the four tamper proof T20 torx screws, as the fixing holes are slotted. IMPORTANT: Teflon grease should be applied to the tracks and wipers to prevent wear =96 Bosch don=92t use any lubricant! If a multimeter is available, the resistance between pins 1 and 2 should be set to around
1070 ohms (pins are numbered 1, 2, 4, 5 from back to front). If necessary the slotted holes in the potentiometer can be elongated with a small file. Ensure that the measurement is made with the throttle closed =96 the stepper motor opens the throttle when the engine is cold and can be temporarily removed, or disengaged by applying 4.5V to the top 2 pins (positive to top pin). Remember to reengage the stepper motor by reversing the polarity and reconnect the plug or the customer=92s car will keep stalling until the engine warms up!
The original ECU is a Bosch MA3.0 no. 0 261 200 780 (Peugeot 106 1 litre 93 on). I have owned three of these and found them all unreliable, giving false fault codes. I was advised by Bosch that this model has been superceded by MA3.0 No. 0 261 204 051 (Peugeot 106 1 litre 95-96). This model works reliably on my car, although it gives a
27 fault code (VSS) as there is no vehicle speed sensor fitted to the
954cc Citroen AX (there is no contact on pin 9 of the ECU multi-plug).
From Haynes Automotive Engine Management and Fuel Injection Systems Manual (3344)
Page 19.14 Pin table - typical 55-pin (Citroen/Peugeot)
1 Ignition coil
2 Earth
3 Engine control module relay
4 =96
5 CFSV
6 Tachometer
7 TPS
8 =96
9 VSS
10 OS
11 RPM sensor
12 TPS
13 SD connector
14 Earth
15 ISCV
16 SD connector
17 Injector
18 Battery supply
19 Earth
20 Ignition coil
21 =96
22 SD warning lamp
25 CTS
26 Sensor return (CTS, ATS, TPS)
27 ATS
28 OS
29 TPS
30 RPM sensor
31 ISCV
32 =96
33 ISCV
34 =96
35 =96
36 =96
37 Engine control module relay
Typical 55-pin multi-plug (Citroen and Peugeot)
19 - - - - - - - - - - - - - - - - - - - 1 (cable end)
37 - - - - - - - - - - - - - - - - - - 20
55 - - - - - - - - - - - - - - - - - - 38
Page 19.16 Fault code table (Citroen and Peugeot) Code Item
11 End of diagnosis
12 Initiation of diagnosis
13x ATS
14x CTS
21x TPS
22 Stepper motor
27x VSS
31x Lambda control
41 CAS
42 Injector or fuel pump control
51 OS
52 Lambda control
53x Battery voltage
54 ECM x Faults that typically will cause the ECM (Electronic Control Module) to enter LOS (limited operating strategy) and use a default value in place of the sensor.
To obtain fault codes short the green lead side of the Fault Code Reader (FCR) multi-plug to earth for 4 seconds with the ignition on while an assistant watches the fault lamp on the dashboard (or use two long lengths of cable). To clear the fault codes short for 10 seconds, or remove the ECM multi-plug. Fault code 21 cannot be removed if the throttle potentiometer resistance is wrong and this fault can generate other fault codes on the original ECU. The FCR is situated by the o/s headlamp. If you're buying second hand check the fault codes. Take the vehicle for a run first in case the owner has cleared the fault codes from the ECU memory!
Happy motoring!