| STEP | OPERATIONS TO BE CARRIED OUT | TEST RESULTS |
|---|
| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Turn the key ON and check that the initial check on the MIL and CODE warning lights takes place.Then check:- that the inertia switch has cut in;
- presence of fuel in the tank;
- air intake circuit;
- correct operation of the exhaust manifolds.
| Move on to Step 1 | The CODE waring light stays on | Continue following the instructions in Table K52 |
| The MIL warning light does not carry out the intial test | Continue following the instructions in Table K53 |
| Intertia 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 FILTERING ELEMENT - REPLACE. |
| Exhaust blocked | Restore exhaust manifolds to working order |
| 1 | CHECK USING DIAGNOSTIC EQUIPMENT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Connect the diagnostic equipment to the diagnostic socket. Check:- that there are no errors in the control unit;
- the plausibility of the parameters;
- check that the rpm sensor is working properly as described in Test 1060GA ;
See Test 1060G PRESSURE PUMP ELECTRIC CONTROL | Move on to Step 2 | Error detected in the control unit | Continue following the instructions for the diagnostic equipment |
| Parameters not plausible | Continue following the instructions for 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 |
| Rpm sensor defective | Change rpm sensor Op. 1060G20 RPM AND TIMING SENSOR - R R |
| 2 | HIGH PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Connect the diagnostic equipment to the diagnostic socket.Check, as described in test Test 1060OD , that the diesel pressure parameter is correct. See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 10 | Pressure not correct | Move on to Step 3 |
| Fuel loss from connectors | Restore the seal |
| 3 | LOW RETURN PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1060OA, that the pressure in the return pipe to the tank is less than 0.5 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 4 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe and replace if necessary Op. 1060F52 PIPE TO RETURN MANIFOLD - R R |
| Pressure relief valve on rail defective | Replace the pressure relief valve Op. 1060G28 FUEL PRESSURE SENSOR - R R |
| Pressure sensor defective | Replace the fuel pressure sensor on the rail Op. 1060G28 FUEL PRESSURE SENSOR - R R |
| 4 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1060OB, that the diesel pressure between the filter and the pressure pump is between 0.6 and 0.7 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 10 | Pressure lower than minimum limit | Move on to Step 5 |
| Pressure above the maximum limit | Replace Bontaz pressure relief valve |
| 5 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| 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 less than or equal to 1 bar | Replace the fuel filter cartridge Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE |
| 6 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the supply pump pressure at the filter inlet is 0.9 bar | Move on to Step 9 | Pressure below 0.9 bar | Move on to Step 7 |
| 7 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the pressure difference between pump outlet and filter inlet 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 | ACTION |
|---|
| Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and that the current absorbed is between 2 and 10 Ampere See Test 1040A FUEL TANK AND COMPONENTS | Move on to Step 9 | Voltage < 12 V | Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| Current > 10 Amps: pump not running smoothly | Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R |
| Current < 2 Amps: pump obstructed | Replace the fuel pump assembly and clean the fuel tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R |
| 9 | CHECK CORRECT OPERATION OF PRESSURE REGULATOR | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the pressure regulator and check that the fault is no longer present Op. 1060G16 PRESSURE RELIEF SENSOR - R R | End of diagnosis | The fault persists | Repair the pressure regulator and move on to Step 10 |
| 10 | CHECK ON CORRECT OPERATION | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the high pressure pump and check that the fault is no longer present. Op. 1060E10 PRESSURE PUMP - R R | End of diagnosis | Fault persists control unit defective | Repair the high pressure pump and replace the engine management control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R |
| STEP | OPERATIONS TO BE CARRIED OUT | TEST RESULTS |
|---|
| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| 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;
- air closure throttle on chamber open;
- correct operation of the exhaust manifolds
| Move on to Step 1 | The CODE waring light stays on | See tableK52CODE FAILURE WARNING LIGHT ON |
| The MIL warning light does not carry out the intial test | See tableK53I.E. FAILURE WARNING LIGHT OFF / (INITIAL TEST NOT CARRIED OUT) |
| Intertia 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 FILTERING ELEMENT - REPLACE. |
| Throttle valve closed | Restore the correct operation of the throttle valve |
| Exhaust blocked | Restore the operation of the exhaust manifolds |
| 1 | CHECK USING DIAGNOSTIC EQUIPMENT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Connect the diagnostic equipment to the diagnostic socket.Check:- that there are no errors in the control unit;
- parameter plausibility
| Move on to Step 2 | Error detected in the control unit | Continue following the instructions for the diagnostic equipment |
| Parameters not plausible | Continue following the instructions for 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 |
| 2 | HIGH PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Connect the diagnostic equipment to the diagnostic socket.Check, as described in test Test 1060OD , that the diesel pressure parameter is correct. See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 10 | Pressure not correct | Move on to Step 3 |
| 3 | LOW RETURN PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1060OA, that the pressure in the return pipe to the tank is less than 1 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 4 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe and replace if necessary Op. 1060F52 PIPE TO RETURN MANIFOLD - R R |
| 4 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1060OB, that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 10 | Pressure below the minimum limit or above the maximum limit | Move on to Step 5 |
| 5 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Constrict the return pipe, downstream of the valve, and carry out Test 1060B again with the pipe constricted checking that the pressure at the filter outlet stays below 2 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 6 | Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted | Replace filter mounting Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 6 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the difference in pressure upstream and downstream of the filter is less than 1 bar | Move on to Step 7 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE |
| 7 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the supply pump pressure at the filter inlet is more than 2.2 bar | Move on to Step 10 | Pressure below 2.2 bar | Move on to Step 8 |
| 8 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the pressure difference between pump outlet and filter inlet is less than 0.3 bar | Move on to Step 9 | Difference in pressure more than 0.3 bar | Replace the pipe |
| 9 | FUEL PUMP CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and that the current absorbed is between 2 and 10 Ampere See Test 1040A FUEL TANK AND COMPONENTS | Move on to Step 10 | Voltage < 12 V | Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| Current > 10 Amps: pump not running smoothly | Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R |
| Current < 2 Amps: pump obstructed | Replace the fuel pump assembly and clean the fuel tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R |
| 10 | CHECK ON CORRECT OPERATION | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the DRV high pressure regulation valve and check that the fault is no longer present Op. 1060E50 PRESSURE REGULATOR - R R | End of diagnosis | The fault persists | Restore the regulator valve and move on to Step 11 |
| 11 | CHECK ON CORRECT OPERATION | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Replace the pressure pump and check that the fault is no longer present Op. 1060E10 PRESSURE PUMP - R R | End of diagnosis | The fault persists: control unit defective | Repair the pressure pump and replace the engine management control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R |