| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
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| Check:- that the level of the oil is correct- the condition of the air intake/vacuum circuit - the condition of the fuel supply circuit and that it is working properly- Battery earth lead connection. | Move on to Step 1. | 1. Oil level incorrect.2. Fault in the air intake circuit.3. Leaks from the diesel pipes.4. Filter blocked.5. Water, petrol, paraffin or dirt found to be present.6. Battery earth lead slack/oxidized. | 1. Restore the correct engine oil level. Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY 2. Renew the air intake circuit.3. Adjust pipe tightness to correct setting and replace if necessary.4. Replace the diesel filter cartridge.5. Clean the tank and pipes and replace the diesel filter cartridge.6. Restore the battery earth lead connection. |
| 1 | CHECK USING DIAGNOSTIC EQUIPMENT | All OK | Problems encountered | Operation |
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| Connect the Examiner diagnostic equipment to the diagnostic socket and select the engine management control unit. Check the value of the following parameters:- Battery voltage.- Measured Diesel pressure.- Target Diesel pressure.- Correct operation of the diesel preheating system. | Move on to Step 2. | 1. Battery voltage low.2. The pressure measured does not correspond to the target figure.3. Heater plugs circuit faulty. | 1. Recharge and, if necessary, replace the battery.2. Move on to Step 3.3. Move on to Step 2. |
| 2 | PREHEATING SYSTEM CHECK | All OK | Problems encountered | Operation |
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| - Carry out the active diagnosis for the diesel preheating relay, checking that the result is positive.- Check that the heater plugs and the preheating system are working properly by carrying out Test_5520CB | Move on to Step 3. | 1. Preheating wiring faulty.2. Preheating control unit defective.3. Heater plugs faulty. | 1.Renew the correct wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT 2.Replace preheating control unit Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R 3. Replace defective heater plugs Op. 5520C10 HEATER PLUGS - R+R |
| 3 | HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check, as described, See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECKthat the diesel pressure parameter is correct. | Move on to Step 11. | Pressure not correct. | Move on to Step 4. |
| 4 | LOW RETURN PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check, as described, 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 and replace if necessary. |
| 5 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check, as described, See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECKcheck that the diesel pressure between the filter and the low pressure pump is between 4.5 and 6 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 |
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| 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 diesel filter cartridge. Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 7 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check that the supply pump pressure at the filter inlet is less than 4.5 bar. | Move on to Step 8. | Pressure below 4.5 bar. | Move on to Step 15. |
| 8 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Measure the difference in pressure between the electric pump outlet and the filter inlet and check that it is more than 0.5 bar. | Move on to Step 9. | Difference in pressure more than 0.5 bar. | Replace the pipe. |
| 9 | PUMP SUPPLY VOLTAGE CHECK | All OK | Problems encountered | Operation |
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| Check, as described, See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKEthat pump supply voltage is equal to 13V and that current uptake is less than or equal to 4.6 Amps. | Move on to Step 10. | Current greater than 4.6 Amps: pump defective. | Replace the fuel pump assembly. Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R |
| 10 | CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
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| Connect to the engine control unit in active diagnosis and check that the high pressure pump regulator is working properlyby carrying out Test_1060EC | Move on to Step 11. | 1.Pressure regulator defective2.Regulator wiring defective | 1.Replace the high pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. 2.Restore correct wiring. |
| 11 | CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
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| Replace the pressure pump and check that the fault is no longer present. | End of diagnosis. | The fault persists. | Move on to Step 12. |
| 12 | CYLINDER COMPRESSION CHECK | All OK | Problems encountered | Operation |
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| Carry out the cylinder compression check. | Move on to Step 14. | Cylinder compression insufficient. | Move on to Step 13. |
| 13 | CAUSE OF INSUFFICIENT COMPRESSION CHECK | All OK | Problems encountered | Operation |
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| R.R. the head to check the valve seal. Check the condition of the cylinders/piston rings. | Move on to Step 14. | 1. Valve seal insufficient.2. Cylinders/piston rings worn. | 1. Overhaul the head.2 . Restore the correct seal. |
| 14 | CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
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| Check that the fault is no longer present. | End of diagnosis. | The fault persists. | Replace the engine management control unit. Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R |
