244000456 - D21 ENGINE CUTS OUT WHILST DRIVING

The engine cuts out unexpectedly whilst driving. It works later on after starting normally.
STEPOPERATIONS TO BE CARRIED OUTTEST RESULTS
0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Check the following, in order:

  • presence of fuel in the tank;
  • wiring on engine correctly fastened to earth;
  • battery correctly fastened to earth;
  • positive battery pole and all leads connected to it correctly fastened;
  • no water in the fuel filter.
Move on to Step 1No fuelIntroduce fuel
Fastenings slack or oxidizedRestore correct fastenings
Water in the fuel tankClean the tank and pipes and replace the filter element    Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
1CHECK USING DIAGNOSTIC EQUIPMENTALL OKPROBLEMS ENCOUNTEREDACTION
Connect the tester to the tester output.Check:

  • for errors saved in the control unit.
  • correct operation of the rpm sensor as described in Test 1060GA
    See Test 1060G PRESSURE PUMP ELECTRIC CONTROL
Move on to Step 2Error detected in the control unitContinue following the instructions for the diagnostic equipment
RPM sensor defectiveChange the rpm sensor    Op. 1060G20 RPM AND TIMING SENSOR - R R
Incorrect gap between phonic wheel and rpm sensorChange the rpm sensor    Op. 1060G20 RPM AND TIMING SENSOR - R R
Phonic wheel damagedChange the phonic wheel    Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX
2ROAD TEST USING DIAGNOSTIC EQUIPMENTALL OKPROBLEMS ENCOUNTEREDACTION
Carry out a road test reproducing the conditions in which the fault occurs, keeping the diagnostic equipment connected.Check:

  • for errors saved in the control unit.
Move on to Step 3Error detected in the control unitContinue following the instructions for the diagnostic equipment
3INJECTOR HIGH PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OC that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 4Considerable leakage from injectorsChange the injectors    Op. 1060F10 FUEL INJECTORS
4HIGH PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Connect the tester to the tester output.Check, as described in Test 1060OD that the diesel pressure value is correct    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 12Pressure level incorrectMove on to Step 5
5LOW RETURN PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OA that the tank return pipe pressure is less than 0.5 bar    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 6Pressure above the maximum limit: return pipe to the tank obstructedRepair the pipe and replace if necessary.
Bontaz pressure relief valve defectiveReplace Bontaz pressure relief valve    Op. 1060G28 FUEL PRESSURE SENSOR - R R
6LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OB, that the diesel pressure between filter and radialjet pump is between 0.6 and 0.7 bar    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 11Pressure lower than minimum limitMove on to Step 7
Pressure above the maximum limitReplace Bontaz pressure relief valve    Op. 1060G28 FUEL PRESSURE SENSOR - R R
7FILTER PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the difference in pressure upstream and downstream of the filter is less0.2 barMove on to Step 9Difference in pressure less than or equal to 1 barChange filter cartridge. Op. 1044B20 ELEMENTO FILTRANTE DEL FILTRO COMBUSTIBILE - SOST.
8LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the supply pump pressure at the filter inlet is between 0.6 and 0.7 barMove on to Step 11Pressure below 0.6 barMove on to Step 10
9LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the pressure difference between the electric pump outlet and the filter inlet is less 0.3 barMove on to Step 10Difference in pressure more than 0.3 barReplace the pipe.    Op. 1040B30 FUEL DELIVERY LINE - R R
10LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and the current uptake is between 2 and 10 Amps    See Test 1040A FUEL TANK AND COMPONENTSEnd of diagnosisVoltage < 12 VCheck wiring    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
Current > 10 Amps: Jet pump blockedChange fuel intake unit and clean tank    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
11CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Replace the high pressure pump pressure regulator and check that the fault is no longer present.    Op. 1060E50 PRESSURE REGULATOR - R REnd of diagnosisFault persistsReset the pressure regulator and continue to Step 12
12CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Replace the high pressure pump and check that the fault is no longer present.    Op. 1060E10 PRESSURE PUMP - R RFault persistsContact the Service Department for further information on the problem
Ошибка в шаблоне. В ближайшее время мы ее исправим. (Error in Templaite)
STEPOPERATIONS TO BE CARRIED OUTTEST RESULTS
0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Check the following, in order:

  • presence of fuel in the tank;
  • wiring on engine correctly fastened to earth;
  • battery correctly fastened to earth;
  • positive battery pole and all leads connected to it correctly fastened;
  • no water in the fuel filter;
  • correct operation of the anti-judder throttle
Move on to Step 1Lack of fuelRestore fuel
Fastenings slack or oxidizedRestore correct fastenings    See E1020 EARTHS
Water in the fuel tankClean the tank and pipes and replace the filter element    Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
Throttle control defectiveRestore correct operation
1CHECK USING DIAGNOSTIC EQUIPMENTALL OKPROBLEMS ENCOUNTEREDACTION
Connect the tester to the tester output.Check for errors saved in the control unit.Move on to Step 2Error detected in the control unitContinue following the instructions for the tester
2ROAD TEST USING DIAGNOSTIC EQUIPMENTALL OKPROBLEMS ENCOUNTEREDACTION
Carry out a road test by reproducing the conditions in which the fault occurs, keeping the tester connected.Check for errors saved in the control unit.Move on to Step 3Error detected in the control unitContinue following the instructions for the tester
3INJECTOR HIGH PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OC that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 4Significant leak from one injectorReplace the injector    Op. 1060F10 FUEL INJECTORS
4HIGH PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Connect the tester to the tester output.Check, as described in Test 1060OD that the diesel pressure value is correct    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 12Pressure level incorrectMove on to Step 5
5LOW RETURN PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OA that the tank return pipe pressure is less than 1 bar    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 6Pressure above the maximum limit: return pipe to the tank obstructedRepair the pipe and replace if necessary
6LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OB, that the diesel pressure between filter and radialjet pump is between 2 and 3 bar    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 12Pressure below the minimum limit or above the maximum limitMove on to Step 7
7LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Restrict the pressure regulator valve return pipe and repeat Test 1060OB with the pipe restricted, checking that the fuel outlet pressure is less than 2 bars    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 8Pressure rises to 5 bars: pressure regulator in filter mount defectiveReplace the pressure regulator    Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
8FILTER PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the pressure difference between filter upstream and downstream is less than 1 barMove on to Step 9Difference in pressure more than 1 barChange filter cartridge.    Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
9LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the supply pump pressure at the filter inlet is more than 2.2 barMove on to Step 12Pressure below 2.2 barMove on to Step 10
10LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the pressure difference between the electric pump outlet and the filter inlet is less 0.3 barMove on to Step 11Difference in pressure more than 0.3 barReplace the pipe
11LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and the current uptake is between 2 and 10 Amps    See Test 1040A FUEL TANK AND COMPONENTSEnd of diagnosisVoltage < 12 VCheck wiring    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
Current > 10 Amps: Jet pump blockedReplace the fuel intake unit    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
Current < 2 Amps: Jet pump blockedChange fuel intake unit and clean tank    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
12CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Replace the DRV high pressure regulation valve and check that the fault is no longer present    Op. 1060E50 PRESSURE REGULATOR - R REnd of diagnosisThe fault persistsReset the pressure regulator and continue to Step 13
13CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Replace the high pressure pump and check that the fault is no longer present    Op. 1060E10 PRESSURE PUMP - R REnd of diagnosisThe fault persistsContact technical service for further information on the problem
Ошибка в шаблоне. В ближайшее время мы ее исправим. (Error in Templaite)
STEPOPERATIONS TO BE CARRIED OUTTEST RESULTS
0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Check the following, in order:

  • presence of fuel in the tank;
  • wiring on engine correctly fastened to earth;
  • battery correctly fastened to earth;
  • positive battery pole and all leads connected to it correctly fastened;
  • no water in the fuel filter;
  • correct operation of the anti-judder throttle
Move on to Step 1Lack of fuelRestore fuel
Fastenings slack or oxidizedRestore correct fastenings    See E1020 EARTHS
Water in the fuel tankClean the tank and pipes and replace the filter element    Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
1CHECK USING DIAGNOSTIC EQUIPMENTALL OKPROBLEMS ENCOUNTEREDACTION
Connect the tester to the tester output.Check for errors saved in the control unit.Move on to Step 2Error detected in the control unitContinue following the instructions for the tester
2ROAD TEST USING DIAGNOSTIC EQUIPMENTALL OKPROBLEMS ENCOUNTEREDACTION
Carry out a road test by reproducing the conditions in which the fault occurs, keeping the tester connected.Check for errors saved in the control unit.Move on to Step 3Error detected in the control unitContinue following the instructions for the tester
3INJECTOR HIGH PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OC that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 4Significant leak from one injectorReplace the injector    Op. 1060F10 FUEL INJECTORS
4HIGH PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Connect the tester to the tester output.Check, as described in Test 1060OD that the diesel pressure value is correct    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 12Pressure level incorrectMove on to Step 5
5LOW RETURN PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OA that the tank return pipe pressure is less than 1 bar    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 6Pressure above the maximum limit: return pipe to the tank obstructedRepair the pipe and replace if necessary
6LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1060OB, that the diesel pressure between filter and radialjet pump is between 2 and 3 bar    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 12Pressure below the minimum limit or above the maximum limitMove on to Step 7
7LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Restrict the pressure regulator valve return pipe and repeat Test 1060OB with the pipe restricted, checking that the fuel outlet pressure is less than 2 bars    See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTSMove on to Step 8Pressure rises to 5 bars: pressure regulator in filter mount defectiveReplace the pressure regulator    Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
8FILTER PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the pressure difference between filter upstream and downstream is less than 1 barMove on to Step 9Difference in pressure more than 1 barChange filter cartridge.    Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
9LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the supply pump pressure at the filter inlet is more than 2.2 barMove on to Step 12Pressure below 2.2 barMove on to Step 10
10LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check that the pressure difference between the electric pump outlet and the filter inlet is less 0.3 barMove on to Step 11Difference in pressure more than 0.3 barReplace the pipe
11LOW SUPPLY PRESSURE CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and the current uptake is between 2 and 10 Amps    See Test 1040A FUEL TANK AND COMPONENTSEnd of diagnosisVoltage < 12 VCheck wiring    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
Current > 10 Amps: Jet pump blockedReplace the fuel intake unit    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
Current < 2 Amps: Jet pump blockedChange fuel intake unit and clean tank    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
12CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Replace the DRV high pressure regulation valve and check that the fault is no longer present    Op. 1060E50 PRESSURE REGULATOR - R REnd of diagnosisThe fault persistsReset the pressure regulator and continue to Step 13
13CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Replace the high pressure pump and check that the fault is no longer present    Op. 1060E10 PRESSURE PUMP - R REnd of diagnosisThe fault persistsContact technical service for further information on the problem