23 · Diagnostics

Engine starts with difficulty

Make: Fiat
Model: Ducato Factory Service Manual
Year: 2002–2006
Section: Starting › Engine starts with difficulty

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Fault diagnosisEngine starts with difficulty

ENGINE STARTS WITH DIFFICULTY

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

The engine, particularly when cold, starts with difficulty and only after repeated attempts. When the key is turned the instruments light up as normal, the starter motor turns, but the engine is difficult to start.

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; diesel pipe seal; condition of the air filter; absence of fuel, water, paraffin or dirt in the diesel filter.	Move on to Step 1	Fault in the air intake circuit	Renew the air intake circuit
			Leaks from the diesel pipes	Adjust pipe tightness to correct setting and replace if necessary
			Filter blocked	Replace the filter element Op. 1048A14 AIR CLEANER FILTERING ELEMENT - REPLACE.
			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
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the Examiner tester to the diagnostic output. Check: that there are no errors in the control unit; the plausibility of the parameters; glow plug operation run active diagnosis on the glow plug control unit	Move on to Step 2	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
			Parameters not plausible	Proceed as instructed by the diagnostic equipment
			Glow plug control unit defective	Replace the glow plug control unit
			Glow plugs not working properly (not heating)	Change glow plug Op. 5520C10 GLOW PLUGS - R+R
2	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the Examiner tester to the diagnostic output. 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 reservoir 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
		Move on to Step 4	Bontaz pressure relief valve defective	Change pressure relief valve 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 filter and high pressure pump is between 0.6 and 0.7 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	INJECTOR HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check as described in Test 1060OC that the injectors are correctly sealed See Test 1060O DIESEL FUEL INJECTION SUPPLY TESTS	Move on to Step 6	Injectors defective	Replace the injectors Op. 1060F10 FUEL INJECTORS
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 less than or equal to 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 between 0.6 and 0.7 bar	Move on to Step 11	Pressure below 0.6 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 Op. 1040B30 FUEL DELIVERY LINE - R R
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 V and current uptake is between 2 and 10 Amps See Test 1040A FUEL TANK AND COMPONENTS	Move on to Step 10	Voltage < 12 V	Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
		Move on to Step 10	Current> 10 Amps: pump not running smoothly	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 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 regulator and continue 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	Reset the pressure pump and continue to Step 12
12	CYLINDER COMPRESSION CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out the cylinder compression check	Move on to Step 14	Cylinder compression insufficient	Move on to Step 13
13	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	R/R head to check valve leakage test Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL Check condition of cylinders/piston rings	Move on to Step 12	Valve seal insufficient	Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
		Move on to Step 12	Cylinders/piston rings worn	Restore the seal Op. 1004E20 ENGINE - DISMANTLE AND RE-BUILD FOLLOWING OPERATION 1004E10 - WASH AND CHECK DISMANTLED PARTS - RE-FIT CYLINDER HEAD AND OIL SUMP - DOES NOT INCLUDE REPAIRS TO CYLINDER HEAD AND AUXILIARY UNIT
14	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present	End of diagnosis	Fault persists control unit defective	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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