22 · Diagnostics

Engine cuts out whilst driving

Make: Fiat
Model: Doblò Factory Service Manual
Year: 2000–2010
Section: Engine › Engine cuts out whilst driving

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Fault diagnosisEngine cuts out whilst driving

ENGINE CUTS OUT WHILST DRIVING

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: earth on engine correctly fastened; battery earth correctly fixed; correct fixing of the positive battery terminal and the leads connected to it for any obstructions in the catalyzer that there is no water or other fluids in the fuel tank	Continue to Step 1	Earth leads incorrectly fixed	Renew or, if necessary, replace the battery earth lead Op. 5505A38
			Battery positive earth incorrectly fixed	Restore battery positive lead Op. 5530B26
			Catalyzer obstructed	Replace the exhaust manifold Op. 1072C16
			Presence of dirt in the fuel tank	Clean the fuel tank Op. 1040A10
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket. check that there are no faults in the engine management control unit; plausibility of all the parameters	Continue to Step 2	Another error dectected in the control unit	Continue following the instructions for the diagnostic equipment
		Continue to Step 2	Inconsistent parameter	Continue following the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. check that there are no faults in the engine management control unit; the plausibility of all the parameters.	Continue to Step 3	Error arises suddenly in the control unit	Continue following the instructions for the diagnostic equipment
			Inconsistent parameter	Continue following the instructions for the diagnostic equipment
			Loss of dialogue between the control unit and diagnostic instrument	Restore the control unit circuit supply See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
3	CHECK ON FUEL PRESSURE ON ROAD	All OK	Problems met	Operation
	Road test the vehicle and check the fuel supply pressure Op. 0510C10 Make sure that the conditions in which the problem occurs are reproduced	Continue to Step 4	Pressure not correct: obstructions in fuel delivery pipe	Remove the obstructions in the fuel pipe, and if necessary replace it Op. 1040B34
			Pressure not correct: tank insufficiently ventilated	Restsore the tank ventilation
			Pressure not correct: fuel pump electrical circuit broken	Repair fuel pump electrical circuit See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Pressure incorrect: fuel pump damaged	Replace fuel pump assembly Op. 1040A70
4	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists: control unit defective	Replace control unit Op. 1056B82

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: that the earth is correctly fixed on the engine that the battery earth is correctly fastened; See E1020 EARTHS that the positive battery terminal and the cables connected to it are correctly fastened See E1010 SUPPLY no water in the fuel filter	Continue to Step 1	Earth leads incorrectly fixed	Renew or, if necessary, replace the battery earth lead Op. 5530B22
			Battery positive earth incorrectly fixed	Restore battery positive lead Op. 5530B26
			Presence of water in the fuel	Replace the fuel
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket. check that there are no faults in the engine management control unit; the plausibility of all the parameters.	Continue to Step 2	An error is detected in the control unit	Continue according to the instructions for the diagnostic equipment
		Continue to Step 2	Inconsistent parameter	Continue according to the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. check that there are no faults in the engine management control unit; the plausibility of all the parameters.	Continue to Step 3	Error arises suddenly in the control unit	Continue according to the instructions for the diagnostic equipment
			Inconsistent parameter	Continue according to the instructions for the diagnostic equipment
			Loss of dialogue between the control unit and diagnostic instrument	Restore the control unit circuit supply See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
3	CHECK ON FUEL PRESSURE ON ROAD	All OK	Problems met	Operation
	Road test the vehicle and check the fuel supply pressure Op. 0510C10 Make sure that the conditions in which the problem occurs are reproduced	Continue to Step 4	Pressure not correct: obstructions in the pipe	Remove the obstructions in the fuel pipe, and if necessary replace it
		Continue to Step 4	Pressure incorrect: fuel pump damaged	Replace fuel pump assembly Op. 1040A70
4	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists: control unit faulty	Replace control unit Op. 1056B82

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: the engine wiring is properly connected to earth battery earth correctly fixed correct fixing of battery positive terminal and all the leads connected to it that there are no faults in the air intake circuit that there is diesel in the tank, and its quality	Continue to Step 1	Attachments loose or corroded	Re-attach correctly
			Faults in the intake circuit	Restore correct operation, if necessary replacing faulty components
			Air filter blocked	Replace the filter element Op. 1048A14
			Diesel of poor quality	Clean the tank Op. 1040A10and put diesel in it
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket check for errors in the control unit plausibility of all the parameters	Continue to Step 2	An error is detected in the control unit	Continue following the instructions for the diagnostic equipment
		Continue to Step 2	unreliable parameters	Continue following the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle keeping the diagnostic instrument connected. Make sure that the conditions in which the problem occurs are reproduced check for errors in the control unit the plausibility of all the parameters.	Continue to Step 3	Errors suddenly occur in the control unit	Continue following the instructions for the diagnostic equipment
			Parameters off scale	Continue following the instructions for the diagnostic equipment
			Loss of dialogue between the control unit and the diagnostic equipment	Restore the correct connections See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
3	CHECK ON TANK VENTILATION	All OK	Problems met	Operation
	Check the correct operation of the valve on the fuel filler cap	Continue to Step 4	Tank ventilation insufficient	Restore the correct operation of the ventilation valve, if necessary, replace the cap Op. 1040A40
4	CHECK ON INLET MANIFOLD BUTTERFLY VALVE	All OK	Problems met	Operation
	Manually check that the throttle valve in the inlet manifold and the pneumatic actuator are working properly	Continue to Step 5	Butterfly valve stuck in closed position	Eliminate the cause of the sticking; if necessary replace the valve
			Actuator damaged	Replace the pneumatic actuator
			Pipes blocked	Eliminate the obstructions; if necessary replace the pipes
5	CHECK ON INJECTORS	All OK	Problems met	Operation
	Check the injectors for leaks and that they are correctly calibrated Op. 1060B10	Continue to Step 6	Incorrect injector calibration	Restore the correct calibration Op. 1060B10
		Continue to Step 6	Faulty injectors	Replace the injectors Op. 1060B10
6	CHECK ON FUEL INJECTION PUMP	All OK	Problems met	Operation
	Check that the fuel injection pump is working correctly	Continue to Step 7	Pump faulty	Replace the pump Op. 1060A10
7	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists: control unit faulty	Replace control unit Op. 1060D80

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	that there is fuel in the tank the engine wiring is properly connected to earth battery earth correctly fixed correct fixing of positive battery terminal and that all leads are connected no water in the fuel filter	Continue to Step 1	No fuel	Introduce fuel
			Fastenings slack or oxidized	Re-attach correctly
			Presence of water in the fuel filter	Clean the tank and pipes and replace the filter element
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket check for errors in the control unit	Continue to Step 2	An error is detected in the control unit	Continue following the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. check that there are no errors in the control unit;	Continue to Step 3	An error is detected in the control unit	Continue following the instructions for the diagnostic equipment
3	INJECTOR HIGH PRESSURE CHECK	All OK	Problems met	Operation
	Check, as described See Test 1060C Injector high pressure, fuel circuit leakage test, that diesel leaks from the injector recirculation connections are small and about the same as one another.	Continue to Step 4	Consistent leak from one injector	Replace the injector
4	HIGH PRESSURE CHECK	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket Check as described See Test 1060D Check high pressure fuel circuitthat the diesel pressure parameter is correct	Continue to Step 12	Pressure not correct	Continue to Step 5
5	CHECK ON RETURN LOW PRESSURE	All OK	Problems met	Operation
	Check as described See Test 1060A Low return fuel pressure circuit checkthat the pressure in the return pipe to the tank is under 1 bar	Continue to Step 6	Pressure above maximum limit: return pipe to tank blocked	Repair the pipe; if necessary replace it
6	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check as described See Test 1060B Low fuel pressure supply circuit checkthat the diesel pressure between filter and pressure pump is between 2 and 3 bar	Continue to Step 12	Pressure below minimum limit or above maximum limit	Continue to Step 7
7	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Choke the return pipe from the pressure regulating valve See Test 1060B Low fuel pressure supply circuit checkwith the pipe restricted, checking that the pressure at the filter outlet is below 2 bar	Continue to Step 8	Pressure rises to 5 bar: blocked pressure regulation valve on filter support	Replace the valve Op. 1044B16
8	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check that the difference in pressure measured upstream and downstream of the filter is less than 1 bar with the pipe restricted. Ensure the pressure at the filter outlet is lower than 2 bars.	Continue to Step 9	Difference in pressure greater than 1 bar	Replace the diesel filter cartridge Op. 1044B20
9	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check that the supply pump pressure at the filter inlet is over 2.2 bar	Continue to Step 12	Pressure below 2.2 bar	Continue to Step 10
10	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Measure the difference in pressure between electric pump outlet and filter inlet, checking that it is less than 0.3 bar	Continue to Step 11	Difference in pressure greater than 0.3 bar	Replace the pipe
11	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check as described See Test 1040A Check supply voltage and absorption currentthat the pump supply voltage is 12 V and that the absorbed current is between 2 and 10 amp.	Continue to Step 12	Voltage < 12 V	Check electric wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current > 10 Amp: pump defective	Replace the fuel pump assembly Op. 1040A70
			Current < 2 Amp.: pump blocked	Replace the fuel pump assembly Op. 1040A70and clean the fuel tank
12	CORRECT OPERATION CHECK	All OK	Problems met	Operation
	Replace the DRV high-pressure valve and check that the fault is no longer present	End of diagnosis	Fault persists	Continue to Step 13
13	CORRECT OPERATION CHECK	All OK	Problems met	Operation
	Replace the pressure pump and check that the fault is no longer present	End of diagnosis	Fault persists	Contact Technical Service for further information on the problem

BIPOWER

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Check: that the leads are correctly tightened at the battery that the battery earth lead and the earth leads on the cylinder block are correctly connected Possible obstruction in the catalyzer Injection system relays correctly fitted	Continue to Step 1	Earth leads slack	Restore correct tightening of leads
		Continue to Step 1	Catalyzer obstructed	Replace the catalyzer
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the Examiner diagnostic equipment to the diagnostic connector and check the following at the petrol and METHANE engine management control units in errors ambient: That there are no faults in the engine management control unit That there are no faults in the METHANE engine management control unit In parameter mode Plausibility of all the parameters After a servicing operation, check that the self-adjustment parameters have been zeroed (reset)	Continue to Step 2	An error is detected in the control unit	Continue according to the instructions for the diagnostic equipment
			Lack of dialogue with the control unit	Restore the connection between the engine management control unit and the diagnostic connector
			Self-adjustment parameters have not been zeroed	Use the Examiner to reset the self-adjustment parameters
2	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis

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