3022585 - D21 ENGINE CUTS OUT WHILST DRIVING
The engine cuts out suddenly whilst driving. Later, after starting normally, it works again| Results of the tests | ||||
| 0 | PRELIMINARY CHECKS | All OK | Problems met | Operation |
|---|---|---|---|---|
| that there is fuel in the tankthe engine wiring is properly connected to earthbattery earth correctly fixedcorrect fixing of positive battery terminal and that all leads are connectedno water in the fuel filter | Continue to Step 1 | No fuel | Introduce fuel | |
| Fastenings slack or oxidized | Re-attach correctly | |||
| Presence of water in the fuel filter | Clean the tank and pipes and replace the filter element | |||
| 1 | CHECKING WITH DIAGNOSTIC EQUIPMENT | All OK | Problems met | Operation |
| Connect
the diagnostic equipment (Examiner or other instruments) to the
diagnostic socket Check:
| Continue to Step 2 | An error is detected in the control unit | Continue following the instructions for the diagnostic equipment | |
| 2 | ROAD TEST WITH DIAGNOSTIC EQUIPMENT | All OK | Problems met | Operation |
| Road
test the vehicle, reproducing the conditions in which the fault
arises, keeping the diagnostic equipment connected. Check:
| Continue to Step 3 | An error is detected in the control unit | Continue following the instructions for the diagnostic equipment | |
| 3 | INJECTOR HIGH PRESSURE CHECK | All OK | Problems met | Operation |
| Check, as described in the procedure See Test 1060C Injector high pressure fuel circuit check , that diesel leaks from the injector recirculation connections are small and about the same as one another. | Continue to Step 4 | Consistent leak from one injector | Replace the injector | |
| 4 | HIGH PRESSURE CHECK | All OK | Problems met | Operation |
| Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socketCheck that the diesel pressure parameter is correct See Test 1060D Check high pressure fuel circuit | Continue to Step 12 | Pressure not correct | Continue to Step 5 | |
| 5 | CHECK ON RETURN LOW PRESSURE | All OK | Problems met | Operation |
| Check that the pressure in the return pipe to the tank is less than 1 bar See Test 1060A Low return fuel pressure circuit check | Continue to Step 6 | Pressure above maximum limit: return pipe to tank blocked | Repair the pipe; if necessary replace it. | |
| 6 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation |
| Check that the diesel pressure between filter and pressure pump is between 2 and 3 bar See Test 1060B Low fuel pressure supply circuit check | Continue to Step 12 | Pressure below minimum limit or above maximum limit | Continue to Step 7 | |
| 7 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation |
| Choke the return pipe from the pressure regulating valve and repeat the test with the pipe choked, checking that the pressure at the filter outlet is below 2 bar See Test 1060B Low fuel pressure supply circuit check | Continue to Step 8 | Pressure rises to 5 bar: blocked pressure regulation valve on filter support | Replace the valve Op. 1044B16 | |
| 8 | LOW SUPPLY PRESSURE CHECK | 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 9 | Difference in pressure greater than 1 bar | Replace the diesel filter cartridge Op. 1044B20 | |
| 9 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation |
| Check that the supply pump pressure at the filter inlet is over 2.2 bar | Continue to Step 12 | Pressure below 2.2 bar | Continue to Step 10 | |
| 10 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation |
| Measure the difference in pressure between electric pump outlet and filter inlet, checking that it is less than 0.3 bar | Continue to Step 11 | Difference in pressure greater than 0.3 bar | Replace the pipe | |
| 11 | LOW SUPPLY PRESSURE CHECK | All OK | Problems met | Operation |
| Check that the pump supply voltage is 12 V and that the absorbed current is between 2 and 10 amp. See Test 1040AA Check supply voltage and absorption current | Continue to Step 12 | 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 | |||
| 12 | CORRECT OPERATION CHECK | All OK | Problems met | Operation |
| Replace the DRV high-pressure valve and check that the fault is no longer present | Fault persists | Continue to Step 13 | ||
| 13 | CORRECT OPERATION CHECK | All OK | Problems met | Operation |
| Replace the pressure pump and check that the fault is no longer present | Fault persists | Contact Technical Service for further information on the problemSearch for the fault starting from another symptom' | ||