First, check:

• eaks from the manifold gasket;
• leaks from the throttle body;
• leaks from the cylinder head.

1. Leaks from the manifold gasket

2. Leaks from the throttle body gasket

3. Leaks from the cylinder head

1. Restore the gasket

2. Restore the gasket

3. Eliminate the leak

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 wiring between the valve and the engine compartment control unit

Check the wiring between the valve and the control unit

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Solenoid faulty

2. Connections not correct

1. Replace the solenoid valve

Op. 1080E28 ENABLEMENT SOLENOID FOR FLOW OF FUEL VAPOUR TO INLET - R+R

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Connect using the Examiner to the engine control unit and check that the phase transformer is working properly in active diagnosis

Check correct operation of the phase transformer by carrying out the

See Test

and the

See Test

1. Transformer defective

2. Transformer solenoid defective

3. Wiring from engine control unit to transformer broken

1. Replace variable valve timing

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

2. Replace transformer solenoid

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

3. Restore correct wiring.

Inspect the spark plugs and check that they are working properly

Check that the coils are working properly by carrying out the

See Test 5510CE IGNITION CONTROL SIGNAL CHECK

, the

See Test 5510CI IGNITION COIL OPERATION 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 coil

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

Check the fuel supply pressure is correct by carrying out the

See Test 1056BY FUEL SYSTEM SUPPLY PRESSURE CHECK

1. Fuel pressure too low: pipe obstructed

2. Fuel pressure too low: pump defective

1. Eliminate the obstructions; if necessary, replace the pipe

2. Replace the pump assembly

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

Check that the engine temperature sensor is working correctly by carrying out the

See Test 1056BC ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK

1. Engine overheating

2. Engine temperature sensor defective

1. Restore the engine cooling system

See E5020 ENGINE COOLING

2. Replace the engine temperature sensor

Op. 1056B50

Check that the injectors are operating correctly by carrying out

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

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 the condition of the motorized throttle actuator connection

Check the condition of the wiring

Check that the motorized throttle is working properly

See Test 1056BW THROTTLE BODY ACTUATOR OPERATION CHECK

1. Connection defective

2. Wiring defective

3. Motorized throttle defective

1. Restore correct connection.

2. Restore the correct wiring.

3. Replace the motorized throttle

Op. 1056B14

Check that the upstream Lambda sensor is working properly by performing the

See Test 1080BA UPSTREAM LAMBDA SENSOR OPERATION CHECK

Check that the downstream Lambda sensor is working properly by performing the

See Test 1080BD DOWNSTREAM LAMBDA SENSOR OPERATION CHECK

1. Upstream lambda sensor defective

2. Downstream Lambda sensor defective

3. Upstream sensor wiring defective

4. Downstream sensor wiring defective

1. Replace the upstream sensor

Op. 1080B94 FRONT LAMBDA SENSOR TO WITH CATALYTIC CONVERTER - R.R

2. Replace the downstream sensor

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

3. Restore correct wiring.

4. Restore correct wiring.

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

Check that the sensor is working properly by carrying out the

See Test 1056BU ASPIRATED AIR TEMPERATURE SENSOR OPERATION CHECK

1. Wiring broken

2. Sensor defective

1. Restore the correct wiring.

2. Replace the sensor

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

Check that the cylinder compression is not too low

Op. 0520G15

Replace the engine management control unit

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

First, check:

• leaks from the manifold gasket;
• leaks from the throttle body;
• leaks from the cylinder head.

1. Leaks from the manifold gasket.

2. Leaks from the throttle body gasket.

3. Leaks from the cylinder head.

1. Restore the correct gasket.

2. Restore the correct gasket.

3. Eliminate the leak

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 wiring between the valve and the engine compartment control unit

Check the wiring between the valve and the engine control unit

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Solenoid faulty

2. Connections not correct

1. Replace the solenoid valve

Op. 1080E28 ENABLEMENT SOLENOID FOR FLOW OF FUEL VAPOUR TO INLET - R+R

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

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

See Test 5510CI IGNITION COIL OPERATION CHECK

,

See Test 5510OB IGNITION COIL RESISTANCE CHECK

and the

See Test 5510CE IGNITION CONTROL SIGNAL CHECK

1. Spark plugs defective

2. Coil defective

1. Replace spark plugs

Op. 5510D10 SPARK PLUGS - R+R

2. Replace coil

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

Check the fuel supply pressure by performing the

See Test 1056BY FUEL SYSTEM SUPPLY PRESSURE CHECK

1. Fuel pressure too low: pipe obstructed

2. Fuel pressure too low: pump defective

1. Eliminate the obstructions; if necessary, replace the pipe

2. Replace the pump assembly

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

Check that the engine temperature sensor is working correctly by carrying out the

See Test 1056BC ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK

1. Engine overheating

2. Engine temperature sensor defective

1. Restore the engine cooling system

See E5020 ENGINE COOLING

2. Replace the engine temperature sensor

Op. 1056B50

Check the injectors are working correctly

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. Repair the connections

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 the condition of the motorized throttle actuator connection

Check the condition of the wiring

Check that the motorized throttle is working properly, carrying out

See Test 1056BW THROTTLE BODY ACTUATOR OPERATION CHECK

1. Connection defective

2. Wiring defective

3. Motorized throttle defective

1. Restore correct connection.

2. Restore the correct wiring.

3. Replace the motorized throttle

Op. 1056B14

Check that the cylinder compression is not too low

Op. 0520G15

Replace the engine management control unit

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

Check:

• Check that the air intake/vacuum circuit is working properly
• Air filter blocked
• Ducts blocked
• Leaks from intake ducts after the compressor
• Fuel leaks

1. Air intake circuit ducts blocked

2. Filter blocked and water, petrol, paraffin or dirt found to be present

3. Fuel leaks

1. Renew the air intake circuit

2. Water, water, paraffin or dirt found to be present

3. Restore the fuel system seal

Check that the EGR solenoid valve is not stuck open

Check that the EGR valve is working properly by carrying out the active diagnosis using the Examiner and checking that the valve does not remain open by carrying out

See Test 1080CB

Check the continuity of the wiring

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

replace the solenoid valve if necessary

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

Check that the high pressure value is correct by carrying out

See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK

Check that the low pressure value is correct by carrying out

See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK

Using the Examiner check that the fuel pump absorption is correct by carrying out

See Test 1040AA

Replace the electric pump

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

Check that the ressure sensor on the rail is working properly by carrying out

See Test 1060GR FUEL PRESSURE SENSOR ON RAIL OPERATION CHECK

1. Regulator wiring defective

2. Pressure sensor defective

1. Restore correct wiring

2. Replace the pressure sensor

Op. 1060G28 FUEL PRESSURE SENSOR ON FUEL MANIFOLD TO INJECTORS - R.R

Check the continuity of the wiring between the engine management control unit and the flow meter

Check that the flow meter is receiving the correct power supply [EL_5050]

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

Check that the flow meter signal is correct using the Examiner by carrying out

See Test 1060GS FLOW METER OPERATION CHECK

1. Flow meter signal not correct

2. Wiring between flow meter and engine management control unit broken

3. Power supply interrupted

1. Replace the flow meter

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

2. Restore correct wiring.

3. Restore correct power supply.

Check that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another by carrying out

See Test 1060OC INJECTOR SEAL TEST

Check that the injectors are working properly by connecting to the engine management control unit in active diagnosis

1. Injector with leaks/poor atomization

2. Check the continuity of the wiring between the engine management control unit and the injectors

1. Replace the injector

Op. 1060F10

2. Restore the correct wiring continuity.

Carry out the cylinder compression check

Op. 0520G15

Carry out

Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

to check the valve seal

Check condition of cylinders/piston rings

1. Valve seal insufficient

2. Cylinder geometry/dimensions faulty

3. Piston rings faulty

1. Overhaul the cylinder head

Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL

2. Restore correct operation

3. Restore correct operation

Replace the engine control unit

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

and check that the fault is no longer present

Replace the high pressure pump

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