| | 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 carrying out the See Test 1040OA FUEL SUPPLY CIRCUIT CHECKVisually inspect the condition of:- High pressure fuel pump- Injector pipe- Fuel pressure sensor on the rail- Fuel pressure regulator- Fuel shutter solenoid valve- Injectors | 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 |
| Components visually faulty | Repair or, if necessary, replace the faulty components |
| 1 | IMA INJECTOR CLASSIFICATION CHECK | All OK | Problems encountered | Operation |
|---|
| Check that the injectors have the correct IMA classification using the diagnostic equipment. If not, carry out the programming and check that the result is positive | Move on to Step 2 | The programming is not successful | Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R |
| 2 | HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check as described in the See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECKthat the diesel pressure parameter is correct. | Move on to Step 13 | Pressure not correct | Move on to Step 3 |
| 3 | INJECTOR HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check, as instructed in the 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 4 | Significant leak from one injector | Replace the injector Op. 1060F10 FUEL INJECTORS - R.R. |
| 4 | LOW RETURN PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check as described in the 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 5 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe, if necessary, replace it |
| 5 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check as described in the 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 11 | Pressure below the minimum limit or above the maximum limit | Move on to Step 6 |
| 6 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Constrict the return pipe downstream of the valve and carry out the test once again See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECKwith the pipe constricted checking that the filter outlet pressure remains below 2 bar | Move on to Step 7 | Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted | Replace the valve |
| 7 | 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 8 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 8 | 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 11 | Pressure below 2.2 bar | Move on to Step 9 |
| 9 | 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 10 | Difference in pressure more than 0.3 bar | Replace the pipe |
| 10 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check as described in the 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 11 | 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 |
| 11 | CHECK ON CORRECT OPERATION | All OK | Problems encountered | Operation |
|---|
| Replace the DRV high pressure regulating valveOp. 1060E50 and check that the fault is no longer present. | End of diagnosis | The fault persists | Move on to Step 12 |
| 12 | CHECK ON CORRECT OPERATION | 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 | The fault persists | Contact technical service for further information on the problem |
| 13 | PRESSURE REGULATOR REPLACEMENT | All OK | Problems encountered | Operation |
|---|
| Replace the fuel pressure regulatorOp. 1060E50 and check the fault has disappeared | Move on to Step 14 | The fault persists | Renew the pressure regulator and replace the flow valve |
| 14 | CHECK ON CORRECT OPERATION | 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 | The fault persists | Contact technical service for further information on the problem |
