Thread: TD5 Driver Demand Faults

G'day All,

I have had an ongoing driver demand fault issue on my 2002 TD5 for the last couple of weeks which I cannot get to the bottom of. I now have the Engine Management Light come on a few seconds after start up & thats how it stays, I am also unable to take the engine off idle.

A few weeks back it started getting a slight miss around some left hand corners , then a week or so later after it had had a miss when I next went to idle that is where it would stay & the engine management light would come on, you could usually clear the fault by turning the engine off then on again but now it is a hard fault that will not clear.

I suspected either a wiring or accelerator pedal potentiometer issue.

I have just purchased a HawkEye to help with the issue & I had many different codes relating to multiple items so after clearing all the codes I am now left with the following codes.

-3165 Faults detected with driver demand
-3141 Driver demand has been faulty
-3166 Inconsistencies found with driver demand

I have fitted a new accelerator pedal/potentiometer, nil fix or change.

After inspecting the engine harness from the ECU as best I could I can find no obvious damage to the looms or plugs.

A wiring check with a good quality Fluke meter detected no open circuit between the ECU & the potentiometer plugs, the resistance on the 2 earths was a little high which traced back to the earth post below the ECU, so I ran a new heavy wire to the post from the battery & it solved the slightly high resistance problem to the ECU & pedal but did not make any difference to the main problem.

At the potentiometer plug I seem to have the correct readings as well.(These figures are similar with the engine running or with the engine off and the ECU powered).

-Pin D, earth good
-Pin G, earth good
-Pin B, 5.022v (ECU supply)
-Pin J, 5.022v (ECU supply)
-Pin F, 0.020v
-Pin C, 4.977v
-Pin K, 4.970v

When you move the accelerator pedal you see the voltages change as you could expect on pins F, C & K, the supply voltage remains stable & 5.022v.

The driver demand voltages from HawkEye with the Engine running,

-Driver demand 1, 0.94v
-Driver demand 2, 4.12v
-Driver demand supply 0v

From what I can determine so far everything seems OK apart from HawkEye telling me the "Driver demand supply is 0V" which is incorrect as I have confirmed with a meter I am getting 5.022v.

To me this is starting to look like an ECU issue where the ECU is supplying 5v but not sensing it. Sadly I don't have access to spare ECU to try for troubleshooting out here in Dubai.

Does anyone have any ideas of what else to try or what else it may be before I get another ECU or send mine to the UK for testing & possible repairing.

If it is my ECU does anyone know who can test & repair the ECU in the UK.

Not really as I do not have the correct new pins for the ECU or pot plugs, I was going to cut into the old loom & solder the new 5 core loom into place, so this would be a permanent repair.