199002956 - D005 ENGINE DOES NOT PRODUCE BEST PERFORMANCE
The customer complains that: Reduced engine performance in all operating conditions| Test results | ||||||
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation | ||
|---|---|---|---|---|---|---|
| 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 See Test 1040OA FUEL SUPPLY CIRCUIT CHECKCheck the operation of the low pressure supply circuit See Test 1060OB LOW FUEL DELIVERY PRESSURE 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: Electronic injection control unit EDC16C39 CF4/EOBD CAN (EP engine 1.9).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 SUPERCHARGING PRESSURE CHECK· Measured air mass See Test 1060GG CHECK MEASURED AIR MASS· Engine coolant temperature See Test 1060OE ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK· Diesel temperature See Test 1060EA DIESEL TEMPERATURE CHECK- Target Diesel pressure- Measured Diesel pressure See Test 1060GH DIESEL PRESSURE CHECK· Engine rpm See Test 1060GI CHECK ENGINE SPEED | Move on to Step 2 | |||||
| 2 | ELECTRICAL EQUIPMENT CHECK | All OK | Problems encountered | Operation | ||
Check that fuse F59 has not blown (second from the left on the second row from the bottom)
| Move on to Step 3 | Fuse F59 has blown | Restore the connections or, if necessary, replace the junction unit in the engine compartment Op. 5505A13 ADDITIONAL JUNCTION UNIT IN ENGINE COMPARTMENT - R.R. | |||
| Fuse F20 has blown | Move on to Step 3 | |||||
| 3 | DIESEL PREHEATING RELAY CHECK | All OK | Problems encountered | Operation | ||
| Check the diesel preheating relay circuitSee Test 5505AC | Move on to Step 4 | |||||
| 4 | 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 | Move on to Step 5 | 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 | |||
| Actuator not working properly | Check the condition of the vacuum circuit, if necessary, replace the damaged components | |||||
| 5 | 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 6 | 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 | |||
| 6 | BRAKE PEDAL SWITCH CHECK | All OK | Problems encountered | Operation | ||
| Check that the brake pedal switch is working properly | Move on to Step 7 | Brake pedal does not return | Eliminate the cause of the sticking | |||
| Switch stuck closed | Replace the switch Op. 1060D38 SWITCH ON BRAKE PEDAL - R.R (DIESEL ENGINES) | |||||
| Wiring short circuited | Restore the correct connection See E2021 BRAKE LIGHTS | |||||
| 7 | TURBOCHARGER CHECK | All OK | Problems encountered | Operation | ||
| Checkthe operation of the turbocharger See Test 1064BA SUPERCHARGING PRESSURE CHECK | Move on to Step 8 | Turbocharger faulty | Replace the turbocharger Op. 1064A27 TURBOCHARGER UNIT AND EXHAUST MANIFOLD - R.R. | |||
| 8 | HIGH PRESSURE CHECK | All OK | Problems encountered | Operation | ||
| Connect the diagnostic equipment to the diagnostic socket.Check that the diesel pressure parameter is correct See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK | Move on to Step 15 | Pressure not correct | Move on to Step 9 | |||
| 9 | LOW RETURN PRESSURE CHECK | All OK | Problems encountered | Operation | ||
| that the pressure in the return pipe to the tank is less than 1 bar See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK | Move on to Step 10 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe and replace if necessary. | |||
| 10 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation | ||
| Check that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK | Move on to Step 15 | Pressure below the minimum limit or above the maximum value | Move on to Step 11 | |||
| 11 | 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 12 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE | |||
| 12 | 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 15 | Pressure below 2 bar | Move on to Step 13 | |||
| 13 | 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 14 | Difference in pressure more than 0.3 bar | Replace the pipe | |||
| 14 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation | ||
| Checkthat 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 15 | 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 | |||||
| 15 | CHECK CORRECT OPERATION | All OK | Problems encountered | Operation | ||
| Replace the high pressure DRV valveOp. 1060E50 and check that the fault is no longer present | End of diagnosis | Fault persists | Move on to Step 16 | |||
| 16 | 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 17 | |||
| 17 | TIMING CHECK | All OK | Problems encountered | Operation | ||
| Check that the timing system timing is correct | Move on to Step 18 | Timing system timing not correct | Restore the correct timing system timing Op. 1032B10 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT | |||
| 18 | VALVE CLEARANCE CHECK | All OK | Problems encountered | Operation | ||
| Check that the tappet clearance is c | ||||||
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