Engine does not start / under no circumstances

Make: Fiat
Model: Ducato Factory Service Manual
Year: 2002–2006
Section: Starting › Engine does not start / under no circumstances

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Fault diagnosisEngine does not start / under no circumstances

ENGINE DOES NOT START / UNDER NO CIRCUMSTANCES

The engine does not start. When the key is turned the instruments light up as normal, the starter motor turns, but the engine does not start up.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Turn the key ON and check that the initial check on the MIL and CODE warning lights takes place. Then check: that the inertia switch has cut in; presence of fuel in the tank; air intake circuit; correct operation of the exhaust manifolds.	Move on to Step 1	The CODE waring light stays on	Continue following the instructions in Table K52
			The MIL warning light does not carry out the intial test	Continue following the instructions in Table K53
			Intertia switch operated	Restore correct operation
			Lack of fuel	Add fuel to the tank
			Filter dirty or partly blocked	Replace the filter element Op. 1048A14 AIR CLEANER FILTERING ELEMENT - REPLACE.
			Exhaust blocked	Restore exhaust manifolds to working order
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment to the diagnostic socket. Check: that there are no errors in the control unit; the plausibility of the parameters; check that the rpm sensor is working properly 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
			Parameters not plausible	Continue following the instructions for the diagnostic equipment
			No communication with the control unit	Restore the connection between the engine control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Rpm sensor defective	Change rpm sensor Op. 1060G20 RPM AND TIMING SENSOR - R R
2	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment to the diagnostic socket. Check, as described in test Test 1060OD, that the diesel pressure parameter is correct. See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 10	Pressure not correct	Move on to Step 3
		Move on to Step 10	Fuel loss from connectors	Restore the seal
3	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OA, that the pressure in the return pipe to the tank is less than 0.5 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 4	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary Op. 1060F52 PIPE TO RETURN MANIFOLD - R R
			Pressure relief valve on rail defective	Replace the pressure relief valve Op. 1060G28 FUEL PRESSURE SENSOR - R R
			Pressure sensor defective	Replace the fuel pressure sensor on the rail Op. 1060G28 FUEL PRESSURE SENSOR - R R
4	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OB, that the diesel pressure between the filter and the pressure pump is between 0.6 and 0.7 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 10	Pressure lower than minimum limit	Move on to Step 5
		Move on to Step 10	Pressure above the maximum limit	Replace Bontaz pressure relief valve
5	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Move on to Step 6	Difference in pressure less than or equal to 1 bar	Replace the fuel filter cartridge Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the supply pump pressure at the filter inlet is 0.9 bar	Move on to Step 9	Pressure below 0.9 bar	Move on to Step 7
7	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between pump outlet and filter inlet is less than 0.3 bar	Move on to Step 8	Difference in pressure more than 0.3 bar	Replace the pipe
8	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 that the current absorbed is between 2 and 10 Ampere See Test 1040A FUEL TANK AND COMPONENTS	Move on to Step 9	Voltage < 12 V	Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current > 10 Amps: pump not running smoothly	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
			Current < 2 Amps: pump obstructed	Replace the fuel pump assembly and clean the fuel tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
9	CHECK CORRECT OPERATION OF PRESSURE REGULATOR	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure regulator and check that the fault is no longer present Op. 1060G16 PRESSURE RELIEF SENSOR - R R	End of diagnosis	The fault persists	Repair the pressure regulator and move on to Step 10
10	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	Fault persists control unit defective	Repair the high pressure pump and replace the engine management control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R

BIPOWER

The engine does not start. When the key is turned the instruments light up as normal, the starter motor turns, but the engine does not start up.

N.B.: The CODE warning light is working properly (it carries out the intial test)

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	First check for petrol in the tank (because the engine always starts in petrol mode whether set to petrol or methane mode). Check the inertia switch cuts in. Check the following, in order: petrol pump fuse condition; relays for methane engine management unit correctly fitted status of spark plugs and leads; condition of the air intake circuit; possible catalytic converter obstruction no water, other fluids or dirt in the fuel tank;	Move on to Step 1	Intertia switch operated	Restore correct operation
			Petrol pump fuse blown	Replace the petrol pump fuse
			Relays incorrectly fitted	Fit correctly
			Spark plugs dirty or damaged	Clean or replace the spark plugs Op. 5510D10 SPARK PLUGS - R.R.
			Spark plug leads damaged	Replace spark plug leads Op. 5510D14 SPARK PLUG CABLE LOOM - R.R.
			Air intake circuit component damaged	Replace the component Op. 1048A VACUUM AIR CIRCUIT
			Catalytic converter obstructed	Replace catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R
			Presence of dirt in the fuel tank	Clean the fuel tank
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the Examiner diagnostic equipment to the diagnostic connector and check the following at the petrol and LPG engine management unit, in the errors ambient: no faults in the petrol engine management control unit; no faults in the methane engine management control unit; in parameters ambient: plausibility of all parameters and correct rpm sensor operation	Move on to Step 2	If an error is detected in the petrol engine management unit	Continue following the instructions for the diagnostic equipment
			If an error is detected in the methane engine management unit	Continue following the instructions for the diagnostic equipment
			No communication with the methane and petrol control unit	Restore the connection between the Methane/Petrol engine management control unit and the diagnostic connector See E5032 METHANE ENGINE ELECTRONIC MANAGEMENT
			Petrol and methane engine management units not connected to earth	Repair the connection See E5032 METHANE ENGINE ELECTRONIC MANAGEMENT
			RPM sensor fault	Check wiring continuity/insulation and replace rpm sensor if necessary Op. 5510C26 ENGINE RPM SENSOR - R.R.
2	CHECK PETROL INJECTORS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic connector, check the following at the petrol engine management unit, in the active diagnosis ambient: Petrol injector operation	Move on to Step 3	Petrol injector connection fault	Restore connection between injectors and control unit See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
		Move on to Step 3	Petrol injector faulty	Replace petrol injectors Op. 1056B70 INJECTOR (ONE) - R.R. WITH FUEL MANIFOLD PIPE REMOVED - INCLUDES REPLACING THE GASKET
3	CHECK PETROL PUMP ACTIVATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic connector, check the following at the petrol engine management unit, in the active diagnosis ambient: Petrol pump relay operation	Move on to Step 4	Petrol pump relay fault	Restore connections between: Fuel pump Relay Engine management control unit Inertia switch See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
		Move on to Step 4	Petrol pump defective	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
4	CHECK COILS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic connector, check the following at the petrol engine management unit, in the active diagnosis ambient: correct coil operation Check the operation of the coils by carrying out Test 5510CC See Test 5510C COIL, ECU, SENSORS	Move on to Step 5	Coil fault	Replace ignition coils Op. 5510C10 IGNITION COIL/S - R+R
			Coil supply not correct	Restore correct power supply See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Wiring defective	Restore wiring See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Petrol engine management unit defective	Replace engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R
5	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

GPL

The engine does not start. When the key is turned the instruments light up as normal, the starter motor turns, but the engine does not start up.

N.B.: The CODE warning light is working properly (it carries out the intial test)

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	First check for petrol in the tank (because the engine always starts in petrol mode whether set to petrol or gas mode). Check the inertia switch cuts in. Check the following, in order: intertia switch possibly operated; petrol pump fuse condition; relays for LPG engine management unit correctly fitted status of spark plugs and leads; condition of the air intake circuit; possible catalytic converter obstruction; no water, other fluids or dirt in the fuel tank;	Move on to Step 1	Intertia switch operated	Restore correct inertia switch operation See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Petrol pump fuse blown	Renew fuse after having confirmed the cause of the break
			Relays incorrectly fitted	Fit correctly
			Spark plugs dirty or damaged	Clean or replace the spark plugs Op. 5510D10 SPARK PLUGS - R.R.
			Spark plug leads damaged	Replace spark plug leads Op. 5510D14 SPARK PLUG CABLE LOOM - R.R.
			Air intake circuit component damaged	Replace the component Op. 1048A VACUUM AIR CIRCUIT
			Catalytic converter obstructed	Replace catalytic converter Op. 1080B62 CATALYTIC CONVERTER - R + R
			Presence of dirt in the fuel filter	Clean the fuel tank
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the Examiner diagnostic equipment to the diagnostic connector and check the following at the petrol and methane engine management unit, in the errors ambient: no faults in the petrol engine management control unit; that there are no faults in the LPG engine management control unit; in parameters ambient: the plausibility of all the parameters; correct operation of rpm sensor	Move on to Step 2	If an error is detected in the petrol engine management unit	Continue following the instructions for the diagnostic equipment
			If an error is detected in the LPG engine management unit	Continue following the instructions for the diagnostic equipment
			No connection to earth for the PETROL engine management control unit	Restore wiring See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			No connection to earth for the LPG engine management control unit	Restore wiring See E5031 LPG FUEL SYSTEM ELECTRONIC MANAGEMENT
			RPM sensor fault	Check wiring continuity/insulation and replace rpm sensor if necessary See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
2	CHECK PETROL INJECTORS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic connector, check the following at the petrol engine management unit, in the active diagnosis ambient: the operation of the petrol injectors	Move on to Step 3	Petrol injector connection fault	Restore connection between injectors and control unit See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
		Move on to Step 3	Petrol injector faulty	Replace the injectors Op. 1056B70 INJECTOR (ONE) - R.R. WITH FUEL MANIFOLD PIPE REMOVED - INCLUDES REPLACING THE GASKET
3	CHECK PETROL PUMP ACTIVATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the Examiner diagnostic equipment connected to the diagnostic connector, check the following at the petrol engine management unit, in the active diagnosis ambient: petrol pump relay operation	Move on to Step 4	Petrol pump relay fault	Check that the connections are correct between: fuel pump; relay and engine management control unit. See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT Replace the relay if damaged
		Move on to Step 4	Petrol pump defective	Replace the petrol pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
4	CHECK COILS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic connector, check the following at the petrol engine management unit, in the active diagnosis ambient: correct coil operation Check the operation of the coils by carrying out Test 5510CC See Test 5510C COIL, ECU, SENSORS	Move on to Step 5	Coil fault	Replace ignition coils
			Coil supply not correct	Restore correct power supply See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Wiring defective	Restore wiring See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Petrol engine management unit defective	Replace engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R
5	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

All versions

The engine does not start. When the key is turned the instruments light up as normal, the starter motor turns, but the engine does not start up.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Turn the key ON and check that the initial check on the MIL and CODE warning lights takes place. The MIL warning light should come on and then go out when the engine is started up, whilst the CODE warning light should come on for about 4 seconds and then go out Then check: that the inertia switch has not been operated; presence of fuel in the tank; air intake circuit; air closure throttle on chamber open; correct operation of the exhaust manifolds	Move on to Step 1	The CODE waring light stays on	See table K52 CODE FAILURE WARNING LIGHT ON
			The MIL warning light does not carry out the intial test	See table K53 I.E. FAILURE WARNING LIGHT OFF / (INITIAL TEST NOT CARRIED OUT)
			Intertia switch operated	Restore correct operation
			Lack of fuel	Add fuel to the tank
			Filter dirty or partly blocked	Replace the filter element Op. 1048A14 AIR CLEANER FILTERING ELEMENT - REPLACE.
			Throttle valve closed	Restore the correct operation of the throttle valve
			Exhaust blocked	Restore the operation of the exhaust manifolds
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment to the diagnostic socket. 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 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 control unit and the diagnostic connector See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
2	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment to the diagnostic socket. Check, as described in test Test 1060OD, that the diesel pressure parameter is correct. See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 10	Pressure not correct	Move on to Step 3
3	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OA, that the pressure in the return pipe to the tank is less than 1 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 4	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary Op. 1060F52 PIPE TO RETURN MANIFOLD - R R
4	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1060OB, that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 10	Pressure below the minimum limit or above the maximum limit	Move on to Step 5
5	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Constrict the return pipe, downstream of the valve, and carry out Test 1060B again with the pipe constricted checking that the pressure at the filter outlet stays below 2 bar See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 6	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace filter mounting Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Move on to Step 7	Difference in pressure more than 1 bar	Replace the fuel filter cartridge Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
7	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 10	Pressure below 2.2 bar	Move on to Step 8
8	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between pump outlet and filter inlet is less than 0.3 bar	Move on to Step 9	Difference in pressure more than 0.3 bar	Replace the pipe
9	FUEL PUMP CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 V and that the current absorbed is between 2 and 10 Ampere See Test 1040A FUEL TANK AND COMPONENTS	Move on to Step 10	Voltage < 12 V	Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current > 10 Amps: pump not running smoothly	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
			Current < 2 Amps: pump obstructed	Replace the fuel pump assembly and clean the fuel tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
10	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	Restore the regulator valve and move on to Step 11
11	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure pump and check that the fault is no longer present Op. 1060E10 PRESSURE PUMP - R R	End of diagnosis	The fault persists: control unit defective	Repair the pressure pump and replace the engine management 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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