| | Test results |
| 0 | Preliminary checks | All OK | Problems encountered | Operation |
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| Turn the key to MAR and make sure that the initial check on the MIL and CODE warning lights takes place.Note: The MIL warning light should come on and then go out when the engine is started up, whilst the CODE warning light should come on for about 4 seconds and then go out.Then check:- that the inertia switch has not been activated; - that there is 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 CODE warning light stays on.2.The MIL warning light does not carry out the intial test.3. The CODE warning light does not carry out the intial test.4.Inertia switch operated.5.No fuel.6. Air filter blocked.7.Drainage blocked.8.Presence of leaks. | 1.Proceed as instructed. See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START) 2.Proceed as instructed. See table K053 M.I.L. WARNING LIGHT OFF (INITIAL TEST NOT CARRIED OUT) / ENGINE DOES NOT START3.Proceed as instructed. See table K054 VEHICLE PROTECTION WARNING LIGHT OFF (ENGINE DOES NOT START)4. Restore correct operation.5. Add fuel to the tank.6.Replace the filter element. Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE. 7. Restore operation.8.Eliminate leaks. |
| 1 | POWER SUPPLY CHECK | All OK | Problems encountered | Operation |
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| -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 2. | 1.Supply voltge not correct2. Main relay defective | 1. Restore correct power supply.2. Replace main relay. |
| 2 | PREHEATING SYSTEM CHECK | All OK | Problems encountered | Operation |
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| Check condition of wiring and operation of heater plugs system by carrying out Test_5520CB | Move on to Step 3. | 1.Wiring faulty2.Heater plugs faulty3.Preheating control unit faulty | 1.Renew the 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 |
| 3 | Rpm sensor check | All OK | Problems encountered | Operation |
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| Check that the rpm sensor is working See Test 1060GI ENGINE SPEED CHECKCheck the wiring continuity | Move on to Step 4. | 1.Sensor faulty2. Wiring faulty.3.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 phonic wheel and reset the parameters in the control unit using the Examiner. |
| 4 | Check using diagnostic equipment | All OK | Problems encountered | Operation |
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| Connect the diagnostic equipment to the diagnostic socket.Check:that there are no errors in the control unit; parameter plausibility | Move on to Step 6. | 1. Error detected in the control unit.2. Parameters not plausible.3. No communication with the control unit. | 1. Continue following the instructions on the diagnostic equipment2. Continue following the instructions on the diagnostic equipment3. Restore the connection between the engine control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT and move on to Step 5. |
| 5 | High pressure check | All OK | Problems encountered | Operation |
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| Check, as described, See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECKthat the diesel pressure parameter is correct.Check correct operation of the diesel pressure sensor. See Test 1060GE CHECK ON OPERATION OF DIESEL HIGH PRESSURE SENSOR | Move on to Step 6. | 1. Pressure not correct.2. Diesel pressure sensor defective.3. Diesel pressure sensor wiring defective. | 1. Move on to Step 7.2. Replace the pressure sensor.3. Restore correct wiring. |
| 6 | Injector seal check | All OK | Problems encountered | Operation |
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| Check, as described 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 7. | Significant leak from one injector. | Replace the injector. Op. 1060F10 FUEL INJECTORS - R.R. |
| 7 | 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 8. | Pressure above the maximum limit: return pipe to the tank obstructed. | Repair the pipe; if necessary, replace it. |
| 8 | Low supply pressure check | All OK | Problems encountered | Operation |
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| Check, as described, See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECKthat the diesel pressure between the filter and the pressure pump is between 4.5 and 6 bar. | Move on to Step 9. | Pressure below the minimum limit or above the maximum limit. | Move on to Step 13. |
| 9 | 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 10. | Difference in pressure more than 1 bar. | Replace the fuel filter cartridge. Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE |
| 10 | Low supply pressure check | All OK | Problems encountered | Operation |
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| Check that the supply pump pressure at the filter inlet is not less than 0.3 bar. | Move on to Step 11. | Pressure below 4.5 bar. | Move on to Step 16. |
| 11 | 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 less than 0.3 bar. | Move on to Step 12. | Difference in pressure more than 0.3 bar. | Replace the pipe. |
| 12 | Electric pump uptake check | All OK | Problems encountered | Operation |
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| Check, as described, See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKEthat the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A. | Move on to Step 13. | 1. Voltage below 1.2. V2. Current greater than 10 A: pump defective.3. Current less than 2 A: pump obstructed. | 1. Renew 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 3. 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 |
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| 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 out Test_1060GV | Move on to Step 14. | 1. Regulation valve defective.2. Valve wiring defective. | 1. Replace valve. Op. 1060G28 FUEL PRESSURE SENSOR ON FUEL MANIFOLD TO INJECTORS - R.R 2. Restore correct wiring. |
| 14 | Correct operation check | All OK | Problems encountered | Operation |
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| Using the Examiner, connect to the engine management control unit and, in active diagnosis, check that the high pressure MPROP regulating valve is working properly by carrying out Test_1060EC | Move on to Step 15. | 1. Regulator wiring defective.2. Regulator defective. | 1. Repair wiring.2. Replace pump. Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. |
| 15 | Check on high pressure pump operation | All OK | Problems encountered | Operation |
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| 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 16. |
| 16 | Check on correct operation of engine management control unit | 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 engine starts correctly. | End of diagnosis. | | |