194001973 - D005 ENGINE DOES NOT PRODUCE BEST PERFORMANCE

The customer complains of: Reduced engine performance in all operating conditions

		Test results
0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
	Check that the engine oil level is correct    Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARYCheck that the air intake/vacuum circuit is working properly by carrying out the    See Test 1048OA AIR INTAKE/VACUUM CIRCUIT CHECKCheck the condition of the fuel supply circuit and make sure that it is working properly carrying out the    See Test 1040OA FUEL SUPPLY CIRCUIT CHECKCheck the operation of the low pressure supply circuit by carrying out the    See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT	Move on to Step 1	Oil level incorrect	Restore the correct engine oil level    Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY
1	AMBIENT PARAMETERS CHECK	All OK	Problems encountered	Operation
	Select the following control unit at the diagnostic equipment: EDC16C39 Diesel electronic injection control unit.Check the value of the following parameters:. Battery voltage    See Test 5530BB BATTERY VOLTAGE CHECK. Accelerator pedal. Accelerator position 1 AD/C. Accelerator position 2 AD/C    See Test 1068AC ACCELERATOR PEDAL CHECKS. Atmospheric pressure    See Test 1060GD ATMOSPHERIC PRESSURE CHECK. Supercharging pressure Objective. Supercharging pressure Measured    See Test 1060GF SUPERCHARGING PRESSURE CHECK. Measured air mass    See Test 1060GG MEASURED AIR MASS CHECK. Air temperature in the intake manifold    See Test 1064BD SUPERCHARGING TEMPERATURE CHECK. Engine coolant temperature    See Test 1060OE CHECK ON OPERATION OF COOLANT TEMPERATURE SENSOR. Diesel temperature    See Test 1060EA DIESEL FUEL TEMPERATURE CHECK. Target Diesel pressure. Measured Diesel pressure    See Test 1060GH DIESEL FUEL PRESSURE CHECK. Engine rpm    See Test 1060GI ENGINE SPEED CHECK	Move on to Step 2
2	ELECTRICAL EQUIPMENT CHECK	All OK	Problems encountered	Operation
	Check that the fuses F1 (the last one at the bottom of the vertical row) and F20 (the first one on the right of the lower row) have not blown. The check on the following system is only necessary if the outside temperature is below 0 °C.	Move on to Step 4	Fuse F1 has blown	Restore the connections or, if necessary, replace the junction unit in the engine compartment    Op. 5505A13 ADDITIONAL JUNCTION UNIT IN ENGINE COMPARTMENT - R.R.
			Fuse F20 has blown	Move on to Step 3
3	DIESEL PREHEATING FUSE CHECK	All OK	Problems encountered	Operation
	Check the circuit for the protective fuse for the diesel preheating relay, carrying out the    See Test 5505AB CHECK DIESEL PREHEATING RELAY PROTECTIVE FUSE	Move on to Step 4
4	DIESEL PREHEATING RELAY CHECK	All OK	Problems encountered	Operation
	Check the diesel preheating relay circuit	Move on to Step 5
5	TURBOCHARGER ADJUSTMENT CHECK	All OK	Problems encountered	Operation
	Using the diagnostic equipment carry out the active diagnosis for the turbocharger regulating solenoid valve.Check the operation of the variable geometry control actuator    See Test 1064BC VARIABLE GEOMETRY TURBOCHARGER ACTUATOR SEAL TEST	Move on to Step 6	Solenoid valve not working	Restore the wiring continuity    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENTReplace the solenoid valve if necessary    Op. 1064B42 SOLENOID CONTROLLING TURBOCHARGER VANE POSITION ACTUATOR - R.R
			Actuator not working properly	Check the condition of the vacuum circuit, if necessary, replace the damaged components
6	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Carry out the active diagnosis for the E.G.R. solenoid valve	Move on to Step 7	E.G.R. solenoid valve not working	Restore the wiring continuity    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENTReplace the solenoid valve if necessary    Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R
7	BRAKE PEDAL SWITCH CHECK	All OK	Problems encountered	Operation
	Check that the brake pedal switch is working properly	Move on to Step 8	Brake pedal does not return	Eliminate the cause of the sticking
			Switch stuck closed	Replace the switch    Op. 1060G38 BRAKE PEDAL SWITCH - R.R
			Wiring short circuited	Restore the correct connection    See E2021 BRAKE LIGHTS
8	TURBOCHARGER CHECK	All OK	Problems encountered	Operation
	Check as described in the    See Test 1064BA SUPRECHARGING PRESSURE CHECKthe operation of the turbocharger	Move on to Step 9	Turbocharger faulty	Replace the turbocharger    Op. 1064A27 TURBOCHARGER UNIT AND EXHAUST MANIFOLD - R.R.
9	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Connect the diagnotsic equipment to the diagnostic socket.Check as described in the    See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUITthat the diesel pressure parameter is correct	Move on to Step 17	Pressure not correct	Move on to Step 10
10	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the    See Test 1060OA CHECK ON RETURN LOW PRESSURE FUEL CIRCUITthat the pressure in the return pipe to the tank is less than 1 bar	Move on to Step 11	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary.
11	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the    See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUITthat the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step 17	Pressure below the minimum limit or above the maximum value	Move on to Step 12
12	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Constrict the return pipe from the pressure relief valve and carry out the test again    See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUITwith the pipe constricted checking that the filter outlet pressure remains below 2 bar	Move on to Step 13	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the valve    Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
13	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Move on to Step 14	Difference in pressure more than 1 bar	Replace the fuel filter cartridge    Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
14	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the supply pump pressure at the filter inlet is more than 2.2 bar	Move on to Step 17	Pressure below 2 bar	Move on to Step 15
15	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Measure the difference in pressure between the electrical pump outlet and the filter inlet checking that it is less than 0.3 bar	Move on to Step 16	Difference in pressure more than 0.3 bar	Replace the pipe
16	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the    See Test 1040AA SUPPLY VOLTAGE AND ABSORPTION CURRENT CHECKSthat the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A	Move on to Step 17	Voltage lower than 12 V	Check electrical wiring    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current greater than 10 A: pump defective	Replace the fuel pump    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
			Current less than 2 A: pump obstructed	Replace the fuel pump    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + Rand cle

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