| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
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| Check that the engine coolant level is correct Op. 0010T21 ENGINE COOLANT - CHECK DENSITY AND TOP UP, IF NECESSARY Check the condition of the fuel supply circuit and make sure that it is working properly See Test 1040OA FUEL SUPPLY CIRCUIT CHECK | Move on to Step 1 | Coolant level incorrect | Restore the correct engine oil level Op. 0010T21 ENGINE COOLANT - CHECK DENSITY AND TOP UP, IF NECESSARY |
| 1 | INJECTOR ACTIVE DIAGNOSIS | All OK | Problems encountered | Operation |
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| Carry out the injector active diagnosis once again checking that the result is positive | Move on to Step 9 | The result of the active diagnosis is negative | Move on to Step 2 |
| 2 | ERRORS IN CONTROL UNIT CHECK | All OK | Problems encountered | Operation |
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| Select the following control unit at the diagnostic equipment: Marelli Diesel Injection 6F3 EOBD CAN (EP engine 1.3 JTD).Check that the following error is present:- P0005 | Move on to Step 3 | Error P0005 is not present | Replace the injector that gave a negative result during active diagnosis Op. 1060F10 FUEL INJECTORS - R.R. |
| 3 | HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Connect the diagnostic equipment to the diagnostic socket.Check that the diesel pressure parameter is correctOp. 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUIT | Move on to Step 9 | Pressure not correct | Move on to Step 4 |
| 4 | LOW RETURN PRESSURE CHECK | All OK | Problems encountered | Operation |
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| that the pressure in the return pipe to the tank is less than 1 bar | Move on to Step 5 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe and replace if necessary |
| 5 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check that the difference in pressure upstream and downstream of the filter is less than 1 bar | Move on to Step 6 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 6 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check that the supply pump pressure at the filter inlet is more than 2.2 bar (75 bhp) or 4.5 bars (90 bhp) | Move on to Step 9 | Pressure lower than 2 bars (75 bhp) or 4.5 bars (90 bhp) | Move on to Step 7 |
| 7 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| 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 8 | Difference in pressure more than 0.3 bar | Replace the pipe |
| 8 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKE | Move on to Step 9 | 1. Voltage lower than 12 V2. Current greater than 10 A: pump defective3. Current less than 2 A: pump obstructed | 1. Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT 2. Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R 3. Replace the fuel pump and clean the fuel tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R |
| 9 | CONFIGURATION TESTS | All OK | Problems encountered | Operation |
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| Select the following control unit at the diagnostic equipment: Marelli Diesel Injection 6F3 EOBD CAN (EP engine 1.3 JTD).Check in the Configurations section whether the replacement of any of the following components was not followed by the subsequent configuration:- injectorIn this case, carry out the configuration checking that the outcome is positive | Move on to Step 12 | The outcome of the configuration is not positive | Move on to Step 10 |
| 10 | ERRORS CHECK | All OK | Problems encountered | Operation |
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| Check whether any of the following errors are present using the diagnostic equipment:- P1301- U0001- U0426- U1700 | Move on to Step 12 | 1. Error P1301 is present2. Error U0001 is present3. Error U0426 is present4. Error B1700 is present | 1. Move on to Step 112. Continue as indicated See table U0001 CAN line error3. Memorise the CODE. If it is not possible, replace the engine control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R 4. Continue as indicated See table U1700 CAN network (NCM - NBC) |
| 11 | IMA CLASSIFICATION | All OK | Problems encountered | Operation |
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| In the Configurations section on the diagnostic tester, rerun the IMA classification and ensure it is successful | End of diagnosis | The classification is unsuccessful | Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R |
| 12 | AMBIENT PARAMETERS CHECK | All OK | Problems encountered | Operation |
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| Select the following control unit at the diagnostic equipment: Marelli Diesel Injection 6F3 EOBD CAN (EP engine 1.3 JTD).Check the value of the following parameters:- Coolant temperature See Test 1060OE ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK- Diesel temperature See Test 1060EA DIESEL TEMPERATURE CHECK. Atmospheric pressure See Test 1060GD ATMOSPHERIC PRESSURE CHECK | Move on to Step 13 | | |
| 13 | INTAKE CIRCUIT CHECK | All OK | Problems encountered | Operation |
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| Check that the air intake/vacuum circuit is working properly See Test 1048OA AIR INTAKE/VACUUM CIRCUIT CHECK | Move on to Step 14 | | |
| 14 | PREHEATING RELAY ACTIVE DIAGNOSIS | All OK | Problems encountered | Operation |
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| Carry out the active diagnosis of the preheating relay, checking that the result is positive | The check on the following system is only necessary if the outside temperature is below 0 °C. |
| Move on to Step 16 | The result of the active diagnosis is negative | Move on to Step 15 |
| 15 | HEATER PLUGS CHECK | All OK | Problems encountered | Operation |
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| Check that the heater plugs are working properly See Test 5520CA CHECK GLOW PLUG OPERATION | Move on to Step 16 | | |
| 16 | CYLINDER COMPRESSION CHECK | All OK | Problems encountered | Operation |
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| Carry out the cylinder compression check Op. 0510A10 CYLINDER COMPRESSION - CHECK FOR LOOSE SPARK PLUGS OR INJECTORS | Move on to Step 19 | Cylinder compression insufficient | Move on to Step 17 |
| 17 | CHECK CYLINDER HEAD GASKET AND VALVE OIL SEALS | All OK | Problems encountered | Operation |
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| Check:- that the cylinder head is correctly tightened;- the seal of the gasket- the seal of the valve oil seals | Move on to Step 18 | 1. Cylinder head tightening incorrect2. Gasket damaged3. Oil seal missing | 1. Proceed with the removing-refitting of the cylinder head and renew the correct tightening Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET 2. Change the head gasket Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET 3. Replace the valve oil seals Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL |
| 18 | CHECK THE CAUSE OF THE INSUFFICIENT COMPRESSION | All OK | Problems encountered | Operation |
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| With the cylinder head removed, check:- valve seal- cylinder/piston ring wear conditions | Move on to Step 19 | 1. Valve seal insufficient2. Cylinder/ring wear outside tolerances | 1. Overhaul cylinder head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL 2. Restore correct operating clearance |
| 19 | BLOW-BY CIRCUIT CHECK | All OK | Problems encountered | Operation |
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| Check the condition of the blow-by gas intake circuit.In particular, check for obstructions in the separator or pipes | Move on to Step 20 | 1. Fault in the pipe from separator to intake2. Fault in the separator (tappet cover) | 1. Restore circuit to working order: change the pipe if necessary2. Restore circuit to working order: if necessary, replace the tappet cover |
| 20 | TURBOCHARGER SEAL CHECK | All OK | Problems encountered | Operation |
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| Check that there are no engine |