939003563 - B010 ENGINE DOES NOT START (UNDER ANY CIRCUMSTANCES)

The customer complains of: The engine does not start, the starter motor turns slowly/does not turn
Results of the tests
0PRELIMINARY CHECKSAll OKProblems encounteredOperation
Turn the key ON and check that the initial check on the MIL and CODE warning lights takes place.
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 operated;- presence of fuel in the tank;- air intake circuit;- correct operation of the flow modification valve;- 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 1The CODE waring light stays onProceed as instructed    See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START)
The MIL warning light does not carry out the intial testProceed as instructed    See table K053 M.I.L. WARNING LIGHT OFF (INITIAL TEST NOT CARRIED OUT) / ENGINE DOES NOT START
The CODE warning light does not carry out the intial testProceed as instructedSee table K054 VEHICLE PROTECTION WARNING LIGHT OFF (ENGINE DOES NOT START)
The warning lights do not carry out the initial testProceed as instructed    See table K049 I.E. FAILURE WARNING LIGHT AND CODE WARNING LIGHT BOTH OFF / ENGINE DOES NOT START
Intertia switch operatedRestore correct operation
Lack of fuelAdd fuel to the tank
Filter dirty or partly blockedReplace the filter element    Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.
Flow modulation valve working incorrectlyMove on to Step 3
Exhaust blockedMove on to Step 2
Presence of leaksEliminate leaks
1ENGINE STARTING ELECTRIC CIRCUIT CHECKAll OKProblems encounteredOperation
Check that the engine starting electric circuit is working properly    See Test 5520BA ENGINE IGNITION SYSTEM CHECKMove on to Step 2
2PARTICLE FILTER SATURATION CHECKAll OKProblems encounteredOperation
Select the following control unit at the diagnostic equipment: EDC16C39 Diesel electronic injection control unit.Check the saturation level of the dust in the particle filter    See Test 1080BE PARTICULATE FILTER SATURATION CHECKMove on to Step 3
3CHECK USING DIAGNOSTIC EQUIPMENTAll OKProblems encounteredOperation
Carry out active diagnosis of flow modification valveMove on to Step 4Solenoid valve not workingCheck the wiring continuity    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Replace the solenoid valve if necessaryOp. 1060G72 SOLENOID FOR THROTTLE BODY PNEUMATIC VALVE - R.R.
4FLOW MODIFICATION VALVE ACTUATOR CHECKAll OKProblems encounteredOperation
Check operation of the pneumatic actuatorMove on to Step 5Actuator not workingReplace electro-pneumatically controlled throttle casingOp. 1060G52
5CHECK USING DIAGNOSTIC EQUIPMENTAll OKProblems encounteredOperation
Connect the diagnotsic equipment to the diagnostic socket.Check:- no errors in control unit- parameter plausibilityMove on to Step 1Error detected in the control unitContinue following the instructions for the diagnostic equipment
Parameters not plausibleContinue following the instructions for the diagnostic equipment
No communication with the control unitRestore the connection between the engine control unit and the diagnostic connector    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
6HIGH PRESSURE CHECKAll OKProblems encounteredOperation
Check    See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUITthat the diesel pressure parameter is correct.Move on to Step 17Pressure not correctMove on to Step 7
7INJECTOR HIGH PRESSURE CHECKAll OKProblems encounteredOperation
Check,    See Test 1060OC INJECTORS SEAL TEST that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another.Move on to Step 8Significant leak from one injectorReplace the injector    Op. 1060F10 FUEL INJECTORS - R.R.
8LOW RETURN PRESSURE CHECKAll OKProblems encounteredOperation
Check,    See Test 1060OA CHECK ON RETURN LOW PRESSURE FUEL CIRCUITthat the pressure in the return pipe to the tank is less than 1 barMove on to Step 9Pressure above the maximum limit: return pipe to the tank obstructedRepair the pipe, if necessary, replace it
9LOW SUPPLY PRESSURE CHECKAll OKProblems encounteredOperation
Check    See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUITthat the diesel pressure between the filter and the pressure pump is between 2 and 3 barMove on to Step 15Pressure below the minimum limit or above the maximum limitMove on to Step 10
10LOW SUPPLY PRESSURE CHECKAll OKProblems encounteredOperation
Constrict the return pipe downstream of the valve and carry out once again    See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUITwith the pipe constricted, checking that the filter outlet pressure remains below 2 barMove on to Step 11Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjustedReplace the valveSee Test 1044B16 FUEL SUPPLY/RETURN REGULATION VALVE ON FUEL FILTER - R.R.
11LOW SUPPLY PRESSURE CHECKAll OKProblems encounteredOperation
Check that the difference in pressure upstream and downstream of the filter is less than 1 barMove on to Step 12Difference in pressure more than 1 barReplace the fuel filter cartridgeSee Test 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
12LOW SUPPLY PRESSURE CHECKAll OKProblems encounteredOperation
Check that the supply pump pressure at the filter inlet is more than 2.2 barMove on to Step 15Pressure below 2,2 barMove on to Step 13
13LOW SUPPLY PRESSURE CHECKAll OKProblems encounteredOperation
Measure the difference in pressure between the electric pump outlet and the filter inlet and check that it is less than 0.3 barMove on to Step 14Difference in pressure more than 0.3 barReplace the pipe
14LOW SUPPLY PRESSURE CHECKAll OKProblems encounteredOperation
Check    See Test 1040AA SUPPLY VOLTAGE AND ABSORPTION CURRENT CHECKS that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 AMove on to Step 15Voltage lower than 12 VRenew electrical wiring    See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
Current greater than 10 A: pump defectiveReplace the fuel pump    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
Current less than 2 A: pump obstructedReplace the fuel pump    Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R and clean the fuel tank
15CHECK ON CORRECT OPERATIONAll OKProblems encounteredOperation
Replace the DRV high pressure regulating valve    Op. 1060E50 PRESSURE REGULATOR ON PRESSURE PUMP - R.R. and check that the fault is no longer present.End of diagnosisFault persistsMove on to Step 16
16CHECK ON CORRECT OPERATIONAll OKProblems encounteredOperation
Replace the pressure pump    Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer presentEnd of diagnosisFault persistsContact technical service for further information on the problem
17CHECK ON CORRECT OPERATIONAll OKProblems encounteredOperation
Replace the engine management control unit    Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R and check that the fault is no longer presentEnd of diagnosisFault persistsContact technical service for further information on the problem