| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
|---|
| Turn the key ON and check that the initial check on the MIL and VEHICLE PROTECTION warning lights takes place. | The MIL warning light should come on and then go out when the engine is started up, whilst the VEHICLE PROTECTION warning light should come on for about 4 seconds and then go out |
Then check: - that the fuel cut off has not been activated;
- presence of fuel in the tank;
- air intake circuit;
- that the filter is not blocked
- correct operation of the exhaust manifolds.
- that there are no leaks or seepage from the high and low pressure fuel pipes
| Move on to Step 1 | 1. The VEHICLE PROTECTION warning light stays on2. The MIL warning light does not carry out the initial test3. The warning lights do not carry out the initial test4. Fuel cut off activated5. Lack of fuel6. Air filter blocked7. Exhaust blocked8. Presence of leaks | 1. Proceed as instructed in theSee K052 2. Proceed as instructed in theSee K053 3. Proceed as instructed in theSee K054 METHANE PRESSURE SENSOR4. Restore correct operation by carrying out theSee Test 5. Add fuel to the tank6. Replace the filter element Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE 7. Restore correct operation.8. Eliminate leaks |
| 1 | CAN CHECK | All OK | Problems encountered | Operation |
|---|
| Connect an EXAMINER and check the following on CAN INFORMATION - No faulty control units
- No faulty CAN
| Move on to Step 2 | Presence of errors | Continue as instructed by the diagnostic equipment |
| 2 | POWER SUPPLY CHECK | All OK | Problems encountered | Operation |
|---|
| Check that the engine management control unit is receiving the correct power supply See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Check the operation of the main relay | Move on to Step 3 | 1. Supply voltge not correct2. Main relay defective | 1. Restore correct power supply2. Replace main relay |
| 3 | PREHEATING SYSTEM CHECK | All OK | Problems encountered | Operation |
|---|
| Check condition of wiring and operation of heater plugs system by carrying outSee Test | Move on to Step 4 | 1. Wiring faulty2. Heater plugs faulty3. Preheating control unit faulty | 1. Restore correct wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT 2. Replace damaged heater plugs Op. 5520C10 HEATER PLUGS - R+R 3. Replace preheating control unit Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R |
| 4 | TIMING SENSOR CHECK | All OK | Problems encountered | Operation |
|---|
| Check that the timing sensor is workingCheck the wiring continuity by carrying out the See Test 1060GC TIMING SENSOR OPERATION CHECK | Move on to Step 5 | 1. Sensor faulty2. Wiring faulty | 1. Replace timing sensor Op. 1060G22 CAM ANGLE SENSOR - R.R 2.Renew the correct wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| 5 | Rpm sensor check | All OK | Problems encountered | Operation |
|---|
| Check that the rpm sensor is workingCheck the wiring continuity by carrying out the See Test 1060GI ENGINE SPEED CHECK | Move on to Step 6 | 1. Sensor faulty2. Wiring faulty3. Phonic wheel damaged | 1. Replace the rpm sensor Op. 1060G20 ENGINE RPM SENSOR - R.R. 2. Restore correct wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT 3. Replace the flywheel and reset the parameters in the control unit using the Examiner |
| 6 | 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.Check correct operation of the diesel pressure sensor by carrying out the See Test 1060GR FUEL PRESSURE SENSOR ON RAIL OPERATION CHECK | Move on to Step 7 | 1. Pressure not correct2. Diesel pressure sensor defective3. Diesel pressure sensor wiring defective | 1. Move on to Step 72. Replace the pressure sensor Op. 1060G28 FUEL PRESSURE SENSOR ON FUEL MANIFOLD TO INJECTORS - R.R 3. Restore correct wiring. |
| 7 | Injector seal 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 8 | Significant leak from one injector | Replace the injectorOp. 1060F10 |
| 8 | 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 9 | Pressure above the maximum limit: return pipe to the tank obstructed | Repair the pipe; if necessary, replace it |
| 9 | 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 correct | Move on to Step 10 | Pressure below the minimum limit or above the maximum limit | Move on to Step 11 |
| 10 | 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 by carrying out theSee Test | Move on to Step 11 | Difference in pressure more than 1 bar | Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 11 | 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 0.5 bar | Move on to Step 12 | Difference in pressure more than 0.5 bar | Replace the pipe |
| 12 | Electric pump absorption check | All OK | Problems encountered | Operation |
|---|
| Check as described in theSee Test 1040AA that the pump supply voltage is correctCheck that the current absorbed is correct | Move on to Step 13 | 1. Voltage lower than 12 V2. Pump absorption not correct | 1. Restore correct electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT 2. Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R and clean the fuel tank |
| 13 | Correct operation check | All OK | Problems encountered | Operation |
|---|
| Using the Examiner connect to the engine management control unit and, in active diagnosis, check that the high pressure regulating valve on the rail is working properly by carrying outSee Test | Move on to Step 14 | 1. Regulation valve defective2. Valve cable defective | 1. Change valve Op. 1060G31 FUEL PRESSURE REGULATOR ON SINGLE MANIFOLD TO INJECTORS - R R 2. Restore correct wiring. |
| 14 | Check on high pressure pump 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 | Move on to Step 15 |
| 15 | Check on correct operation of engine management control unit | All OK | Problems encountered | Operation |
|---|
| Replace the engine control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R and check that the engine starts correctly | End of diagnosis | | |