22 · Diagnostics

Engine starts with difficulty

Make: Fiat
Model: Grande Punto Factory Service Manual
Year: 2005–2012
Section: Starting › Engine starts with difficulty

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Fault diagnosisEngine starts with difficulty

ENGINE STARTS WITH DIFFICULTY

1.9 Multijet

The customer complains of: Engine starting poor, the starter motor works normally.

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	Check that the engine oil level is correct Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY Check that the air intake/vacuum circuit is working properly See Test 1048OA AIR INTAKE/VACUUM CIRCUIT CHECK Check the condition of the fuel supply circuit and make sure that it is working properly See Test 1040OA FUEL SUPPLY CIRCUIT CHECK	Move on to Step 1	Oil level incorrect	Restore the correct engine oil level Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY
1	AMBIENT PARAMETERS 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 the value of the following parameters: . Battery voltage See Test 5530BB BATTERY VOLTAGE CHECK - Target diesel pressure - Measured diesel pressure See Test 1060GH DIESEL PRESSURE CHECK . Atmospheric pressure See Test 1060GD ATMOSPHERIC PRESSURE CHECK . Engine rpm See Test 1060GI CHECK ENGINE SPEED . Engine coolant temperature See Test 1060OE ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK	Move on to Step 2
2	PREHEATING RELAY ACTIVE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis of the preheating relay, checking that the result is positive The check on the following system is only necessary if the outside temperature is below 0 °C.	Move on to Step 4	The result of the active diagnosis is negative	Move on to Step 3
3	HEATER PLUGS CHECK	All OK	Problems encountered	Operation
	Check that the heater plugs are working properly See Test 5520CA CHECK GLOW PLUG OPERATION	Move on to Step 4
4	ELECTRICAL EQUIPMENT CHECK	All OK	Problems encountered	Operation
	Check that fuse F59 has not blown (second from the left on the second row from the bottom)	Move on to Step 5	Fuse F59 has blown	Restore the connections or, if necessary, replace the junction unit in the engine compartment Op. 5505A13 ADDITIONAL JUNCTION UNIT IN ENGINE COMPARTMENT - R.R.
5	DIESEL PREHEATING RELAY CHECK	All OK	Problems encountered	Operation
	Check the diesel preheating relay circuit See Test 5505AC CHECK DIESEL PREHEATING RELAY	Move on to Step 6
6	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Connect the diagnostic equipment to the diagnostic socket. Check that the diesel pressure parameter is correct See Test 1060OD HIGH PRESSURE FUEL CIRCUIT CHECK	Move on to Step 13	Pressure not correct	Move on to Step 7
7	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the pressure in the return pipe to the tank is less than 1 bar See Test 1060OA LOW FUEL RETURN PRESSURE CIRCUIT CHECK	Move on to Step 8	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe, if necessary, replace it
8	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the test that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK	Move on to Step 13	Pressure below the minimum limit or above the maximum limit	Move on to Step 9
9	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 10	Difference in pressure more than 1 bar	Replace the diesel filter cartridge Op. 1044B10 FUEL FILTER ASSEMBLY - R + R OR REPLACE
10	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 13	Pressure below 2 bar	Move on to Step 11
11	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Measure the difference in pressure between the electrical pump outlet and the filter inlet checking that it is less than 0.3 bar	Move on to Step 12	Difference in pressure more than 0.3 bar	Replace the pipe
12	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the test that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 Amps	Move on to Step 13	Voltage less than 12 volt	Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			Current greater than 10 A: pump defective	Replace the fuel pump assembly 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
13	CHECK CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the DRV high pressure regulator Op. 1060E50 and check that the fault is no longer present	End of diagnosis	Fault persists	Move on to Step 14
14	CHECK CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the high pressure pump Op. 1060E10 DIESEL INJECTION PRESSURE PUMP - R.R. and check that the fault is no longer present	End of diagnosis	Fault persists	Move on to Step 15
15	CYLINDER COMPRESSION CHECK	All OK	Problems encountered	Operation
	Carry out the cylinder compression check Op. 0510A10 CYLINDER COMPRESSION - CHECK FOR LOOSE SPARK PLUGS OR INJECTORS	Move on to Step 17	Cylinder compression insufficient	Move on to Step 16
16	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems encountered	Operation
	Carry out Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET to check the valve seal Check condition of cylinders/piston rings	Move on to Step 17	Valve seal insufficient	Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
		Move on to Step 17	Cylinders/piston rings worn	Restore the seal
17	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists	Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R

1.3 Multijet

The customer complains of: Engine starting poor, the starter motor works normally.

1	AMBIENT PARAMETERS CHECK	All OK	Problems encountered	Operation
		Test results
	Select the following control unit at the diagnostic equipment: Marelli Diesel Injection 6F3 EOBD CAN (EP engine 1.3 JTD). Check the value of the following parameters: - Coolant temperature See Test 1060OE ENGINE COOLANT TEMPERATURE SENSOR OPERATION CHECK - Pressure regulator opening (MPROP) (only 90 bhp) See Test 1060GR CHECK OPERATION OF FUEL PRESSURE SENSOR ON RAIL - Measured Diesel pressure See Test 1060GH DIESEL PRESSURE CHECK - Engine rpm See Test 1060GI CHECK ENGINE SPEED	Move on to Step 2
2	PREHEATING RELAY ACTIVE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis of the preheating relay, checking that the result is positive The check on the following system is only necessary if the outside temperature is below 0 °C.	End of diagnosis	The result of the active diagnosis is negative	Move on to Step 3
3	HEATER PLUGS CHECK	All OK	Problems encountered	Operation
	Check that the heater plugs are working properly See Test 5520CA CHECK GLOW PLUG OPERATION	End of diagnosis

1.2 8v, 1.4 8v

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Test results
	First, check: - that there are no obstructions in the air filter; - the condition of the air intake circuit. Remove the spark plugs and check their status and the electrode gap	Move on to Step 1	Air intake circuit component damaged	Repair or replace the damaged component
			Air filter blocked	Replace the filter Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.
			Spark plugs damaged	Replace spark plugs Op. 5510D10 SPARK PLUGS - R+R
			Spark plugs wet	Dry the spark plugs and continue to step 1
1	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Connect the Examiner 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	Proceed as instructed by the diagnostic tester
		Move on to Step 2	Parameters not plausible	Proceed as instructed by the diagnostic tester
2	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Carry out the active diagnosis for the canister solenoid valve	Move on to Step 3	Solenoid valve faulty	Replace the solenoid valve Op. 1080E28 ENABLEMENT SOLENOID FOR FLOW OF FUEL VAPOUR TO INLET - R+R
3	PETROL VAPOUR RECOVERY SYSTEM CHECK	All OK	Problems encountered	Operation
	Check the seal of the petrol vapour recovery system	Move on to Step 4	Air leaks	Restore the correct seal
	Check the seal of the petrol vapour recovery system	Move on to Step 4	Pipes connected to the supply broken	Replace the pipes
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	Fuel pressure too low: supply pipe obstructed	Eliminate the obstructions, if necessary, replace the pipe
		Move on to Step 5	Fuel pressure too low: pump defective	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
5	TIMING CHECK	All OK	Problems encountered	Operation
	Check that the valve gear timing is correct Op. 0510A20 TIMING GEAR WITH BELT DRIVE - CHECK - CARRY OUT OPERATION WITH CAM COVER(S) REMOVED AND TAPPETS ADJUSTED AND CRANKSHAFT PULLEY DETACHED (IF NECESSARY)	Move on to Step 6	Valve gear timing not correct	Restore the correct valve gear timing Op. 1032B14 TOOTHED TIMING BELT - R + R FOR TIMING ADJUSTMENT OR REPLACEMENT VERSIONS WITH AIR CONDITIONER
6	CYLINDER COMPRESSION CHECK	All OK	Problems encountered	Operation
	Carry out the cylinder compression check Op. 0510A10 CYLINDER COMPRESSION - CHECK FOR LOOSE SPARK PLUGS OR INJECTORS	Move on to Step 8	Cylinder compression insufficient	Move on to Step 7
7	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems encountered	Operation
	R/R head for valve leakage test Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET Check condition of cylinders/piston rings	Move on to Step 8	Valve seal insufficient	Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
			Cylinders/piston rings worn	Restore the seal
			Cylinder head/cylinder block-crankcase matching faulty	Restore correct matching
8	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 control unit Op. 1056B82 INJECTION/IGNITION SYSTEM E.C.U. (ONE) - R + R

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