Engine does not start (under any circumstances)

Make: Fiat
Model: Grande Punto Factory Service Manual
Year: 2005–2012
Section: Starting › Engine does not start (under any circumstances)

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Fault diagnosisEngine does not start (under any circumstances)

ENGINE DOES NOT START (UNDER ANY CIRCUMSTANCES)

1.9 Multijet

The customer complains of: The engine does not start, the starter motor turns slowly/does not turn

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	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; - correct operation of the flow modification valve; - correct operation of the exhaust manifolds. - that there are no leaks or seepage from the high and low pressure fuel pipes	Move on to Step 1	The CODE waring light stays on	Proceed as instructed See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START)
			The MIL warning light does not carry out the intial test	Proceed as instructed See table K53 GPL PRESSURE SENSOR
			The CODE warning light does not carry out the intial test	Proceed as instructed See table
			The warning lights do not carry out the initial test	Proceed as instructed See table K49 ALTITUDE SENSOR
			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 FILTER ELEMENT - REPLACE.
			Flow modulation valve working incorrectly	Move on to Step 3
			Exhaust blocked	Move on to Step 2
			Presence of leaks	Eliminate leaks
1	ENGINE STARTING ELECTRIC CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check that the engine starting electric circuit is working properly See Test 5520BA ENGINE STARTING CIRCUIT CHECK	Move on to Step 2
2	FLOW MODIFICATION VALVE ACTUATOR CHECK	All OK	Problems encountered	Operation
	Select the following control unit on the diagnostic equipment: Diesel electronic injection control unit EDC16C39 CF4/EOBD CAN (EP engine 1.9) Check operation of the pneumatic actuator	Move on to Step 3	Actuator not working	Replace electro-pneumatically controlled throttle body Op. 1060G50 THROTTLE BODY - R.R
3	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Connect the diagnostic equipment to the diagnostic socket. Check: - no errors in control unit - parameter plausibility	Move on to Step 4	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
4	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Check See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK that the diesel pressure parameter is correct.	Move on to Step 14	Pressure not correct	Move on to Step 5
5	INJECTOR HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Check, See Test 1060OC INJECTOR SEAL TEST that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another.	Move on to Step 6	Significant leak from one injector	Replace the injector Op. 1060F10 FUEL INJECTORS - R.R.
6	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check, See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK that the pressure in the return pipe to the tank is less than 1 bar	Move on to Step 7	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe, if necessary, replace it
7	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step 12	Pressure below the minimum limit or above the maximum limit	Move on to Step 8
8	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Move on to Step 9	Difference in pressure more than 1 bar	Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
9	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	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	Operation
	Measure the difference in pressure between the electric pump outlet and the filter inlet and check that it is less than 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	Operation
	Check See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKE that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A	Move on to Step 12	Voltage lower than 12 V	Renew electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current greater than 10 A: pump defective	Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
			Current less than 2 A: pump obstructed	Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R and clean the fuel tank
12	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the DRV high pressure regulating valve Op. 1060E50 PRESSURE REGULATOR ON PRESSURE PUMP - R.R. and check that the fault is no longer present.	End of diagnosis	Fault persists	Move on to Step 13
13	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer present	End of diagnosis	Fault persists	Contact technical service for further information on the problem
14	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R and check that the fault is no longer present	End of diagnosis	Fault persists	Contact technical service for further information on the problem

1.3 Multijet

The customer complains of: The engine does not start, the starter motor turns slowly/does not turn

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	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; - correct operation of the flow modification valve; - correct operation of the exhaust manifolds. - that there are no leaks or seepage from the high and low pressure fuel pipes	Move on to Step 1	The CODE waring light stays on	Proceed as instructed See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START)
			The MIL warning light does not carry out the intial test	Proceed as instructed See table K053 M.I.L. WARNING LIGHT OFF (INITIAL TEST NOT CARRIED OUT) / ENGINE DOES NOT START
			The CODE warning light does not carry out the intial test	Proceed as instructed See table K054 VEHICLE PROTECTION WARNING LIGHT OFF (ENGINE DOES NOT START)
			The warning lights do not carry out the initial test	Proceed as instructed See table K049 I.E. FAILURE WARNING LIGHT AND CODE WARNING LIGHT BOTH OFF / ENGINE DOES NOT START
			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 FILTER ELEMENT - REPLACE.
			Flow modulation valve working incorrectly	Move on to Step 2
			Presence of leaks	Eliminate leaks
1	ENGINE STARTING ELECTRIC CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check that the engine starting electric circuit is working properly See Test 5520BA ENGINE STARTING CIRCUIT CHECK	Move on to Step 2
2	RPM SENSOR CHECK	All OK	Problems encountered	Operation
	Check the operation of the rpm sensor by carrying out the See Test 1060GA RPM SENSOR EFFICIENCY CHECK	Move on to Step 3
3	TIMING SENSOR CHECK	All OK	Problems encountered	Operation
	Check the operation of the timing sensor by carrying out the See Test 1060GC CHECK TIMING SENSOR OPERATION	Move on to Step 4
4	PREHEATING SYSTEM CHECK	All OK	Problems encountered	Operation
	Preheating system check See Test 5520CA CHECK GLOW PLUG OPERATION Check the condition of the wiring and the operation of the preheating system	Move on to Step 5
5	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Connect the diagnotsic equipment to the diagnostic socket. Check: - no errors in control unit - parameter plausibility	Move on to Step 6	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
6	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK that the diesel pressure parameter is correct.	Move on to Step 14	Pressure not correct	Move on to Step 7
7	INJECTOR HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Injector high pressure check See Test 1060OC INJECTOR SEAL TEST Check, as instructed in the that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another.	Move on to Step 18	Significant leak from one injector	Replace the injector
8	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK that the pressure in the return pipe to the tank is less than 1 bar	Move on to Step 9	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe, if necessary, replace it
9	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Low supply pressure check Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Move on to Step 10	Difference in pressure more than 1 bar	Replace the fuel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
10	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Low supply pressure check Check that the pressure of the fuel pump at the filter inlet is more than 2.2 bar (75 CV) or 4.5 bar (90 CV)	Move on to Step 13	Pressure below 2.2 bar/4.5 bar	Move on to Step 11
11	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Low supply pressure check Measure the difference in pressure between the electric pump outlet and the filter inlet and check that it is less than 0.3 bar	Move on to Step 12	Difference in pressure more than 0.3 bar Pressure below 2.2 bar/4.5 bar	Replace the pipe
12	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the See Test 1040AA CHECK ON SUPPLY VOLTAGE AND CURRENT UPTAKE that the pump supply voltage is equal to 13V and that the current uptake is between 2 and 10 A	Move on to Step 13	Voltage lower than 12 V	Renew electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
		Move on to Step 13	Current outside the range: pump defective	Replace the fuel pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
13	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer present	End of diagnosis	Fault persists	Contact technical service for further information on the problem
14	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R and check that the fault is no longer present	End of diagnosis	Fault persists	Contact technical service for further information on the problem

1.2 8v, 1.4 8v

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.

The MIL warning light should come on with the ignition on and go out once the engine is started;

A CODE system fault is present if the control panel displays a Code fault message.

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	Check the following, in order: - that no CODE system fault is present - that the inertia switch has not been operated;	Move on to Step 1	CODE fault present	Proceed as instructed in the See table K052 VEHICLE PROTECTION WARNING LIGHT ON (ENGINE DOES NOT START)
		Move on to Step 1	Intertia switch operated	Restore correct operation
1	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Connect the Examiner diagnostic equipment to the diagnostic connector and check the following at the engine management control unit: - that there are no errors in the control unit; - parameter plausibility	Move on to Step 2	Error detected in the control unit	Proceed as instructed by the diagnostic tester
		Move on to Step 2	Parameters not plausible	Proceed as instructed by the diagnostic tester
2	FUEL PUMP ACTIVATE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis of the fuel pump and check that it is working properly	Move on to Step 4	Pump not working	Move on to Step 3
3	PETROL PUMP ELECTRIC CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check petrol pump supply and earth See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT	Move on to Step 4	Connections not correct	Repair the connections See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT
		Move on to Step 4	Pump faulty	Replace the petrol pump Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
4	SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the fuel pressure is correct Op. 0510C10 FUEL SYSTEM - CHECK DELIVERY PRESSURE	Move on to Step 5	Pressure not correct: front pipe obstructed	Eliminate the obstructions. If necesssary, replace the pipe
		Move on to Step 5	Pressure not correct: fuel pump assembly faulty	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
5	CHECK IGNITION OPERATION	All OK	Problems encountered	Operation
	Check the coil ignition efficiency by performing See Test 5510CC IGNITION COIL OPERATION CHECK	End of diagnosis	No spark present at more than one coil	Move on to Step 6
		End of diagnosis	No spark present on all coils	Move on to Step 7
6	COIL ELECTRICAL CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check the continuity of the primary circuit of the non-operational coils See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT	Move on to Step 8	Connections not correct	Repair the connections See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT
7	COIL ELECTRICAL CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check the continuity of the primary circuit of the coils See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT	Move on to Step 9	Connections not correct	Repair the connections See E5030 PETROL ENGINES ELECTRONIC MANAGEMENT
8	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists: coil defective	Replace the defective coils Op. 5510C14 IGNITION COIL/S - R.R.
9	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists: control unit defective	Replace the engine management control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

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