| TEST RESULTS |
| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Select diesel injection engine control unit on the diagnostic equipmentCarry out the following tests using the Examiner before a forced regeneration with the engine at 90°CIt is vital to make a note of the measurements taken using the Examiner before the forced regeneration because they will be required if the problem is not solved.1. Differential sensor pressure with engine off2. Differential sensor pressure with engine running3. Air mass measured (with engine idling for at least 2 minutes so that the EGR is closed and the air flow meter temperature is less than 35 °C)4. Particle filter blocked5. Particle filter temperature6. Average temperature for last 5 regenerations7. Mileometer8. Milometer at last DPF replacement9. Milometer since last regeneration10. Objective air mass11. Precatalyzer temperature12. Particle filter status13. Average distance for last 5 regenerations14. Average time for last 5 regenerations15. Check the correspondence of the IMA codes on the injectors with those displayed on the Examiner16. Check for presence of other errors17. Determine the following identification data: SW number, SW version, FIAT design no., Programming date | Move on to Step 1 | | |
| 1 | CHECKS USING THE EXAMINER | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Connect the Examiner to the engine management control unit and check that there are no errors | End of diagnosis | 1. Only Error P1206 detected2. Presence of other errors in addition to P1206 | 1. Move on to Step 22. Eliminate the errors, delete them and then carry out the forced regeneration. Make sure that the forced regeneration is properly concluded and that error P1206 is no longer present. At the end of the regeneration check whether the DPF is blocked using the Examiner; figures of around 75% are acceptable and the vehicle can be handed back to the customer. If the forced regeneration has not been successful and/or error P1206 is still present, move on to step 2 |
| 2 | ENGINE COOLANT TEMPERATURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Using the Examiner, with the engine warmed up and the vehicle moving - 4th - 5th gear at 70 or 90 km/h - measure the engine temperature.Check that the figure measured is above 85°C | Move on to Step 3 | Temperature values below 85°C | For 1.9 JTD 8V versions:Replace the thermostat Op. 1088C30 THERMOSTAT UNIT - R+R For 1.9 JTD 16V versions:Replace the thermostat Op. 1088C40 THERMOSTAT- R + R |
| 3 | ENGINE OIL LEVEL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check that the oil level is at least 2mm below the Max level | Move on to Step 4 | Engine oil level not correct | Top up to the correct oil level |
| 4 | INJECTOR CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check that the design number of the jets conforms to the engine typeCheck there are no vents | Move on to Step 5 | 1. Injectors do not conform2. Vents present | 1. Replace the injectors Op. 1060F10 FUEL INJECTORS - R.R. 2. Replace the injectors Op. 1060F10 FUEL INJECTORS - R.R. |
| 5 | INJECTOR CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check that the injector seat has one single 2mm washerCheck that the jet design number is correct | Move on to Step 6 | 1. Size of washer does not conform2. Jet design number does not conform | 1. Replace with washers of the correct size2. Replace with injectors that conform see Design Number in Step 10 |
| 6 | PLUGS CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check that the design number of the plugs conforms to the engine type | Move on to Step 7 | The design number of hte plugs does not conform | Replace with plugs that conform Op. 5520C10 HEATER PLUGS - R+R see Design Number in Step 10 |
| 7 | AIR PIPES CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check that there are no leaks/vents in the air pipes between the flow meter and engine intake | Move on to Step 8 | The air intake circuit is not sealed | Restore the correct seal for the intake circuit |
| 8 | CHECK FOR PRESENCE OF INTERCOOLER FLUID | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check that there is no oil in the air intake/intercooler circuit | Move on to Step 9 for 1.9 JTD 8vMove on to Step 11 for all versions | Presence of oil | Clean the areas involved and check the turbocharger |
| 9 | CAMSHAFT CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| For 1.9 JTD 8V versions:Check the camshaft sockets for wear | Move on to Step 11 | Camshaft sockets found to be worn | For 1.9 JTD 8V versions:Replace the camshafts Op. 1036B10 OVERHEAD CAMSHAFT IN CYLINDER HEAD - R.R ON VEHICLE For 1.9 JTD 16V versions:Replace the camshafts Op. 1036L14 CAMSHAFTS IN CAMSHAFT HOUSING - R.R. WITH CAMSHAFT HOUSING REMOVED - INCLUDES POSSIBLE REPLACEMENT. OF CAMSHAFT HOUSING |
| 10 | DESIGN NO. OF INJECTORS, JETS AND PLUGS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| For 1.9 JTD 8V 120 CV versions:Fiat Design Injector: 55200259Bosch Design Injector: 0 445 110 244Jet: DLLA 142 PV3 197 707Fiat Design Plug: 55200817Bosch Design Plug: 0 250 202 132For 1.9 JTD 16V 150 CV versions:Fiat Design Injector: 55198218Bosch Design Injector: 0 445 110 243Jet: DLLA 148 P 1347Fiat Design Plug: 46792355Bosch Design Plug: 0 250 203 001 | | | |
| 11 | FOR THE ITALIAN MARKET ONLY | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| If no problems and/or non conformity has emerged by the end of the check list, fax Teseo Prodotto to look into the matter furtherUse the following procedure for models subject to tutorship | End of diagnosis | | |
