23 · Diagnostics

Engine cuts out whilst driving

Make: Fiat
Model: Ducato Factory Service Manual
Year: 2002–2006
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 unexpectedly whilst driving. It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: presence of fuel in the tank; wiring on engine correctly fastened to earth; battery correctly fastened to earth; positive battery pole and all leads connected to it correctly fastened; no water in the fuel filter.	Move on to Step 1	No fuel	Introduce fuel
			Fastenings slack or oxidized	Restore correct fastenings
			Water in the fuel tank	Clean the tank and pipes and replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check: for errors saved in the control unit. correct operation of the rpm sensor as described in Test 1060GA See Test 1060G PRESSURE PUMP ELECTRIC CONTROL	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
			RPM sensor defective	Change the rpm sensor Op. 1060G20 RPM AND TIMING SENSOR - R R
			Incorrect gap between phonic wheel and rpm sensor	Change the rpm sensor Op. 1060G20 RPM AND TIMING SENSOR - R R
			Phonic wheel damaged	Change the phonic wheel Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test reproducing the conditions in which the fault occurs, keeping the diagnostic equipment connected. Check: for errors saved in the control unit.	Move on to Step 3	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
3	INJECTOR HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OC that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 4	Considerable leakage from injectors	Change the injectors Op. 1060F10 FUEL INJECTORS
4	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check, as described in Test 1060OD that the diesel pressure value is correct See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 12	Pressure level incorrect	Move on to Step 5
5	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OA that the tank return pipe pressure is less than 0.5 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 6	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary.
		Move on to Step 6	Bontaz pressure relief valve defective	Replace Bontaz pressure relief valve Op. 1060G28 FUEL PRESSURE SENSOR - R R
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OB, that the diesel pressure between filter and radialjet pump is between 0.6 and 0.7 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 11	Pressure lower than minimum limit	Move on to Step 7
		Move on to Step 11	Pressure above the maximum limit	Replace Bontaz pressure relief valve Op. 1060G28 FUEL PRESSURE SENSOR - R R
7	FILTER PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the difference in pressure upstream and downstream of the filter is less0.2 bar	Move on to Step 9	Difference in pressure less than or equal to 1 bar	Change filter cartridge. Op. 1044B20 ELEMENTO FILTRANTE DEL FILTRO COMBUSTIBILE - SOST.
8	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the supply pump pressure at the filter inlet is between 0.6 and 0.7 bar	Move on to Step 11	Pressure below 0.6 bar	Move on to Step 10
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between the electric pump outlet and the filter inlet is less 0.3 bar	Move on to Step 10	Difference in pressure more than 0.3 bar	Replace the pipe. Op. 1040B30 FUEL DELIVERY LINE - R R
10	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and the current uptake is between 2 and 10 Amps See Test 1040A FUEL TANK AND COMPONENTS	End of diagnosis	Voltage < 12 V	Check wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
		End of diagnosis	Current > 10 Amps: Jet pump blocked	Change fuel intake unit and clean tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
11	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the high pressure pump pressure regulator and check that the fault is no longer present. Op. 1060E50 PRESSURE REGULATOR - R R	End of diagnosis	Fault persists	Reset the pressure regulator and continue to Step 12
12	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the high pressure pump and check that the fault is no longer present. Op. 1060E10 PRESSURE PUMP - R R		Fault persists	Contact the Service Department for further information on the problem

2.0 16V · BIPOWER

The engine stalls suddenly while in motion (during METHANE operation). It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check leads are properly tightened to the battery Check the battery earth lead is properly tightened and the earth leads are secured to the engine block Check that the catalytic converter is not blocked. Check the Injection system relay is correctly installed	Move on to Step 1	Earth leads loose	Restore lead tightness See E1020 EARTHS
		Move on to Step 1	Catalytic converter obstructed	Replace catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester connector and check the following at the petrol and METHANE engine management unit in error mode: that there are no faults in the petrol engine management control unit; that there are no faults in the METHANE engine management control unit	End of diagnosis	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
			No communication with the petrol control unit	Restore the connection between the engine management control unit and the diagnostic connector See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			No communication with the METHANE control unit	Restore the connection between the engine management control unit and the diagnostic connector See E5032 METHANE ENGINE ELECTRONIC MANAGEMENT

2.0 16V · GPL

The engine stalls suddenly while in motion (during LPG operation). It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check leads are properly tightened to the battery Check the battery earth lead is properly tightened and the earth leads are secured to the engine block Check for obstructions in the catalytic converter. Check the Injection system relay is correctly installed	Move on to Step 1	Earth leads loose	Restore lead tightness See E1020 EARTHS
			Intertia switch operated	Restore inertia switch
			Catalytic converter obstructed	Replace catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester connector and check the following at the petrol and LPG engine management unit in error mode: that there are no faults in the petrol engine management control unit; that there are no faults in the LPG engine management control unit	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
			No communication with the petrol control unit	Restore the connection between the engine management control unit and the diagnostic connector See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			No communication with the LPG control unit	Restore the connection between the engine management control unit and the diagnostic connector See E5031 LPG FUEL SYSTEM ELECTRONIC MANAGEMENT
2	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the tester connected to the tester connector, check, in active test mode, that both the supply and return solenoid valves are working properly	End of diagnosis	Solenoid defective	Replace the solenoid valve

All versions

The engine cuts out unexpectedly whilst driving. It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: presence of fuel in the tank; wiring on engine correctly fastened to earth; battery correctly fastened to earth; positive battery pole and all leads connected to it correctly fastened; no water in the fuel filter; correct operation of the anti-judder throttle	Move on to Step 1	Lack of fuel	Restore fuel
			Fastenings slack or oxidized	Restore correct fastenings See E1020 EARTHS
			Water in the fuel tank	Clean the tank and pipes and replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
			Throttle control defective	Restore correct operation
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check for errors saved in the control unit.	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the tester
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test by reproducing the conditions in which the fault occurs, keeping the tester connected. Check for errors saved in the control unit.	Move on to Step 3	Error detected in the control unit	Continue following the instructions for the tester
3	INJECTOR HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OC that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 4	Significant leak from one injector	Replace the injector Op. 1060F10 FUEL INJECTORS
4	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check, as described in Test 1060OD that the diesel pressure value is correct See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 12	Pressure level incorrect	Move on to Step 5
5	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OA that the tank return pipe pressure is less than 1 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 6	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OB, that the diesel pressure between filter and radialjet pump is between 2 and 3 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 12	Pressure below the minimum limit or above the maximum limit	Move on to Step 7
7	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Restrict the pressure regulator valve return pipe and repeat Test 1060OB with the pipe restricted, checking that the fuel outlet pressure is less than 2 bars See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 8	Pressure rises to 5 bars: pressure regulator in filter mount defective	Replace the pressure regulator Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
8	FILTER PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between filter upstream and downstream is less than 1 bar	Move on to Step 9	Difference in pressure more than 1 bar	Change filter cartridge. Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the supply pump pressure at the filter inlet is more than 2.2 bar	Move on to Step 12	Pressure below 2.2 bar	Move on to Step 10
10	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between the electric pump outlet and the filter inlet is less 0.3 bar	Move on to Step 11	Difference in pressure more than 0.3 bar	Replace the pipe
11	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and the current uptake is between 2 and 10 Amps See Test 1040A FUEL TANK AND COMPONENTS	End of diagnosis	Voltage < 12 V	Check wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current > 10 Amps: Jet pump blocked	Replace the fuel intake unit Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
			Current < 2 Amps: Jet pump blocked	Change fuel intake unit and clean tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
12	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the DRV high pressure regulation valve and check that the fault is no longer present Op. 1060E50 PRESSURE REGULATOR - R R	End of diagnosis	The fault persists	Reset the pressure regulator and continue to Step 13
13	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the high pressure pump and check that the fault is no longer present Op. 1060E10 PRESSURE PUMP - R R	End of diagnosis	The fault persists	Contact technical service for further information on the problem

The engine cuts out unexpectedly whilst driving. It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: presence of fuel in the tank; wiring on engine correctly fastened to earth; battery correctly fastened to earth; positive battery pole and all leads connected to it correctly fastened; no water in the fuel filter; correct operation of the anti-judder throttle	Move on to Step 1	Lack of fuel	Restore fuel
			Fastenings slack or oxidized	Restore correct fastenings See E1020 EARTHS
			Water in the fuel tank	Clean the tank and pipes and replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check for errors saved in the control unit.	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the tester
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test by reproducing the conditions in which the fault occurs, keeping the tester connected. Check for errors saved in the control unit.	Move on to Step 3	Error detected in the control unit	Continue following the instructions for the tester
3	INJECTOR HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OC that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 4	Significant leak from one injector	Replace the injector Op. 1060F10 FUEL INJECTORS
4	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check, as described in Test 1060OD that the diesel pressure value is correct See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 12	Pressure level incorrect	Move on to Step 5
5	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OA that the tank return pipe pressure is less than 1 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 6	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OB, that the diesel pressure between filter and radialjet pump is between 2 and 3 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 12	Pressure below the minimum limit or above the maximum limit	Move on to Step 7
7	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Restrict the pressure regulator valve return pipe and repeat Test 1060OB with the pipe restricted, checking that the fuel outlet pressure is less than 2 bars See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 8	Pressure rises to 5 bars: pressure regulator in filter mount defective	Replace the pressure regulator Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
8	FILTER PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between filter upstream and downstream is less than 1 bar	Move on to Step 9	Difference in pressure more than 1 bar	Change filter cartridge. Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the supply pump pressure at the filter inlet is more than 2.2 bar	Move on to Step 12	Pressure below 2.2 bar	Move on to Step 10
10	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between the electric pump outlet and the filter inlet is less 0.3 bar	Move on to Step 11	Difference in pressure more than 0.3 bar	Replace the pipe
11	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and the current uptake is between 2 and 10 Amps See Test 1040A FUEL TANK AND COMPONENTS	End of diagnosis	Voltage < 12 V	Check wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current > 10 Amps: Jet pump blocked	Replace the fuel intake unit Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
			Current < 2 Amps: Jet pump blocked	Change fuel intake unit and clean tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
12	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the DRV high pressure regulation valve and check that the fault is no longer present Op. 1060E50 PRESSURE REGULATOR - R R	End of diagnosis	The fault persists	Reset the pressure regulator and continue to Step 13
13	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the high pressure pump and check that the fault is no longer present Op. 1060E10 PRESSURE PUMP - R R	End of diagnosis	The fault persists	Contact technical service for further information on the problem

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