3022583 - 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 | Eliminate the leaks | |||||
| Accelerator pedal travel incomplete | Eliminate the cause of the problem | |||||
| Catalyzer obstructed | Replace the catalyzer | |||||
| Operation incorrect | Carry out the actuator leak test See Test 1064BC Variable geometry turbocharger actuator leakage test | |||||
| 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 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 | |||
| Actuator does not work correctly | Check the condition of the vacuum circuit and, if necessary, replace the damaged components | |||||
| 2 | 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 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. 1080C74 | |||||
| 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 See Test 1064BA Check the supercharging pressure | Continue to Step 6 | Turbocharger faulty | Replace the turbocharger | |||
| 6 | HIGH PRESSURE CHECK | All OK | Problems met | Operation | ||
| Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socketCheck as described in test 1060D 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 that the pressure in the fuel return pipe to the tank is less than 1 bar See Test 1060A Low return fuel pressure circuit check | Continue to Step 8 | Pressure above maximum limit: return pipe to tank blocked | Repair the pipe, if necessary, replace it. | |||
| 8 | 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 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, with the pipe choked, check that the filter outlet pressure remains below 2 bar See Test 1060B Low fuel pressure supply circuit check | 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 | LOW SUPPLY PRESSURE CHECK | 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 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 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 | 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 | Fault persists | Continue to Step 16 | ||||
| 16 | CHECK ON TIMING | All OK | Problems met | Operation | ||
| Check that the timing is correct | Continue to Step 17 | Timing not correct | Restore the correct timing Op. 1032B14 | |||
| 17 | VALVE CLEARANCE CHECK | All OK | Problems met | Operation | ||
| Check that the valve tappet clearance is correct. | 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 | 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 | Insufficient valve seal | Overhaul the cylinder head Op. | |||
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