| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| 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 CHECKVisually inspect the condition of:- Fuel pressure sensor on the rail
- Fuel shutter solenoid valve
| Move on to Step 1 | 1. Oil level incorrect | 1. Restore the correct engine oil level Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY |
| 2. Components visually faulty | 2. Repair or, if necessary, replace the faulty components |
| 1 | IMA INJECTOR CLASSIFICATION CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the injectors have the correct IMA classification using the diagnostic equipment. If not, carry out the programming and check that the result is positive | Move on to Step 2 | The programming is not successful | Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R |
| 2 | HIGH PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the diesel pressure parameter is correct. See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUIT | Move on to Step 13 | Pressure not correct | Move on to Step 3 |
| 3 | INJECTOR HIGH PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another. See Test 1060OC INJECTORS SEAL TEST | Move on to Step 4 | Significant leak from one injector | Replace the injector |
| 4 | LOW RETURN PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the pressure in the return pipe to the tank is less than 1 bar See Test 1060OA CHECK ON RETURN LOW PRESSURE FUEL CIRCUIT | Move on to Step 5 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe, if necessary, replace it |
| 5 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT | Move on to Step 11 | Pressure below the minimum limit or above the maximum limit | Move on to Step 6 |
| 6 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Constrict the return pipe downstream of the valve and carry out the test again See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUITwith the pipe constricted checking that the pressure at the filter outlet remains below 2 bar | Move on to Step 7 | Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted | Replace the valveOp. 1044B16 FUEL SUPPLY/RETURN REGULATION VALVE ON FUEL FILTER - R.R. |
| 7 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the difference in pressure upstream and downstream of the filter is less than 1 bar | Move on to Step 8 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE |
| 8 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the supply pump pressure at the filter inlet is more than 2.2 bar | Move on to Step 11 | Pressure below 2.2 bar | Move on to Step 9 |
| 9 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Measure the difference in pressure between the electric pump outlet and the filter inlet and check that it is less than 0.3 bar | Move on to Step 10 | Difference in pressure more than 0.3 bar | Replace the pipe |
| 10 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A See Test 1040AA SUPPLY VOLTAGE AND ABSORPTION CURRENT CHECKS | Move on to Step 11 | 1. Voltage lower than 12 V | 1. Renew electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| 2. Current greater than 10 A: pump defective | 2. Replace the fuel pump |
| 3. Current less than 2 A: pump obstructed | 3. Replace the fuel pump and clean the fuel tank |
| 11 | CHECK ON CORRECT OPERATION | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the DRV high pressure regulation valve and check that the fault is no longer present. Op. 1060E50 PRESSURE REGULATOR ON PRESSURE PUMP - R.R. | End of diagnosis | The fault persists | Move on to Step 12 |
| 12 | CHECK ON CORRECT OPERATION | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the pressure pump and check that the fault is no longer present Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. | End of diagnosis | The fault persists | Contact the Service Department for further information on the problem |
| 13 | PRESSURE REGULATOR REPLACEMENT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the fuel pressure regulator and check that the problem disappears Op. 1060E50 PRESSURE REGULATOR ON PRESSURE PUMP - R.R. | Move on to Step 14 | The fault persists | Renew the pressure regulator and replace the flow valveOp. 1060E20 FUEL -R.R. CUT-OFF SOLENOID VALVE |
| 14 | CHECK ON CORRECT OPERATION | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the engine management control unit and check that the fault is no longer present Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R | End of diagnosis | The fault persists | Contact the Service Department for further information on the problem |
