Engine does not start (starter motor working)

Make: Alfa Romeo
Model: 159 Factory Service Manual
Year: 2005–2011
Section: Starting › Engine does not start (starter motor working)

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Fault diagnosisEngine does not start (starter motor working)

ENGINE DOES NOT START (STARTER MOTOR WORKING)

1.9 JTD 8V, 1.9 JTD 16V, 2.4 JTD 20V

The customer complains of: The engine does not start, the starter motor is working normally

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Results of the tests
	Check that the engine oil level is correct Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY Check that the air intake/vacuum circuit is working properly See Test 1048OA AIR INTAKE/VACUUM CIRCUIT CHECK Check the condition of the fuel supply circuit and make sure that it is working properly See Test 1040OA FUEL SUPPLY CIRCUIT CHECK	Move on to Step 1	Oil level incorrect	Restore the correct oil level Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY
1	AMBIENT PARAMETERS CHECK	All OK	Problems encountered	Operation
	Select the following control unit at the diagnostic equipment: EDC16C39 Diesel electronic injection control unit. Check the value of the following parameters: . Battery voltage See Test 5530BB BATTERY VOLTAGE CHECK . Objective Diesel pressure . Measured Diesel pressure See Test 1060GH DIESEL FUEL PRESSURE CHECK . Engine rpm See Test 1060GI ENGINE SPEED CHECK	Move on to Step 2
2	PARTICLE FILTRATION SYSTEM CHECKS	All OK	Problems encountered	Operation
	Check that the DPF system is working properly See Test 1080BE PARTICULATE FILTER SATURATION CHECK	Move on to Step 3
3	PREHEATING RELAY ACTIVE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis for the preheating relay, checking that the result is positive. The check on the following system is only necessary if the outside temperature is below 0 °C.	Move on to Step 5	The result of the active diagnosis is negative	Move on to Step 4
4	HEATER PLUGS CHECK	All OK	Problems encountered	Operation
	Check that the heater plugs are working properly, by carrying out the See Test 5520CA GLOW PLUGS FUNCTIONAL TEST	Move on to Step 5
5	ELECTRICAL EQUIPMENT CHECK	All OK	Problems encountered	Operation
	Check that the F1 fuse has not blown (it is the last one at the bottom of the vertical row)	Move on to Step 7	Fuse F1 has blown	Restore the connections or, if necessary, replace the junction unit in the engine compartment Op. 5505A13 ADDITIONAL JUNCTION UNIT IN ENGINE COMPARTMENT - R.R.
		Move on to Step 7	Fuse F1 has blown		6	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Connect the diagnostic equipment to the diganostic socket. Check as described in the See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUIT that the diesel pressure parameter is correct	Move on to Step 14	Pressure not correct	Move on to Step 9
7	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1060OA CHECK ON RETURN LOW PRESSURE FUEL CIRCUIT that 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
	Check as described in the See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step 14	Pressure below the minimum limit or above the maximum limit	Move on to Step 9
9	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Constrict the return pipe from the pressure relief valve and carry out the test again See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT with the pipe constricted, checking that the filter outlet pressure remains below 2 bar	Move on to Step 10	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the valve See Test 1044B16
10	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 11	Difference in pressure more than 1 bar	Replace the diesel filter cartridge See Test 1044B20
11	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 14	Pressure below 2 bar	Move on to Step 12
12	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Measure the difference in pressure between the electrical pump outlet and the filter inlet checking that it is less than 0.3 bar	Move on to Step 15	Difference in pressure more than 0.3 bar	Replace the pipe
13	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the 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 14	Voltage lower than 12 V	Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current greater than 10 A: pump defective	Replace the fuel pump
			Current less than 2 A: pump obstructed	Replace the fuel pump and clean the fuel tank
14	CHECK CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the DRV high pressure 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 15
15	CHECK CORRECT OPERATION	All OK	Problems encountered	Operation
	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	Fault persists	Move on to Step 16
16	CYLINDER COMPRESSION CHECK	All OK	Problems encountered	Operation
	Carry out the cylinder compression check Op. 0520G15 COMPRESSION TEST - CHECK WITH EXAMINER WITH SPARK PLUGS/INJECTORS REMOVED	Move on to Step 18	Cylinder compression insufficient	Move on to Step 17
17	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems encountered	Operation
	Carry out Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET to check the seal of the valves. Check the condition of the cylinders/flexible bands	Move on to Step 18	Valve seal insufficient	Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
		Move on to Step 18	Cylinders/piston rings worn	Restore the seal
18	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R

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Parts & tools for this job For 2005 Alfa Romeo 159

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