2398744 - D05 ENGINE DOES NOT PRODUCE BEST PERFORMANCE
.| Results of the tests | ||||||
| 0 | PRELIMINARY CHECKS | All OK | Problems met | Operation | ||
|---|---|---|---|---|---|---|
Check, in order:
| Continue to Step 1 | Fault in air intake circuit | Repair the air intake circuit | |||
| Air filter blocked | Replace the filter element Op. 1048A14 | |||||
| Leaks from the diesel pipes | stop the leak | |||||
| Accelerator pedal travel incomplete | Eliminate the cause of the problem | |||||
| Catalyzer obstructed | Replace the catalyzer Op. 1080B62 | |||||
| Operation incorrect | Continue to Step 1 | |||||
| 1 | CHECK TURBOCHARGER ADJUSTMENT | All OK | Problems met | Operation | ||
| With the diagnostic equipment, carry out active diagnosis on the turbocharger regulating solenoidCheck the operation of the variable geometry control actuator by carrying out the test See Test 1064BC Variable geometry turbocharger actuator leakage test | Continue to Step 2 | Solenoid not working | Check the continuity of the wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT and if necessary replace the solenoid Op. 1064B34 | |||
| Actuator does not work correctly | Check the condition of the vacuum circuit and, if necessary, replace the damaged components | |||||
| 2 | CHECK WITH DIAGNOSTIC EQUIPMENT | All OK | Problems met | Operation | ||
| Connect
the diagnostic equipment (Examiner or other instruments) to the
diagnostic socket Check:
| Continue to Step 3 | An error is detected in the control unit | Continue following the instructions for the diagnostic equipment | |||
| unreliable parameters | Continue following the instructions for the diagnostic equipment | |||||
| E.G.R. solenoid not working | Check wiring continuity See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT | |||||
| E.G.R. solenoid not working | Replace the solenoid valve Op. 1080C24 | |||||
| 3 | ROAD TEST WITH DIAGNOSTIC EQUIPMENT | All OK | Problems met | Operation | ||
Road
test the vehicle keeping the diagnostic instrument connected.
Check:
| Continue to Step 4 | Errors suddenly occur in the control unit | Continue following the instructions for the diagnostic equipment | |||
| Parameters off scale | Continue following the instructions for the diagnostic equipment | |||||
| Lack of dialogue with the control unit | Restore the connection between engine management control unit and diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT | |||||
| 4 | CHECK ON BRAKE PEDAL SWITCH | All OK | Problems met | Operation | ||
| Check that the brake pedal switch is working properly | Continue to Step 5 | Brake pedal does not return | Eliminate the cause of the sticking | |||
| Switch stuck in closed position | Replace the switch Op. 1060G38 | |||||
| Wiring short circuited | Restore the correct connection | |||||
| 5 | CHECK ON TURBOCHARGER | All OK | Problems met | Operation | ||
| Check the operation of the turbocharger as described in the Test See Test 1064BA Check turbo presure | Continue to Step 6 | Turbocharger faulty | Replace the turbocharger Op. 1064A19 | |||
| 6 | HIGH PRESSURE CHECK | All OK | Problems met | Operation | ||
| Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socketCheck as described in the test See Test 1060D Check high pressure fuel circuit that the diesel pressure parameter is correct | Continue to Step 14 | Pressure not correct | Continue to Step 7 | |||
| 7 | CHECK ON RETURN LOW PRESSURE | All OK | Problems met | Operation | ||
| Check as described in the test See Test 1060A Low return fuel pressure circuit check that the pressure in the return pipe to the tank is under 1 bar | Continue to Step 8 | Pressure above maximum limit: return pipe to tank blocked | Repair the pipe, if necessary, replace it. | |||
| 8 | LOW SUPPLY PRESSUR CHECK | All OK | Problems met | Operation | ||
| Check as described in the test See Test 1060B Low fuel pressure supply circuit check that the diesel pressure between filter and pressure pump is between 2 and 3 bar | Continue to Step 14 | Pressure below minimum limit or above maximum value | Continue to Step 9 | |||
| 9 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation | ||
| Choke the return pipe and repeat the test See Test 1060B Low fuel pressure supply circuit check with the pipe choked, checking that the pressure at the filter outlet remains below 2 bar | Continue to Step 10 | Pressure rises to 5 bar: blocked pressure regulation valve on filter support | Replace the valve Op. 1044B16 | |||
| 10 | CHECK DELIVERY LOW PRESSURE | All OK | Problems met | Operation | ||
| Check that the difference in pressure upstream and downstream of the filter is less than 1 bar | Continue to Step 11 | Difference in pressure greater than 1 bar | Replace the fuel filter cartridge Op. 1044B20 | |||
| 11 | CHECK ON RETURN LOW PRESSURE | All OK | Problems met | Operation | ||
| Check that the pressure downstream of the supply pump is over 2.2 bar | Continue to Step 14 | Pressure below 2 bar | Continue to Step 12 | |||
| 12 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation | ||
| Measure the difference in pressure between the electric pump outlet and filter inlet, checking that it is less than 0.3 bar | Continue to Step 13 | Difference in pressure greater than 0.3 bar | Replace the pipe | |||
| 13 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation | ||
| Check as described in the test See Test 1060A Low return fuel pressure circuit check that the pump's supply voltage is 12V and that the absorbed current is between 2 and 10 amps. | Continue to Step 14 | Voltage < 12 V | Check electric wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT | |||
| Current > 10 Amp: pump defective | Replace the fuel pump assembly Op. 1040A70 | |||||
| Current < 2 Amp.: pump blocked | Replace the fuel pump assembly Op. 1040A70 and clean the fuel tank | |||||
| 14 | CHECK ON CORRECT OPERATION | All OK | Problems met | Operation | ||
| Replace the DRV pressure regulating valve and check that the fault is no longer present | End of diagnosis | Fault persists | Continue to Step 15 | |||
| 15 | CHECK ON CORRECT OPERATION | All OK | Problems met | Operation | ||
| Replace the pressure pump and check that the fault is no longer present | End of diagnosis | Fault persists | Continue to Step 16 | |||
| 16 | CHECK ON TIMING | All OK | Problems met | Operation | ||
| Check that the timing is correct Op. 0510A20 | Continue to Step 17 | Timing not correct | Restore the correct timing | |||
| 17 | VALVE CLEARANCE CHECK | All OK | Problems met | Operation | ||
| Check that the valve tappet clearance is correct. Op. 1036H14 | Continue to Step 18 | Valve clearance not correct | Adjust the tappets Op. 1036H10 | |||
| 18 | CHECK ON CYLINDER COMPRESSION | All OK | Problems met | Operation | ||
| Carry out the cylinder compression test Op. 0520G15 | Continue to Step 20 | Cylinder compression insufficient | Continue to Step 19 | |||
| 19 | CHECKING CAUSE OF INSUFFICIENT COMPRESSION | All OK | Problems met | Operation | ||
| Carry out R.R. on head to check the valve seal and check the condition of the cylinders/piston rings | Continue to Step 20 | |||||
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