Engine not running smoothly / (irregular operation)

Make: Fiat
Model: Bravo Factory Service Manual
Year: 2007–2014
Section: Engine › Engine not running smoothly / (irregular operation)

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Fault diagnosisEngine not running smoothly / (irregular operation)

ENGINE NOT RUNNING SMOOTHLY / (IRREGULAR OPERATION)

1.4 16v

Metallic noises are coming from the engine, which change when the throttle opens. It sounds like popcorn popping - Excessive knock

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
	Battery correctly fastened to earth See E1010 POWER SUPPLY	Move on to Step 1	Fastening to earth incorrect	Restore the correct wiring.
1	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	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	Move on to Step 2	Error detected in the control unit	Continue following the instructions on the diagnostic equipment
2	FUEL PRESSURE CHECK	All OK	Problems encountered	Operation
	Check the fuel supply pressure, if necessary on the road (to reproduce the conditions in which the problem occurs) Op. 0520G46 FUEL SYSTEM - CHECK SUPPLY PRESSURE USING THE EXAMINER	Move on to Step 3	Pressure not correct: obstructions in the fuel supply pipe	Remove the obstructions in the fuel pipe, replace it if necessary
		Move on to Step 3	Pressure not correct: petrol pump damaged	Replace the petrol pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
3	IGNITION SYSTEM CHECK	All OK	Problems encountered	Operation
	Inspect the spark plugs and check their operation Check for any coil defects by carrying out See Test 5510CI IGNITION COIL OPERATION CHECK	Move on to Step 4	Spark plugs defective	Replace spark plugs Op. 5510D10 SPARK PLUGS - R+R
		Move on to Step 4	Coil leakage	Replace coils Op. 5510C14 IGNITION COIL/S - R.R.
4	AIR INTAKE SYSTEM CHECK	All OK	Problems encountered	Operation
	- Check the condition of the air intake circuit;	Move on to Step 5	Air intake circuit faulty (air entering via the intake manifold gasket)	Restore the correct seal.
	- Check the condition of the air intake circuit;	Move on to Step 5	Air intake circuit faulty (air entering via the throttle body gasket)	Restore the correct seal.
5	KNOCK SENSOR CHECK	All OK	Problems encountered	Operation
	Check the correct operation of the knock sensor by carrying out the See Test 5510CH Check on operation of knock sensor	Move on to Step 6	Connection defective	Restore correct connection.
			Wiring defective	Restore the correct wiring.
			Knock sensor defective	Replace the knock sensor Op. 5510C42 DETONATION SENSOR (ONE) - R.R.
6	ENGINE TEMPERATURE SENSOR CHECK	All OK	Problems encountered	Operation
	Check that the engine temperature sensor is working properly by carrying out the See Test 1056BC Engine coolant temperature sensor operation check	Move on to Step 7	Engine temperature sensor not working correctly.	Replace the engine temperature sensor Op. 1056B50 ENGINE COOLANT TEMPERATURE SENSOR - R + R
7	INJECTOR OPERATION CHECK	All OK	Problems encountered	Operation
	Check the condition of the injector connections Check the condition of the wiring Check that the injectors are operating correctly by carrying out See Test 1056BA Injector operation check	Move on to Step 8	Connections defective	Renew the correct connections
			Wiring defective	Restore the correct wiring.
			Injector defective	Replace the injector Op. 1056B70 INJECTOR (ONE) - R + R WITH FUEL MANIFOLD PIPE REMOVED - INCLUDES SEAL REPLACEMNT
8	ENGINE CONTROL UNIT CHECK	All OK	Problems encountered	Operation
	Check that the engine control unit is working properly	End of diagnosis	Engine management control unit defective.	Replace the engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

1.9 JTD 8v, 1.9 JTD 16v

The customer complains that: The engine is not running smoothly

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	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 Check the operation of the low pressure supply circuit See Test 1060OB Low pressure fuel supply circuit check Check the fastening of the battery earth terminal	Move on to Step 1	Oil level incorrect Battery earth terminal insecure	Restore the correct engine oil level Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY Restore the correct earth lead fastening See E1020 EARTHS
1	MODE 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 · Accelerator pedal · Accelerator position 1 AD/C · Accelerator position 2 AD/C See Test 1068AC ACCELERATOR PEDAL CHECKS · Engine coolant temperature See Test 5030AA COOLANT TEMPERATURE SENSOR CHECK · Diesel temperature · Measured air mass · Engine rpm Reach a constant speed of around 30 km/h and check that the reading on the diagnostic equipment for the vehicle speed coincides more or less with the speed shown on the instrument panel	Move on to Step 4	The vehicle speed is not measured correctly	Move on to Step 2
2	ABS CHECKS	All OK	Problems encountered	Operation
	Select the following control unit at the diagnostic equipment: BOSCH ABS control unit Check that the system is working properly See Test 3340AB SPEED SIGNAL CHECK	Move on to Step 3
3	SOFTWARE VERSION CHECK	All OK	Problems encountered	Operation
	Check the software version of the EDC16C39 Diesel electronic injection control unit See Test 1060GJ CHECK ENGINE CONTROL UNIT SOFTWARE RELEASE	Move on to Step 4
4	PREHEATING RELAY ACTIVE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis for the preheating relay, checking that the result is positive.	Move on to Step 6	The result of the active diagnosis is negative	Move on to Step 5
5	GLOW HEATER PLUGS CHECK	All OK	Problems encountered	Operation
	Check that the glow heater plugs are working properly See Test 5520CA GLOW HEATER PLUGS OPERATION CHECK	Move on to Step 7
6	DIESEL PREHEATING FUSE CHECK	All OK	Problems encountered	Operation
	Check the protective fuse circuit for the diesel preheating relay	End of diagnosis

1.4 16v TJet

Metallic noises are coming from the engine which change when the throttle opens and it sounds like popcorn popping - excessive detonation

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	Battery correctly fastened to earth See E1010 POWER SUPPLY	Move on to Step 1	Fastening to earth incorrect	Restore the correct wiring.
1	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	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	Move on to Step 2	Error detected in the control unit	Continue following the instructions on the diagnostic equipment
2	FUEL PRESSURE CHECK	All OK	Problems encountered	Operation
	Check the fuel supply pressure, if necessary on the road (to reproduce the conditions in which the problem occurs) Op. 0520G46 FUEL SYSTEM - CHECK SUPPLY PRESSURE USING THE EXAMINER	Move on to Step 3	Pressure not correct: obstructions in the fuel supply pipe	Remove the obstructions in the fuel pipe, replace it if necessary
		Move on to Step 3	Pressure not correct: petrol pump damaged	Replace the petrol pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
3	IGNITION SYSTEM CHECK	All OK	Problems encountered	Operation
	Inspect the spark plugs and check their operation Check for any coil defects by carrying out See Test 5510CI IGNITION COIL OPERATION CHECK See Test 5510CE IGNITION CONTROL SIGNAL CHECK See Test 5510OB IGNITION COIL RESISTANCE CHECK	Move on to Step 4	Spark plugs defective	Replace spark plugs Op. 5510D10 SPARK PLUGS - R+R
		Move on to Step 4	Coil leakage	Replace coils Op. 5510C14 IGNITION COIL/S - R.R.
4	AIR INTAKE SYSTEM CHECK	All OK	Problems encountered	Operation
	Check the condition of the air intake circuit;	Move on to Step 5	Air intake circuit faulty (air entering via the intake manifold gasket)	Restore the correct seal.
	Check the condition of the air intake circuit;	Move on to Step 5	Air intake circuit faulty (air entering via the throttle body gasket)	Restore the correct seal.
5	KNOCK SENSOR CHECK	All OK	Problems encountered	Operation
	Check the detonation sensor is working properly using the Examiner	Move on to Step 6	Connection defective	Restore correct connection.
			Wiring defective	Restore the correct wiring.
			Detonation sensor defective	Replace the knock sensor Op. 5510C42 DETONATION SENSOR (ONE) - R.R.
6	ENGINE WATER TEMPERATURE SENSOR CHECK	All OK	Problems encountered	Operation
	Check that the engine temperature sensor is working properly by carrying out the See Test 1056BC Engine coolant temperature sensor operation check	Move on to Step 7	Engine temperature sensor not working correctly.	Replace the engine temperature sensor Op. 1056B50 ENGINE COOLANT TEMPERATURE SENSOR - R + R
7	INJECTOR OPERATION CHECK	All OK	Problems encountered	Operation
	Check the condition of the injector connections Check the condition of the wiring Check that the injectors are operating correctly by carrying out See Test 1056BA Injector operation check	Move on to Step 8	Connections defective	Renew the correct connections
			Wiring defective	Restore the correct wiring.
			Injector defective	Replace the injector Op. 1056B70 INJECTOR (ONE) - R + R WITH FUEL MANIFOLD PIPE REMOVED - INCLUDES SEAL REPLACEMNT
8	ENGINE CONTROL UNIT CHECK	All OK	Problems encountered	Operation
	Check that the engine control unit is working properly	End of diagnosis	Engine management control unit defective.	Replace the engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

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