Engine does not achieve maximum performance

Make: Lancia
Model: Thesis Factory Service Manual
Year: 2002–2009
Section: Engine › Engine does not achieve maximum performance

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Fault diagnosisEngine does not achieve maximum performance

ENGINE DOES NOT ACHIEVE MAXIMUM PERFORMANCE

2.4 JTD 10V

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; that there are no faults in the air filter; the seal of the diesel pipes; the accelerator pedal travel; no obstructions at the catalyzer	Move on to Step	1. Fault in the air intake circuit	1. Renew the air intake circuit
			2. Air filter blocked	2. Replace the filter element See in Op. 1048A14 air cleaner filtering element - replace.
			3. Leaks from the diesel pipes	3. Eliminate the leaks
			4. Accelerator pedal does not complete its full travel	4. Eliminate the cause of the problem
			5. Catalyzer obstructed	5. Replace the catalyzer
			6. Operation not correct	6. Carry out the actuator leakage test [test 1064BC] Continue following the instructions in the test 1064BC Variable geometry turbocharger actuator leakage test
1	TURBOCHARGER ADJUSTMENT CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Using the diagnostic equipment, carry out the active diagnosis of the turbocharger regulation solenoid valve. Check the operation of the variable geometry control actuator [by carrying out test 1064BC] Continue following the instructions in the test 1064BA Check the supercharging pressure	Move on to Step	1. Solenoid valve not working	1. Check continuity of wiring, if necessary, replace solenoid valve See in Op. 1064A28 Solenoid valve for turbocharger vanes actuator
		Move on to Step	2. Actuator not working properly	2. Check the condition of the vacuum circuit, if necessary, replace the damaged components
2	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check: that there are no errors in the control unit; the plausibility of the parameters; carry out the active diagnosis of the E.G.R. solenoid valve	Move on to Step	1. Error detected in the control unit	1. Continue following the instructions for the diagnostic equipment
			2. Parameters not plausible	2. Continue following the instructions for the diagnostic equipment
			3. E.G.R. solenoid valve not working	3. Check the continuity of the wiring (Wiring Diagram ) E5050 DIESEL ENGINE ELECTRONIC MANAGEMENT
			4. E.G.R. solenoid valve not working	4. Replace the solenoid valve [PR. 1080C74] See in Op. 1080C74 E.G.R. VALVE - R.R.
3	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test keeping the diagnostic equipment connected. Make sure that the conditions in which the problem occurs are reproduced Check: that there are no errors in the control unit; parameter plausibility	Move on to Step	1. The sudden onset of errors in the control unit is detected	1. Continue following the instructions for the diagnostic equipment
			2. Parameters off the scale	2. Continue following the instructions for the diagnostic equipment
			3. No dialogue with the control unit	3. Restore the connection between the engine management control unit and the diagnostic connector (Wiring Diagram ) E5050 DIESEL ENGINE ELECTRONIC MANAGEMENT
4	BRAKE PEDAL SWITCH CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the brake pedal switch is working properly	Move on to Step	1. Brake pedal does not return	1. Eliminate the cause of the sticking
			2. Switch stuck closed	2. Replace the switch See in Op. 1060G38 Switch on brake pedal - R.R.
			3. Wiring short circuited	3. Eliminate the cause of the problem
5	TURBOCHARGER CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the operation of the turbocharger as described in test 1064BA Continue following the instructions in the test 1064BA Check the supercharging pressure	Move on to Step	Turbocharger faulty	Replace the turbocharger See in Op. 1064A24 TURBOCHARGER - EXHAUST MANIFOLD - HOSE CONNECTED TO EXHAUST PIPE - R.R.
6	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check that the diesel pressure parameter is correct Continue following the instructions in the test 1060D Injector high pressure fuel circuit check	Move on to Step	Pressure not correct	Move on to Step
7	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060A, that the pressure in the fuel return pipe to the tank is less than 1 bar	Move on to Step	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	ACTION
	Check that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar Continue following the instructions in the test 1060B Low pressure fuel supply circuit check	Move on to Step	Pressure below the minimum limit or above the maximum value	Move on to Step
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Constrict the return pipe and carry out test 1060B again with the pipe constricted checking that the filter outlet pressure remains below 2 bar Continue following the instructions in the test 1060B Low pressure fuel supply circuit check	Move on to Step	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the valve See in Op. 1044B16 Fuel supply/return adjustment valve on fuel filter - R.R.
10	CHECK LOW SUPPLY PRESSURE	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	Difference in pressure more than 1 bar	Replace the fuel filter cartridge See in Op. 1044B20 fuel filter filtering element - replace
11	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure downstream of the supply pump is more than 2.2 bar	Move on to Step	Pressure below 2 bar	Move on to Step
12	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Measure the difference in pressure between the electric pump outlet and the filter inlet checking that it is less than 0.3 bar	Move on to Step	Difference in pressure more than 0.3 bar	Replace the pipe
13	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 Continue following the instructions in the test 1040AA Check the supply voltage and the absorption current	Move on to Step	1. Voltage < 12 volt	1. Check electrical wiring (Wiring Diagram ) E5050 DIESEL ENGINE ELECTRONIC MANAGEMENT
			2. Current > 10 Ampere: pump defective	2. Replace the fuel pump assembly See in Op. 1040A70 SUBMERGED PUMP ASSEMBLY complete with level gauge - R.R.
			3. Current < 2 Ampere: pump obstructed	3. Replace the fuel pump assembly and clean the fuel tank See in Op. 1040A70 SUBMERGED PUMP ASSEMBLY complete with level gauge - R.R.
14	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the DRV pressure regulation valve and check that the fault is no longer present		Fault persists	Move on to Step
15	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure pump and check that the fault is no longer present		Fault persists	Move on to Step
16	TIMING CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the valve gear timing is correct	Move on to Step	Valve gear timing not correct	Restore the correct valve gear timing See in Op. 1032B10 TOOTHED timing BELT - R.R. for timing adjustment or replacement
17	VALVE CLEARANCE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the tappet clearance is correct	Move on to Step	Valve clearance not correct	Adjust the tappets See in Op. 1036H10 CHECK AND ADJUST VALVE TAPPETS
18	CYLINDER COMPRESSION CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out the cylinder compression check	Move on to Step	Cylinder compression insufficient	Move on to Step
19	CHECK THE CAUSE OF THE INSUFFICIENT COMPRESSION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	R.R. the head to check the valve seal and check the condition of the cylinders/piston rings	Move on to Step	Valve seal insufficient	Overhaul the cylinder head See in Op. 1016E10 SINGLE CYLINDER HEAD, removed - Overhaul
20	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present		Fault persists control unit defective	Replace the engine management control unit See in Op. 1060G80 Diesel electronic injection system CONTROL UNIT - R.R.

2.0 TB, 2.4 20V, 3.0 V6

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	First, check: the condition of the air filter; the condition of the air intake circuit; that there are no obstructions in the exhaust pipe	Move on to Step	1. Air intake circuit faulty	1. Eliminate the problem, if necessary, replace the filter element See in Op. 1048A14 air cleaner filtering element - replace.
		Move on to Step	2. Pipe obstructed	2. Restore the operation of the exhaust pipes
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check: that there are no faults in the engine management control unit; parameter plausibility	Move on to Step	1. "Fuel system" error detected	1. Continue following the instructions in Table Z050
			2. Another error detected in the control unit	2. Continue following the instructions for the diagnostic equipment
			3. Parameter not consistent	3. Continue following the instructions for the diagnostic equipment
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test keeping the diagnostic equipment connected.Check: that there are no faults in the engine management control unit; parameter plausibility	Move on to Step	1. "Fuel system" error detected	1. Continue following the instructions in Table Z050
			2. The sudden onset of another error is detected	2. Continue following the instructions for the diagnostic equipment
			3. Parameters not consistent	3. Continue following the instructions for the diagnostic equipment
3	FUEL PRESSURE ROAD TEST	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Carry out a road test and check the fuel supply pressure in the conditions in which the problem occurs See in Op. 0510C10 FUEL SYSTEM - Check DELIVERY PRESSURE	Move on to Step	1. Fuel pressure too low: pipes obstructed	1. Eliminate the constrictions
2.4 20 V,2.0 TB		Move on to Step	2. Fuel pressure too low: pump defective	2. Replace the pump assembly See in Op. 1040A70 SUBMERGED PUMP ASSEMBLY complete with level gauge - R.R.
3	FUEL PRESSURE ROAD TEST	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test and check the fuel supply pressure in the conditions in which the problem occurs See in Op. 0510C10 FUEL SYSTEM - Check DELIVERY PRESSURE	Move on to Step	1. Fuel pressure too low: pipes obstructed	1. Eliminate the constrictions
		Move on to Step	2. Fuel pressure too low: pump defective	2. Replace the pump assembly See in Op. 1040A70 SUBMERGED PUMP ASSEMBLY complete with level gauge - R.R.
4	MODULAR MANIFOLD SOLENOID VALVE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Carry out the active diagnosis of the modular manifold solenoid valve	Move on to Step	Solenoid valve not working	Move on to Step
5	MODULAR MANIFOLD SOLENOID VALVE CIRCUIT CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Check the supply and earth for the modular manifold solenoid valve (Wiring Diagram ) E5030 PETROL ENGINE ELECTRONIC MANAGEMENT	Move on to Step	1. Solenoid valve faulty	1. Replace the solenoid valve
2.4 20 V,2.0 TB		Move on to Step	2. Connections not correct	2. Renew the connections (Wiring Diagram ) E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
6	MODULAR MANIFOLD CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Check that the modular manifold is working properly	Move on to Step	1. Pneumatic actuator not working	1. Restore the correct connection. If necessary, replace the actuator (Wiring Diagram ) E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
2.4 20 V,2.0 TB	Check that the modular manifold is working properly	Move on to Step	2. Manifold not working	2. Replace the manifold
7	PHASE TRANSFORMER SOLENOID VALVE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Carry out the active diagnosis of the phase transformer solenoid valve	Move on to Step	Solenoid valve not working	Move on to Step
8	PHASE TRANSFORMER ELECTRICAL CIRCUIT CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Check the supply and earth for the phase transformer solenoid valve (Wiring Diagram ) E5030 PETROL ENGINE ELECTRONIC MANAGEMENT	Move on to Step	1. Phase transformer faulty	1. Replace the phase transformer
2.4 20 V,2.0 TB		Move on to Step	2. Connections not correct	2. Renew the connections (Wiring Diagram ) E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
9	PHASE TRANSFORMER CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
2.4 20 V,2.0 TB	Check the operation of the phase transformer supplying the phase transformer solenoid avlve directly whilst idlingThe engine speed should vary considerably (very irregular idling)	Move on to Step	There are no speed variations: phase transformer stuck	Replace the phase transformer
10	TIMING CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the valve gear timing is correct	Move on to Step	Valve gear timing not correct	Restore the correct valve gear timing
11	CYLINDER COMPRESSION CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out the cylinder compression check See in Op. 0510A10 CYLINDER COMPRESSION - Check with spark plugs or injectors removed	Move on to Step	Cylinder compression insufficient	Move on to Step
12	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	R/R head for valve leakage test Check condition of cylinders/piston rings	Move on to Step	1. Valve seal insufficient	1. Overhaul the head
		Move on to Step	2. Cylinders/piston rings worn	2. Restore the seal
13	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present		Fault persists control unit defective	Replace the control unit See in Op. 1056B82 Injection/ignition system CONTROL UNIT (one) - R.R.

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