| | Results of the tests |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
|---|
| 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 1 | The CODE waring light stays on | Proceed as instructed See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START) |
| The MIL warning light does not carry out the intial test | Proceed 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 test | Proceed as instructedSee table K054 VEHICLE PROTECTION WARNING LIGHT OFF (ENGINE DOES NOT START) |
| The warning lights do not carry out the initial test | Proceed as instructed See table K049 I.E. FAILURE WARNING LIGHT AND CODE WARNING LIGHT BOTH OFF / ENGINE DOES NOT START |
| Intertia switch operated | Restore correct operation |
| Lack of fuel | Add fuel to the tank |
| Filter dirty or partly blocked | Replace the filter element Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE. |
| Flow modulation valve working incorrectly | Move on to Step 3 |
| Exhaust blocked | Move on to Step 2 |
| Presence of leaks | Eliminate leaks |
| 1 | ENGINE STARTING ELECTRIC CIRCUIT CHECK | All OK | Problems encountered | Operation |
|---|
| Check that the engine starting electric circuit is working properly See Test 5520BA ENGINE IGNITION SYSTEM CHECK | Move on to Step 2 | | |
| 2 | PARTICLE FILTER SATURATION CHECK | All OK | Problems encountered | Operation |
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| 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 CHECK | Move on to Step 3 | | |
| 3 | CHECK USING DIAGNOSTIC EQUIPMENT | All OK | Problems encountered | Operation |
|---|
| Carry out active diagnosis of flow modification valve | Move on to Step 4 | Solenoid valve not working | Check the wiring continuity See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Replace the solenoid valve if necessaryOp. 1060G72 SOLENOID FOR THROTTLE BODY PNEUMATIC VALVE - R.R. |
| 4 | FLOW MODIFICATION VALVE ACTUATOR CHECK | All OK | Problems encountered | Operation |
|---|
| Check operation of the pneumatic actuator | Move on to Step 5 | Actuator not working | Replace electro-pneumatically controlled throttle casingOp. 1060G52 |
| 5 | CHECK USING DIAGNOSTIC EQUIPMENT | All OK | Problems encountered | Operation |
|---|
| Connect the diagnotsic equipment to the diagnostic socket.Check:- no errors in control unit- parameter plausibility | Move on to Step 1 | Error detected in the control unit | Continue following the instructions for the diagnostic equipment |
| Parameters not plausible | Continue following the instructions for the diagnostic equipment |
| No communication with the control unit | Restore the connection between the engine control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| 6 | HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUITthat the diesel pressure parameter is correct. | Move on to Step 17 | Pressure not correct | Move on to Step 7 |
| 7 | INJECTOR HIGH PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| 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 8 | Significant leak from one injector | Replace the injector Op. 1060F10 FUEL INJECTORS - R.R. |
| 8 | LOW RETURN PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check, See Test 1060OA CHECK ON RETURN LOW PRESSURE FUEL CIRCUITthat 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 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 bar | Move on to Step 15 | Pressure below the minimum limit or above the maximum limit | Move on to Step 10 |
| 10 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| 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 bar | Move on to Step 11 | Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted | Replace the valveSee Test 1044B16 FUEL SUPPLY/RETURN REGULATION VALVE ON FUEL FILTER - R.R. |
| 11 | 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 | Move on to Step 12 | Difference in pressure more than 1 bar | Replace the fuel filter cartridgeSee Test 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE |
| 12 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| Check that the supply pump pressure at the filter inlet is more than 2.2 bar | Move on to Step 15 | Pressure below 2,2 bar | Move on to Step 13 |
| 13 | 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 0.3 bar | Move on to Step 14 | Difference in pressure more than 0.3 bar | Replace the pipe |
| 14 | LOW SUPPLY PRESSURE CHECK | All OK | Problems encountered | Operation |
|---|
| 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 A | Move on to Step 15 | Voltage lower than 12 V | Renew electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT |
| Current greater than 10 A: pump defective | Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R |
| Current less than 2 A: pump obstructed | Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R and clean the fuel tank |
| 15 | CHECK ON CORRECT OPERATION | All OK | Problems encountered | Operation |
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| 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 diagnosis | Fault persists | Move on to Step 16 |
| 16 | CHECK ON CORRECT 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 | Fault persists | Contact technical service for further information on the problem |
| 17 | CHECK ON CORRECT OPERATION | All OK | Problems encountered | Operation |
|---|
| Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R and check that the fault is no longer present | End of diagnosis | Fault persists | Contact technical service for further information on the problem |