Check that there is enough fuel in the tank.

Turn the ignition switch ON for 2 seconds and then OFF.

Check that the fuel pipe feels the pressure with the ignition ON

Check:

• Check the condition of the air filter;
• Check the condition of the air intake circuit;
• Check that there are no obstructions in the exhaust pipe

1. Not enough fuel in the tank

2. No pressure in the fuel circuit

3. Obstruction in the air intake circuit

4. Air intake via the inlet manifold/throttle body seal

5. Exhaust pipe blocked

1. Top up the fuel with the correct amount.

2. Move on to Step 5

3. Eliminate the problem, if necessary, replace the filter element

Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.

4. Restore the correct seal

5. Restore the operation of the exhaust pipe.

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. Key not recognised by the Body Computer

3. CAN faulty

4. Impossible to establish a dialogue with the engine control unit

1. Continue following the instructions on the diagnostic equipment.

2. Move on to Step 2

3. Restore CAN

4. Restore the correct engine control unit power supply

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Try to use the emergency key and check the system recognises it correctly

See E7010 CODE

1. Key not recognised

2. Key recognised

1. Move on to Step 2

2. Replace the key with transponder and record it in the Body Computer memory

Check the condition of the CODE aerial by carrying out the

See Test

Check that it is correctly connected to the Body Computer

See E7010 CODE

1. Aerial defective

2. CODE aerial wiring interrupted

1. Replace code aerial

Op. 5580E08 AERIAL FOR ELECTRONIC KEY (CODE) - R.R

2. Restore wiring continuity

Replace body computer

Op. 5505A32 BODY COMPUTER - R.R

Check the fuel supply pressure by carrying out

See Test 1056BY FUEL SYSTEM SUPPLY PRESSURE CHECK

Check the continuity of the wiring between the pump and the junction unit.

Check that the pump is working properly by carrying out the

See Test 1040AB SUBMERGED FUEL PUMP CHECK

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

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

1. Fuel pressure too low: pipes obstructed

2. Fuel pressure too low: pump defective

3. Wiring broken

1. Eliminate the constrictions

2. Replace the pump assembly

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

3. Restore the correct wiring.

Inspect the spark plugs and check their operation

Check for any defects in the high voltage leads

Using the Examiner check for the presence of the ignition signal at the primary circuit by carrying out

See Test 5510CE IGNITION CONTROL SIGNAL CHECK

Check that the ignition coils are working by carrying out

See Test 5510OA IGNITION COIL RESISTANCE CHECK

See Test 5510CI IGNITION COIL OPERATION CHECK

1. Spark plugs defective

2. High voltage cable connection leaking

3. High voltage cable connection slack

4. Ignition signal interrupted

5. Coils defective

1. Replace spark plugs

Op. 5510D10 SPARK PLUGS - R+R

2. Replace HV cables

3. Tighten HV cable correctly

4. Restore the ignition signal

5. Replace coils

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

Using the Examiner in active diagnosis, check that the injectors are working properly:

Check that the correct injector opening signal is present by carrying out the

See Test 1056BA INJECTOR OPERATION CHECK

Check that the injector needle seal is correct

Check the continuity of the injection wiring

Check the operation of the main relay

1. Injector opening signal interrupted at engine management control unit output

2. Injector seal not intact

3. Wiring broken

4. Main relay defective

1. Replace the engine control unit

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

2. Replace the injectors

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

3. Restore wiring

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

4. Replace the relay

Carry out the cylinder compression check

Op. 0520G15

R & R head to check valve seal

Check condition of cylinders/piston rings

1. Valve seal insufficient

2. Cylinders/piston rings worn

1. Restore the correct seal.

2. Overhaul the head

Replace the engine management control unit

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

Turn the key ON and check that the initial check on the MIL and VEHICLE PROTECTION warning lights takes place.

The MIL warning light should come on and then go out when the engine is started up, whilst the VEHICLE PROTECTION warning light should come on for about 4 seconds and then go out

Then check:

• that the fuel cut off has not been activated;
• presence of fuel in the tank;
• air intake circuit;
• that the filter is not blocked
• correct operation of the exhaust manifolds.
• that there are no leaks or seepage from the high and low pressure fuel pipes

1. The VEHICLE PROTECTION warning light stays on

2. The MIL warning light does not carry out the initial test

3. The warning lights do not carry out the initial test

4. Fuel cut off activated

5. Lack of fuel

6. Air filter blocked

7. Exhaust blocked

8. Presence of leaks

1. Proceed as instructed in the

See K052

2. Proceed as instructed in the

See K053

3. Proceed as instructed in the

See K054 METHANE PRESSURE SENSOR

4. Restore correct operation by carrying out the

See Test

5. Add fuel to the tank

6. Replace the filter element

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

7. Restore correct operation.

8. Eliminate leaks

Connect an EXAMINER and check the following on CAN INFORMATION

• No faulty control units
• No faulty CAN

Check that the engine management control unit is receiving the correct power supply

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

Check the operation of the main relay

1. Supply voltge not correct

2. Main relay defective

1. Restore correct power supply

2. Replace main relay

Check condition of wiring and operation of heater plugs system by carrying out

See Test

1. Wiring faulty

2. Heater plugs faulty

3. Preheating control unit faulty

1. Restore correct wiring

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

2. Replace damaged heater plugs

Op. 5520C10 HEATER PLUGS - R+R

3. Replace preheating control unit

Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R

Check that the timing sensor is working

Check the wiring continuity by carrying out the

See Test 1060GC TIMING SENSOR OPERATION CHECK

1. Sensor faulty

2. Wiring faulty

1. Replace timing sensor

Op. 1060G22 CAM ANGLE SENSOR - R.R

2.Renew the correct wiring

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

Check that the rpm sensor is working

Check the wiring continuity by carrying out the

See Test 1060GI ENGINE SPEED CHECK

1. Sensor faulty

2. Wiring faulty

3. Phonic wheel damaged

1. Replace the rpm sensor

Op. 1060G20 ENGINE RPM SENSOR - R.R.

2. Restore correct wiring

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

3. Replace the flywheel and reset the parameters in the control unit using the Examiner

Check as described in the

See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK

that the diesel pressure parameter is correct.

Check correct operation of the diesel pressure sensor by carrying out the

See Test 1060GR FUEL PRESSURE SENSOR ON RAIL OPERATION CHECK

1. Pressure not correct

2. Diesel pressure sensor defective

3. Diesel pressure sensor wiring defective

1. Move on to Step 7

2. Replace the pressure sensor

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

3. Restore correct wiring.

Check, as instructed in the

See Test 1060OC INJECTOR SEAL TEST

that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another.

Replace the injector

Op. 1060F10

Check as described in the

See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK

that the pressure in the return pipe to the tank is less than 1 bar

Check as described in the

See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK

that the diesel pressure between the filter and the pressure pump is correct

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

See Test

Replace the fuel filter cartridge

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

Check as described in the

See Test 1040AA

that the pump supply voltage is correct

Check that the current absorbed is correct

1. Voltage lower than 12 V

2. Pump absorption not correct

1. Restore correct 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

and clean the fuel tank

Using the Examiner connect to the engine management control unit and, in active diagnosis, check that the high pressure regulating valve on the rail is working properly by carrying out

See Test

1. Regulation valve defective

2. Valve cable defective

1. Change valve

Op. 1060G31 FUEL PRESSURE REGULATOR ON SINGLE MANIFOLD TO INJECTORS - R R

2. Restore correct wiring.

Replace the pressure pump

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

and check that the fault is no longer present

Replace the engine control unit

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

and check that the engine starts correctly