D005 ENGINE DOES NOT PRODUCE BEST PERFORMANCE - Fiat - NUOVA BRAVO - eLearn

198001694 - D005 ENGINE DOES NOT PRODUCE BEST PERFORMANCE

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

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	Check that the engine oil level is correct Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY Check 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 Low pressure fuel supply circuit check	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	MODE 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 TURBOCHARGING PRESSURE CHECK· Measured air mass· Air temperature in the intake manifold See Test 1064BD SUPERCHARGING TEMPERATURE CHECK· Engine coolant temperature See Test 5030AA COOLANT TEMPERATURE SENSOR CHECK· Diesel temperature· Target Diesel pressure· Measured Diesel pressure See Test 1060GH DIESEL PRESSURE CHECK· Engine rpm	Move on to Step 2
2	TURBOCHARGER ADJUSTMENT CHECK	All OK	Problems encountered	Operation
	Using the diagnostic equipment, carry out the active diagnosis for the turbocharger regulating solenoid.Check the operation of the variable geometry control actuator by carrying out the See Test 1064BC VARIABLE GEOMETRY TURBOCHARGER ACTUATOR LEAKAGE TEST	Move on to Step 3	Solenoid not working	Restore the wiring continuity See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Replace the solenoid if necessary Op. 1064B42 SOLENOID CONTROLLING TURBOCHARGER VANE POSITION ACTUATOR - R.R
		Move on to Step 3	Actuator not working properly	Check the condition of the vacuum circuit, if necessary, replace the damaged components
3	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 4	E.G.R. solenoid not working	Restore the wiring continuity See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Replace the solenoid if necessary Op. 1080C24 E.G.R. SYSTEM SOLENOID - R + R
4	BRAKE PEDAL SWITCH CHECK	All OK	Problems encountered	Operation
	Check that the brake pedal switch is working properly	Move on to Step 5	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
5	TURBOCHARGER CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1064BA TURBOCHARGING PRESSURE CHECKthe operation of the turbocharger	Move on to Step 6	Turbocharger faulty	Replace the turbocharger Op. 1064A27 PIPE BETWEEN VACUUM RESERVOIR AND ACTUATOR CONTROL SOLENOID VALVE - R.R.
6	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Connect the diagnostic equipment to the diagnostic socket.Check as described in the See Test 1060OD Injector high pressure fuel circuit checkthat the diesel pressure parameter is correct	Move on to Step 7	Pressure not correct	Move on to Step 13
7	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1060OA Low pressure fuel return circuit checkthat the pressure in the return pipe to the tank is less than 1 bar	Move on to Step 8	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary
8	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1060OB Low pressure fuel supply circuit checkthat the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step 10	Pressure below the minimum limit or above the maximum value	Move on to Step 9
9	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check by carrying out the See Test that the difference in pressure upstream and downstream of the filter is less than 0.5 bar	Move on to Step 11	Difference in pressure more than 0.5 bar	Replace the fuel filter Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
10	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 12	Pressure below 2 bar	Move on to Step 11
11	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 13	Difference in pressure more than 0.3 bar	Replace the pipe
12	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKEthat the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A	Move on to Step 13	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 + R and clean the fuel tank
13	CORRECT OPERATION CHECK	All OK	Problems encountered	Operation
	Replace the high pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer present	End of diagnosis	Fault persists	Move on to Step 14
14	TIMING CHECK	All OK	Problems encountered	Operation
	Check that the timing system timing is correct	Move on to Step 15	Timing system timing not correct	Restore the correct timing system timing
15	CYLINDER COMPRESSION CHECK	All OK	Problems encountered	Operation
	Carry out the cylinder compression check Op. 0520G15 COMPRESSION TEST - CHECK WITH EXAMINER WITH SPARK PLUGS/INJECTORS REMOVED	Move on to Step 17	Cylinder compression insufficient	Move on to Step 16
16	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems encountered	Operation
	Carry out Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET to check the valve seal.Check condition of cylinders/piston rings	Move on to Step 17	Valve seal insufficient	Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
		Move on to Step 17	Cylinders/piston rings worn	Restore the correct seal
17	CORRECT OPERATION CHECK	All OK	Problems encountered	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJ

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