First, check:

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

1. Obstruction in the air intake circuit

2. Air intake via the intake manifold/throttle body seal

3. Exhaust pipe blocked

1. Eliminate the problem, 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.

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

• that there are 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

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 their operation

Check for any defects in the spark plug high tension leads

Check the operation of the ignition coil by carrying out

See Test 5510OA IGNITION COIL RESISTANCE CHECK

See Test 5510CE IGNITION CONTROL SIGNAL CHECK

1. Spark plug defective

2. High voltage cable connection leaking

3. High voltage cable connection slack

4. Ignition coil defective.

1. Replace spark plug

Op. 5510D10 SPARK PLUGS - R+R

2. Replace HV cable

3. Tighten HV cable correctly

4. Replace ignition coil

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

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

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

See Test

1. Injector stuck/incorrectly adjusted

2. Connections not correct

3. Injector seal not intact

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

3. Change the injectors

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

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 ENGINE COOLANT TEMPERATURE SENSOR - R + R

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 ACCELERATOR PEDAL - R + R

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

Check that the motorized throttle is working properly by carrying out the

See Test 1056BW THROTTLE BODY ACTUATOR OPERATION CHECK

1. Motorized throttle defective

2. Connections not correct.

1. Replace the motorized throttle

Op. 1056B14 THROTTLE CASE - R + R

2. Restore the correct connections

See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT

R & R head to check 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

Check:

• That the level of the oil is correct
• The condition of the air intake/vacuum circuit
• The condition of the fuel supply circuit and make sure that it is working properly
• Battery earth lead connection

1. Oil level incorrect

2. Fault in the air intake circuit

3. Leaks from the diesel pipes

4. Filter blocked

5. Water, petrol, paraffin or dirt found to be present

6. Battery earth lead slack/oxidized

1. Restore the correct engine oil level

Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY

2. Renew the air intake circuit

3. Adjust pipe tightness to correct setting and replace if necessary

4. Replace the diesel filter cartridge

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

5. Clean the tank and pipes and replace the diesel filter cartridge

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

6. Restore the battery earth lead connection

Connect the Examiner diagnostic equipment to the diagnostic connector and check the following at the engine management control unit.

Check the value of the following parameters:

• Battery voltage
• Measured diesel pressure
• Target diesel pressure
• Correct operation of the diesel preheating system

1. Battery voltage low

2. The pressure measured does not correspond to the target figure

3. Heater plugs circuit faulty

1. Recharge and, if necessary, replace the battery

2. Move on to Step 3

3. Move on to Step 2

Carry out the active diagnosis for the diesel preheating relay, checking that the result is positive.

Check that the heater plugs and the preheating system are working properly, by carrying out the

See Test

1. Preheating wiring faulty

2. Preheating control unit defective

3. Heater plugs faulty

1. Restore wiring

See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT

2. Replace preheating control unit

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

3. Replace defective heater plugs

Op. 5520C10 HEATER PLUGS - R+R

Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.

Check that the diesel pressure parameter is correct by carrying out the

See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK

Check that the pressure in the return pipe to the tank is correct by carrying out the

See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK

Check that the diesel pressure between the filter and the low pressure pump is correct by carrying out the

See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK

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 diesel filter cartridge

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

Check that the pump supply voltage is correct.

Check that the pump absorption current is correct by carrying out the

See Test 1040AA SUPPLY VOLTAGE AND ABSORPTION CURRENT CHECKS

Replace the fuel pump assembly

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

Replace the high pressure pump

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

and check that the fault is no longer present.

Carry out the cylinder compression check

Op. 0520G15

R/R head for valve leakage test

Check condition of cylinders/piston rings

1. Valve seal insufficient

2. Cylinders/piston rings worn

1. Overhaul the head

2. Restore the correct seal.

Replace the engine management control unit

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