Engine starts, and cuts out straight away

Make: Fiat
Model: Ducato Factory Service Manual
Year: 2002–2006
Section: Starting › Engine starts, and cuts out straight away

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Fault diagnosisEngine starts, and cuts out straight away

ENGINE STARTS, AND CUTS OUT STRAIGHT AWAY

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

The engine starts normally, though possibly with difficulty, then suddenly stalls

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: no water, other fluids or dirt in the fuel filter no water, other fluids or dirt in the fuel tank no obstructions in the catalytic converter	Move on to Step 1	Water, other fluids or dirt in the fuel filter	Replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
			Water, other fluids or dirt in the tank	Clean tank
			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 diagnostic equipment to the diagnostic socket. Re-create the conditions under which the fault occurs and check: that there are no errors in the control unit; parameter plausibility	Move on to Step 2	Errors detected in 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 correct connections 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 1060OD, that the diesel pressure parameter is correct. See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 9	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 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
4	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the diesel pressure between the filter and the radial jet pump is between 0.6and 0.7 bar	Move on to Step 9	Pressure lower than minimum limit	Move on to Step 5
		Move on to Step 9	Pressure above the maximum limit	Replace Bontaz pressure relief valve Op. 1060G28 FUEL PRESSURE SENSOR - R R
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 0.2 bar	Move on to Step 6	Difference in pressure more than 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 between 0.6 and 0.7 bar	Move on to Step 9	Pressure below 0.6 bar	Move on to Step 8
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 Op. 1040B30 FUEL DELIVERY LINE - R R
8	CHECK LOW OUTLET PRESURE PUMP UPTAKE	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 volt and that the current absorbed is between 2and10 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
		Move on to Step 9	Current > 10 Amps pump not running smoothly	Change fuel pump assembly and clean tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
9	CHECK ON CORRECT OPERATION	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	Fault persists	Renew the pressure regulator and move on to Step 10
10	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	Fault persists: control unit defective	Restore the pressure pump and replace the engine management control unit. Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R

The engine starts normally, though possibly with difficulty, then suddenly stalls

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: no water, other fluids or dirt in the fuel filter no water, other fluids or dirt in the fuel tank no obstructions in the catalytic converter	Move on to Step 1	Water, other fluids or dirt in the fuel filter	Replace the filter element Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
			Water, other fluids or dirt in the fuel tank	Clean tank
			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 diagnostic equipment to the diagnostic socket. Re-create the conditions under which the fault occurs and check: no errors in control unit parameter plausibility	Move on to Step 2	Errors detected in 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 correct connections 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 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 that the diesel pressure between the filter and the radial jet pump is between 2and 3 bar	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 the valve Op. 1044B16 DELIVERY ADJUSTMENT VALVE - R R
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	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in Test 1040AA, that the pump supply voltage is equal to 12 volt 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 jet blocked	Change fuel pump assembly and clean 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	Fault persists	Repair 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	Fault persists: control unit defective	Repair the 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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