First, check:

• condition of the air filter;
• the condition of the air intake circuit;
• that there are no obstructions in the exhaust pipe
• Check that the brakes do not offer resistance to the wheels

1. Obstruction in the air intake circuit

2. Air intake via the inlet manifold/throttle body

3. Exhaust pipe blocked

4. Wheels braked

1. Eliminate the obstruction; if necessary, replace the filter element

Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.

2. Restore the correct seal.

3. Restore the operation of the exhaust pipe.

4. Restore the correct operation of the braking system

Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket and check:

• no faults in the engine management control unit;
• parameter plausibility

1. Error detected in the control unit

2. Parameter not consistent

1. Continue following the instructions on the diagnostic equipment

2. Continue following the instructions on the diagnostic equipment

Check that the fuel supply pressure is correct by carrying out

See Test 1056BY FUEL SYSTEM SUPPLY PRESSURE CHECK

1. Fuel pressure too low: pipes obstructed

2. Fuel pressure too low: pump defective

1. Eliminate the constrictions

2. Replace the pump assembly

Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R

Inspect the spark plugs and check that they are working properly

Check the operation of the ignition coils by carrying out

See Test 5510CI IGNITION COIL OPERATION CHECK

, the

See Test 5510CE IGNITION CONTROL SIGNAL CHECK

and the

See Test 5510OA IGNITION COIL RESISTANCE CHECK

1. Spark plugs defective

2. Coil defective

1. Replace spark plugs

Op. 5510D10 SPARK PLUGS - R+R

2. Replace coils

Op. 5510C14 IGNITION COIL/S - R.R.

1. Connection defective

2. Wiring defective

3. Detonation sensor defective

1. Restore correct connection.

2. Restore the correct wiring.

3. Replace the knock sensor

Op. 5510C42 DETONATION SENSOR (SINGLE) - R.R.

- Check that the air pressure/temperature sensor is working properly by carrying out the

See Test 1056BU ASPIRATED AIR TEMPERATURE SENSOR OPERATION CHECK

Check the continuity of the wiring between the sensor and the engine control unit

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Sensor defective

2. Wiring broken

1. Replace the sensor

Op. 1056B54 INTAKE AIR PRESSURE/TEMPERATURE SENSOR - R.R.

2. Restore the correct wiring continuity.

Check that the injectors are working properly

Check that the injector needle seal is correct

1. Injector stuck/incorrectly adjusted

2. Connections not correct

1. Replace the injector

Op. 1056B70 INJECTOR (ONE) - R + R WITH FUEL MANIFOLD PIPE REMOVED - INCLUDES SEAL REPLACEMNT

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the sensor operates correctly by carrying out

See Test 1056BC ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK

1. Temperature sensor defective

2. Connections not correct

1. Replace the temperature sensor

Op. 1056B50

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the accelerator pedal is working correctly

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Accelerator pedal potentiometer defective

2. Connections not correct

1. Replace the accelerator pedal

Op. 1068A14

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the motorized throttle is working properly, carrying out

See Test 1056BW THROTTLE BODY ACTUATOR OPERATION CHECK

1. Motorized throttle defective

2. Connections not correct

1. Replace the motorized throttle

Op. 1056B14

2.Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the phase transformer is working properly by carrying out the

See Test

Check the continuity of the wiring between the engine control unit and the phase transformer solenoid

Check phase transformer solenoid by carrying out the

See Test

1. Variable valve timing defective

2. Wiring broken

3. Phase transformer solenoid defective

1. Replace the variable valve timing

Op. 1036B39 PHASE TRANSFORMER ON CAMSHAFT IN CYLINDER HEAD - R.R.

2. Restore wiring

3. Replace the solenoid

Op. 1056B48 PHASE TRANSFORMER ELECTROMAGNET - R.R.

Carry out the cylinder compression check

Op. 0520G15

R.R. head

Op. 1016C11 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET ON VERSIONS WITH AIR CONDITIONING

to check the valve seal.

Check condition of cylinders/piston rings

1. Valve seal insufficient

2. Cylinders/piston rings worn

1. Overhaul the head

Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

2. Restore the correct seal.

Replace the engine management control unit

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

First, check:

• condition of the air filter;
• the condition of the air intake circuit;
• that there are no obstructions in the exhaust pipe
• Check that the brakes do not offer resistance to the wheels

1. Obstruction in the air intake circuit

2. Air intake via the inlet manifold/throttle body

3. Exhaust pipe blocked

4. Wheels braked

1. Eliminate the obstruction; if necessary, replace the filter element

Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.

2. Restore the correct seal.

3. Restore the operation of the exhaust pipe.

4. Restore the correct operation of the braking system.

Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket and check:

• no faults in the engine management control unit;
• parameter plausibility

1. Error detected in the control unit

2. Parameter not consistent

1. Continue following the instructions on the diagnostic equipment

2. Continue following the instructions on the diagnostic equipment

Check the fuel supply pressure by carrying out

See Test 1056BY FUEL SYSTEM SUPPLY PRESSURE CHECK

1. Fuel pressure too low: pipes obstructed

2. Fuel pressure too low: pump defective

1. Eliminate the constrictions

2. Replace the pump assembly

Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R

Inspect the spark plugs and check that they are working properly Check the operation of the ignition coils by carrying out the

See Test 5510CE IGNITION CONTROL SIGNAL CHECK

,

See Test 5510CI IGNITION COIL OPERATION CHECK

and the

See Test 5510OB IGNITION COIL RESISTANCE CHECK

1. Spark plugs defective

2. Coil defective

1. Replace spark plugs

Op. 5510D10 SPARK PLUGS - R+R

2. Replace coils

Op. 5510C14 IGNITION COIL/S - R.R.

1. Connection defective.

2. Wiring defective.

3. Detonation sensor defective.

1. Restore correct connection.

2. Restore the correct wiring.

3. Replace the knock sensor

Op. 5510C42 DETONATION SENSOR (SINGLE) - R.R.

- Check that the air pressure/temperature sensor is working properly by carrying out the

See Test 1056BU ASPIRATED AIR TEMPERATURE SENSOR OPERATION CHECK

Check the continuity of the wiring between the sensor and the engine control unit

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Sensor defective

2. Wiring broken

1. Replace the sensor

Op. 1056B54 INTAKE AIR PRESSURE/TEMPERATURE SENSOR - R.R.

2. Restore the correct wiring continuity.

Check that the injectors are working correctly

Check that the injector needle seal is correct by carrying out the

See Test 1056BA INJECTOR OPERATION CHECK

1. Injector stuck/incorrectly adjusted

2. Connections not correct

1. Replace the injector

Op. 1056B70 INJECTOR (ONE) - R + R WITH FUEL MANIFOLD PIPE REMOVED - INCLUDES SEAL REPLACEMNT

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the sensor operates correctly by carrying out

See Test 1056BC ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK

1. Temperature sensor defective

2. Connections not correct

1. Replace the sensor

Op. 1056B50

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the accelerator pedal is working correctly

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Accelerator pedal potentiometer defective

2. Connections not correct

1. Replace the accelerator pedal

Op. 1068A14

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the motorized throttle is working properly, carrying out

See Test 1056BW THROTTLE BODY ACTUATOR OPERATION CHECK

1. Motorized throttle defective

2. Connections not correct

1. Replace the motorized throttle

Op. 1056B14

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Carry out the cylinder compression check

Op. 0520G15

R.R. head

Op. 1016C11 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET ON VERSIONS WITH AIR CONDITIONING

to check the valve seal.

Check condition of cylinders/piston rings

1. Valve seal insufficient

2. Cylinders/piston rings worn

1. Overhaul the head

Op. 1016E20 CYLINDER HEAD (ONE), LEFT OR RIGHT, REMOVED - OVERHAUL

2. Restore the correct seal.

Replace the engine management control unit

Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

Check that the air intake/vacuum circuit is working properly.

Check for leaks from the inlet ducts after the compressor.

Check for any fuel leaks from the pipes

1. Leaks from the air intake circuit

2. Fuel leaks from the pipes

1. Restore the seal on the air intake system.

2. Restore the seal for the pipes

Check correct operation of the timing sensor by carrying out

See Test 1060GC TIMING SENSOR OPERATION CHECK

Replace the timing sensor

Op. 1060G22 CAM ANGLE SENSOR - R.R

Check by connecting to the engine management control unit using the Examiner that the accelerator pedal sensor is working properly by carrying out

See Test 1068AC ACCELERATOR PEDAL CHECKS

Replace the accelerator pedal

Op. 1068A20 ACCELERATOR PEDAL WITH BUILT-IN POTENTIOMETER - R.R

Check that the EGR valve is not stuck open by carrying out

See Test 1080CB

Replace EGR valve

Op. 1080C82 E.G.R. - VALVE HEAT EXCHANGER ASSEMBLY - CONNECTOR PIPES - R.R.

Using the Examiner carry out the active diagnosis for the turbocharger regulating valve.

Check the operation of the turbo pressure control valve

See Test 1064BB TURBOCHARGING PRESSURE SOLENOID (PIERBURG) VALVE OPERATION CHECK

Check the maximum turbocharger supercharging pressure by carrying out

See Test 1064BA TURBOCHARGING PRESSURE CHECK

1. Solenoid not working

2. Fuse blown

3. Turbine control actuator not working properly

4. Vacuum circuit defective

1. Restore the wiring continuity

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

Replace the solenoid if necessary

Op. 1064B42 SOLENOID CONTROLLING TURBOCHARGER VANE POSITION ACTUATOR - R.R

2. Replace the fuse after having identified what caused it to blow

3. Change the turbocharger

Op. 1064A11 TURBOCHARGER WITH CATALYTIC CONVERTER - R.R.

4. Restore the vacuum circuit

1. Brake pedal does not return

2. Switch stuck closed

3. Wiring short circuited

Eliminate the cause of the sticking

Replace the switch

Op. 5550D10 BRAKE LIGHT SWITCH - R+R

Restore correct insulation

See E2021 BRAKE LIGHTS

Check that the injectors are not leaking

See Test 1060OC INJECTOR SEAL TEST

Replace the injectors

Op. 1060F10

Check that the flow meter is working properly, carrying out

See Test 1060GS FLOW METER OPERATION CHECK

(checking that the flow meter signal is not too low)

Replace the flow meter

Op. 1060G10 AIR FLOW METER - R.R.

Connect an Examiner to the engine control unit

Check, as described,

See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK

that the diesel pressure parameter is correct

Check that the pressure in the return pipe to the tank is correct

See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK

Check, as described,

See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK

that the diesel pressure is correct

Check that the difference in pressure upstream and downstream of the filter is less than 1 bar by carrying out

See Test

Replace the fuel filter cartridge

Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE

Check that the pump supply voltage is correct Check that the current absorbed by the pump is correct by carrying out

See Test 1040AA

1. Voltage lower than 12 V

2. Current greater than 10 A: pump defective

3. Current less than 2 A: pump obstructed

1. Check 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

Replace the high pressure pump

Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R.

If the previous checks have not given any results

Replace the engine control unit

Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R

Check that the air intake/vacuum circuit is working properly.

Check for leaks from the intake manifolds after the compressor.

Check for possible fuel leaks from the pipes

1. Leaks from the air intake circuit

2. Fuel leaks from the pipes

1. Restore the seal on the air intake system.

2. Restore the seal for the pipes

Check that there are no errors by connecting to the engine management control unit using the Examiner

Check for possible DPF blockage

1. Presence of errors

2. DPF blocked

1. Continue as instructed by the diagnostic equipment.

2. Continue as instructed by the diagnostic equipment.

Check correct operation of the timing sensor by carrying out

See Test 1060GC TIMING SENSOR OPERATION CHECK

Replace the timing sensor

Op. 1060G22 CAM ANGLE SENSOR - R.R

Check by connecting to the engine management control unit using the Examiner that the accelerator pedal sensor is working properly by carrying out

See Test 1068AC ACCELERATOR PEDAL CHECKS

Replace the accelerator pedal

Op. 1068A20 ACCELERATOR PEDAL WITH BUILT-IN POTENTIOMETER - R.R

Check that the EGR valve is not stuck open by carrying out

See Test 1080CB

Replace EGR valve

Op. 1080C82 E.G.R. - VALVE HEAT EXCHANGER ASSEMBLY - CONNECTOR PIPES - R.R.

Using the Examiner carry out the active diagnosis of the turbocharger regulating solenoid valve.

Check the operation of the turbo pressure solenoid valve

See Test 1064BB TURBOCHARGING PRESSURE SOLENOID (PIERBURG) VALVE OPERATION CHECK

Check the maximum turbocharger supercharging pressure by carrying out

See Test 1064BA TURBOCHARGING PRESSURE CHECK

1. Solenoid not working

2. Fuse blown

3. Turbine control actuator not working properly

4. Vacuum circuit defective

1. Restore the wiring continuity

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

Replace the solenoid if necessary

Op. 1064B42

2. Replace the fuse after having identified what caused it to blow

3. Change the turbocharger

Op. 1064A11 TURBOCHARGER WITH CATALYTIC CONVERTER - R.R.

4. Restore vacuum circuit

1. Brake pedal does not return

2. Switch stuck closed

3. Wiring short circuited

Eliminate the cause of the sticking

Replace the switch

Op. 5550D10 BRAKE LIGHT SWITCH - R+R

Restore correct insulation

See E2021 BRAKE LIGHTS

Check that the injectors are correctly sealed.

See Test 1060OC INJECTOR SEAL TEST

Replace the injectors

Op. 1060F10

Check that the flow meter is working properly, carrying out

See Test 1060GS FLOW METER OPERATION CHECK

(checking that the flow meter signal is not too low)

Replace the flow meter

Op. 1060G10 AIR FLOW METER - R.R.

Connect the Examiner to the engine control unit

Check, as described,

See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK

that the diesel pressure parameter is correct

Check that the pressure in the return pipe to the tank is correct

See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK

Check, as described,

See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK

that the diesel pressure is correct

Check that the difference in pressure upstream and downstream of the filter is less than 1 bar by carrying out

See Test

Replace the fuel filter cartridge

Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE

Check that the pump supply voltage is correct. Check that the current absorbed by the pump is correct by carrying out

See Test 1040AA

1. Voltage lower than 12 V

2. Current greater than 10 A: pump defective

3. Current less than 2 A: pump obstructed

1. Check 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

Replace the high pressure pump

Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R.

If the previous checks have not provided a result

Replace the engine control unit

Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R