| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
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| - Carry out an initial visual inspection to locate the component that is leaking or the area of the leak.- Check that there is no engine oil in the coolant.- Check that there is no water or emulsion in the engine oil.- If the visual check is not sufficient, wash the engine, dry it and start slowly to bring it up to the correct temperature. Test the watertightness of the system to identify the leak Op. 0510C30 ENGINE COOLING SYSTEM - LEAKAGE TEST | Move on to Step 1 | 1. Leaks from pipes2. Leak from the radiator3. Leak from the expansion tank4. Leak from the water pump5. Leak from the thermostat unit6. Leak from the cylinder head7. Leak from the heater radiator8. Oil or water leaking between the engine and the cooling circuit | 1. Move on to Step 12. Move on to Step 23. Move on to Step 34. Move on to Step 45. Move on to Step 56. Move on to Step 67. Move on to Step 78. Move on to Step 8 |
| 1 | PIPE CHECK | All OK | Problems encountered | Operation |
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| Check the condition of the pipes and the seal. More specifically:- the condition of the bands making sure they are correctly fitted;- the condition of the hoses, connectors and plugs | Move on to Step 2 | Tightening not correct or components damaged | Restore the correct tightening or replace the components involved |
| 2 | RADIATOR CHECK | All OK | Problems encountered | Operation |
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| Check the condition of the radiator | Move on to Step 3 | Radiator damaged or distorted | Replace the radiator Op. 1088B20 ENGINE COOLING RADIATOR - R + R |
| 3 | EXPANSION TANK CHECK | All OK | Problems encountered | Operation |
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| Visually check:- the condition of the expansion tank;- the tap seal. Check the condition of the plug breather valve | Move on to Step 4 | Tank damaged or distorted | Replace the tank or the cap |
| 4 | WATER PUMP CHECK | All OK | Problems encountered | Operation |
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| Visually check:- the condition of the water pump;- the seal of the gaskets | Move on to Step 5 | Water pump faulty | Replace the water pump or the gaskets Op. 1088C14 WATER PUMP - R + R WITH TIMING BELT(S) REMOVED |
| 5 | CHECK THERMOSTAT UNIT | All OK | Problems encountered | Operation |
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| Visually check:- condition of the thermostat unit;- the seal of the gaskets | Move on to Step 6 | Thermostat unit fault | Replace the thermostat unit or the gaskets Op. 1088C40 THERMOSTAT- R + R |
| 6 | CYLINDER HEAD GASKET CHECK | All OK | Problems encountered | Operation |
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| Check:- that the cylinder head is correctly tightened;- the seal of the gasket | Move on to Step 7 | 1. Cylinder head tightening incorrect2. Gasket damaged | 1. Restore correct tightening2. Replace the gasket |
| 7 | HEATER RADIATOR CHECK | All OK | Problems encountered | Operation |
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| Check the condition of the heater radiator | Move on to Step 8 | Heater radiator damaged or distorted | Replace the heater radiator Op. 5040C54 AIR CONDITIONING HEATER RADIATOR - R+R WITH AIR CONDITIONING CASING REMOVED |
| 8 | CHECK ENGINE BLOCK SURFACE | All OK | Problems encountered | Operation |
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| Remove the cylinder head. Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET Check that there are no leaks:- oil deposits on valves;- defects on engine block;- defects on cylinder head gasket | Move on to Step 9 | 1. Cylinder block plane defective2. Oil deposits on the valves | 1. Level the engine block2. Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL |
| 9 | CHECK ON CORRECT OPERATION | All OK | Problems encountered | Operation |
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| Check that the fault is no longer present | End of diagnosis | The fault persists | Contact technical service for further information on the problem |
