| STEP | OPERATIONS TO BE CARRIED OUT | TEST RESULTS |
|---|
| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check the following, in order:- no water, other fluids or dirt in the fuel filter
- no water, other fluids or dirt in the fuel tank
- no obstructions in the catalytic converter
| Move on to Step 1 | Water, other fluids or dirt in the fuel filter | Replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE |
| Water, other fluids or dirt in the tank | Clean tank |
| Catalytic converter obstructed | Replace the catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R |
| 1 | CHECK USING DIAGNOSTIC EQUIPMENT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Connect the diagnostic equipment to the diagnostic socket.Re-create the conditions under which the fault occurs and check:- that there are no errors in the control unit;
- parameter plausibility
| Move on to Step 2 | Errors detected in 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 correct connections 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 1060OD, that the diesel pressure parameter is correct. See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS | Move on to Step 9 | 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 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 |
| 4 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check that the diesel pressure between the filter and the radial jet pump is between 0.6 and 0.7 bar | Move on to Step 9 | Pressure lower than minimum limit | Move on to Step 5 |
| Pressure above the maximum limit | Replace Bontaz pressure relief valve Op. 1060G28 FUEL PRESSURE SENSOR - R R |
| 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 0.2 bar | Move on to Step 6 | Difference in pressure more than 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 between 0.6 and 0.7 bar | Move on to Step 9 | Pressure below 0.6 bar | Move on to Step 8 |
| 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 Op. 1040B30 FUEL DELIVERY LINE - R R |
| 8 | CHECK LOW OUTLET PRESURE PUMP UPTAKE | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 volt 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 | Change fuel pump assembly and clean tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R |
| 9 | CHECK ON CORRECT OPERATION | 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 | Fault persists | Renew the pressure regulator and move on to Step 10 |
| 10 | 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 | Fault persists: control unit defective | Restore the 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 |
|---|
| Check the following, in order:- no water, other fluids or dirt in the fuel filter
- no water, other fluids or dirt in the fuel tank
- no obstructions in the catalytic converter
| Move on to Step 1 | Water, other fluids or dirt in the fuel filter | Replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE |
| Water, other fluids or dirt in the fuel tank | Clean tank |
| Catalytic converter obstructed | Replace the catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R |
| 1 | CHECK USING DIAGNOSTIC EQUIPMENT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Connect the diagnostic equipment to the diagnostic socket.Re-create the conditions under which the fault occurs and check:- no errors in control unit
- parameter plausibility
| Move on to Step 2 | Errors detected in 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 correct connections 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 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 that the diesel pressure between the filter and the radial jet pump is between 2and 3 bar | 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 the valve Op. 1044B16 DELIVERY ADJUSTMENT VALVE - R R |
| 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 | LOW SUPPLY PRESSURE CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 volt 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 jet blocked | Change fuel pump assembly and clean 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 | Fault persists | Repair 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 | Fault persists: control unit defective | Repair the pump and replace the engine management control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R |