| | Test results |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
|---|
| Check:- That the air intake/vacuum circuit is working properly.- Air filter blocked.- Ducts blocked.- Leaks from intake ducts after the compressor.- Fuel leaks. | Move on to Step 1. | 1. Air intake circuit ducts blocked.2. Filter blocked and water, petrol, paraffin or dirt found to be present.3. Fuel leaks. | 1. Renew the air intake circuit.2. Water, petrol, paraffin or dirt found to be present.3. Restore the fuel system seal. |
| 1 | CHECK USING DIAGNOSTIC EQUIPMENT | All OK | Problems encountered | Operation |
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| Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket and check that there are no errors present in the control unit. | End of diagnosis. | Presence of errors in control unit. | Continue following the instructions for the diagnostic equipment. |
| 2 | EGR VALVE CHECK | All OK | Problems encountered | Operation |
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| Check that the EGR solenoid valve is not stuck open.Check that the EGR valve is working properly by carrying out active diagnosis using the Examiner and checking that the valve does not remain open. See Test 1080CB EGR SOLENOID OPERATION CHECK | Move on to Step 3. | Solenoid valve not working. | Check the continuity of the wiring. See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT replace the solenoid if necessary. |
| 3 | DIESEL HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECKthat the high pressure value is correct | Move on to Step 7. | Pressure not correct. | Move on to Step 4. |
| 4 | DIESEL LOW PRESSURE CHECK | All OK | Problems encountered | Operation |
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| Check See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECKthat the high pressure value is correct | Move on to Step 5. | Pressure not correct. | Move on to Step 6. |
| 5 | FUEL PUMP CHECK | All OK | Problems encountered | Operation |
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| Using the Examiner check that the fuel pump demand is correct. See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKE | Move on to Step 6. | Electric pump defective. | Replace the electric pump. Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R |
| 6 | DIESEL PRESSURE SENSOR ON RAIL CHECK | All OK | Problems encountered | Operation |
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| Check correct operation of the pressure sensor on the rail. See Test 1060GE CHECK ON OPERATION OF DIESEL HIGH PRESSURE SENSOR | Move on to Step 7. | 1. Regulator wiring defective.2. Pressure sensor defective. | 1.Restore the correct wiring2. Replace pressure sensor. Op. 1060G28 FUEL PRESSURE SENSOR ON FUEL MANIFOLD TO INJECTORS - R.R |
| 7 | FLOW METER CHECK | All OK | Problems encountered | Operation |
|---|
| Check the continuity of the wiring between the engine management control unit and the flow meter.- Check that the flow meter is receiving the correct power supply. See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Check that the flow meter signal is correct using the Examiner. See Test 1060GS FLOW METER OPERATION CHECK | Move on to Step 8. | 1.Debimeter signal incorrect.2.Wiring between flow meter and engine management control unit broken.3.Power supply interrupted | 1.Replace debimeter. Op. 1060G10 AIR FLOW METER - R.R. 2.Restore correct wiring.3.Restore correct power supply. |
| 8 | INJECTOR CHECK | All OK | Problems encountered | Operation |
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| Check See Test 1060OC INJECTOR SEAL TESTthat the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another.- Check that the injectors are working properly by connecting to the engine management control unit in active diagnosis | Move on to Step 9. | 1. Injector with leaks/poor atomization.2. Check the continuity of the wiring between the engine management control unit and the injectors. | 1. Replace the injector. Op. 1060F10 FUEL INJECTORS - R.R. 2. Restore wiring continuity |
| 9 | ENGINE CONTROL UNIT OPERATION CHECK | All OK | Problems encountered | Operation |
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| Replace the engine management control unit. Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R and check that the fault is no longer present | End of diagnosis. | The fault persists. | Move on to Step 10. |
| 10 | HIGH PRESSURE PUMP CORRECT OPERATION CHECK | All OK | Problems encountered | Operation |
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| Replace the high 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 11. |
| 11 | CYLINDER COMPRESSION CHECK | All OK | Problems encountered | Operation |
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| Carry out the cylinder compression check. Op. 0510A10 CYLINDER COMPRESSION - CHECK FOR LOOSE SPARK PLUGS OR INJECTORS | End of diagnosis. | Cylinder compression insufficient. | Move on to Step 12. |
| 12 | CAUSE OF INSUFFICIENT COMPRESSION CHECK | All OK | Problems encountered | Operation |
|---|
| - Carry out Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET to check the valve seal.- Check condition of cylinders/piston rings. | End of diagnosis. | 1. Valve seal insufficient.2. Cylinder geometry/dimensions faulty.3. Piston rings faulty. | 1. Overhaul the cylinder head. Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL 2. Restore correct operation.3. Restore correct operation. |
