| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
|---|
| Turn the key ON and check that the initial check on the MIL and CODE warning lights takes place. | The MIL warning light should come on and then go out when the engine is started up, whilst the CODE warning light should come on for about 4 seconds and then go out |
Then check:- that the inertia switch has not been operated;- presence of fuel in the tank;- air intake circuit;- correct operation of the flow modification valve;- correct operation of the exhaust manifolds.- that there are no leaks or seepage from the high and low pressure fuel pipes | Move on to Step 1 | The CODE warning light stays on | Proceed as instructed See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START) |
| The MIL warning light does not carry out the initial test | Proceed as instructedSee table K053 M.I.L. WARNING LIGHT OFF (INITIAL TEST NOT CARRIED OUT) / ENGINE DOES NOT START |
| The CODE warning light does not carry out the initial test | Proceed as instructedSee table K054 VEHICLE PROTECTION WARNING LIGHT OFF (ENGINE DOES NOT START) |
| The warning lights do not carry out the initial test | Proceed as instructedSee table K049 MIL WARNING LIGHT AND VEHICLE PROTECTION WARNING LIGHT BOTH OFF (ENGINE DOES NOT START) |
| Inertia switch operated | Restore correct operation |
| Lack of fuel | Add fuel to the tank |
| Filter dirty or partly blocked | Replace the filter element Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE. |
| Flow modulation valve working incorrectly | Move on to Step 3 |
| Exhaust blocked | Move on to Step 2 |
| Presence of leaks | Eliminate leaks |
| 1 | ENGINE STARTING ELECTRIC CIRCUIT CHECK | All OK | Problems encountered | Operation |
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| Check that the engine starting electric circuit is working properly See Test 5520BA ENGINE STARTING CIRCUIT CHECK | Move on to Step 2 | | |
| 2 | FLOW MODIFICATION VALVE ACTUATOR CHECK | All OK | Problems encountered | Operation |
|---|
| Select the following control unit at the diagnostic equipment: Diesel electronic injection control unit EDC16C39 CF4/EOBD CAN (EP engine 1.9)Check operation of the pneumatic actuator | Move on to Step 3 | Actuator not working | Replace electro-pneumatically controlled throttle body Op. 1060G50 THROTTLE BODY - R.R |
| 3 | CHECK USING DIAGNOSTIC EQUIPMENT | All OK | Problems encountered | Operation |
|---|
| Connect the diagnostic equipment to the diagnostic socket.Check:- no errors in control unit- parameter plausibility | Move on to Step 4 | Error detected in the control unit | Continue following the instructions on the diagnostic equipment |
| Parameters not plausible | Continue following the instructions on the diagnostic equipment |
| No communication with the control unit | Restore the connection between the engine control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| 4 | HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECKthat the diesel pressure parameter is correct. | Move on to Step 14 | Pressure not correct | Move on to Step 5 |
| 5 | INJECTOR HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check, See Test 1060OC INJECTOR SEAL TESTthat the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another. | Move on to Step 6 | Significant leak from one injector | Replace the injector Op. 1060F10 FUEL INJECTORS - R.R. |
| 6 | LOW RETURN PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check, See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECKthat the pressure in the return pipe to the tank is less than 1 bar | Move on to Step 7 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe; if necessary, replace it |
| 7 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECKthat the diesel pressure between the filter and the pressure pump is between 2 and 3 bar | Move on to Step 12 | Pressure below the minimum limit or above the maximum limit | Move on to Step 8 |
| 8 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check that the difference in pressure upstream and downstream of the filter is less than 1 bar | Move on to Step 9 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 9 | 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 2.2 bar | Move on to Step 10 |
| 10 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| 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 11 | Difference in pressure more than 0.3 bar | Replace the pipe |
| 11 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check 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 12 | Voltage lower than 12 V | Renew 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 |
| 12 | CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
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| Replace the DRV high pressure regulating valveOp. 1060E50 FUEL PRESSURE REGULATOR - R.R.and check that the fault is no longer present. | End of diagnosis | Fault persists | Move on to Step 13 |
| 13 | CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
|---|
| Replace the pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer present | End of diagnosis | Fault persists | Contact technical service for further information on the problem |
| 14 | CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
|---|
| Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R and check that the fault is no longer present | End of diagnosis | Fault persists | Contact technical service for further information on the problem |