23 · Diagnostics

Engine not running smoothly

Make: Fiat
Model: Ducato Factory Service Manual
Year: 2002–2006
Section: Engine › Engine not running smoothly

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Fault diagnosisEngine not running smoothly

ENGINE NOT RUNNING SMOOTHLY

2.0 JTD 8V, 2.3 JTD 16V, 2.8 JTD 8V

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: condition of the air intake circuit; that there are no faults in the air filter; the seal of the diesel pipes; no obstructions in the catalytic converter; no water, petrol, paraffin or dirt in the tank.	Move on to Step 1	Air intake circuit faulty	Repair the air intake circuit
			Air filter blocked	Replace the filter element Op. 1048A14 AIR CLEANER FILTERING ELEMENT - REPLACE.
			Leaks from diesel pipes	Eliminate the leaks
			Water, petrol, paraffin or dirt found to be present	Clean the tank and pipes and replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
			Catalytic converter obstructed	Replace the catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the testert to the tester output. Check: that there are no errors in the control unit; the plausibility of the parameters; check operation of accelerator pedal potentiometer	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
			Parameters not plausible	Continue following the instructions for the diagnostic equipment
			Potentiometer defective	Replace potentiometer Op. 1068A20 ACCELERATOR PEDAL WITH BUILT-IN POTENTIOMETER - R R
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: that there are no errors in the control unit; parameter plausibility	Move on to Step 3	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
			Parameters not plausible	Continue following the instructions for the diagnostic equipment
			No communication with the control unit	Restore the connection between the engine management control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
3	TURBOCHARGER CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check turbocharger operation as described in Test 1064BA. See Test 1064B CONTROL/SAFETY DEVICES	Move on to Step 4	Turbocharger faulty	Replace the turbocharger
4	EGR VALVE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check EGR valve operation following removal Op. 1080C10 E.G.R. VALVE - R + R	Move on to Step 5	EGR valve blocked open	Replace the EGR valve
5	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace the control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R
STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: condition of the air intake circuit; that there are no faults in the air filter; the seal of the diesel pipes; the accelerator pedal travel; no obstructions in the catalytic converter; that there is no water, petrol, paraffin or dirt in the tank.	Move on to Step 1	Air intake circuit faulty	Repair the air intake circuit
			Air filter blocked	Replace the filter element Op. 1048A14 AIR CLEANER FILTERING ELEMENT - REPLACE.
			Leaks from diesel pipes	Eliminate the leaks
			Accelerator pedal does not complete its full travel	Eliminate the cause of the problem
			Water, petrol, paraffin or dirt found to be present	Clean the tank and pipes and replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
			Catalytic converter obstructed	Replace the catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the tester to the tester output. Check: that there are no errors in the control unit; parameter plausibility	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the tester
		Move on to Step 2	Parameters not plausible	Continue following the instructions for the tester
2	CHECK 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: that there are no errors in the control unit; parameter plausibility	Move on to Step 3	Error detected in the control unit	Continue following the instructions for the tester
			Parameters not plausible	Continue following the instructions for the tester
			No communication with the control unit	Restore the connection between the engine management control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
3	TURBOCHARGER CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check turbocharger operation as described in Test 1064BA. See Test 1064B CONTROL/SAFETY DEVICES	Move on to Step 4	Turbocharger faulty	Replace the turbocharger
4	EGR VALVE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check EGR valve operation by sight following removal Op. 1080C10 E.G.R. VALVE - R + R	Move on to Step 5	EGR valve blocked open	Replace the EGR valve
5	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace the control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R

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Parts & tools for this job For 2002 Fiat Ducato

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