22 · Diagnostics

The engine cuts out whilst driving

Make: Lancia
Model: Thesis Factory Service Manual
Year: 2002–2009
Section: Engine › The engine cuts out whilst driving

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Fault diagnosisThe engine cuts out whilst driving

THE ENGINE CUTS OUT WHILST DRIVING

2.4 JTD 10V

The engine cuts out unexpectedly whilst driving. It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	presence of fuel in the tank; wiring on engine correctly fastened to earth; battery correctly fastened to earth; positive battery pole and all leads connected to it correctly fastened; no water in the fuel filter	Move on to Step	1. No fuel	1. Introduce fuel
			2. Fastenings slack or oxidized	2. Restore correct fastenings
			3. Presence of water in the fuel filter	3. Clean the tank and pipes and replace the filter element
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 errors in the control unit;	Move on to Step	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test reproducing the conditions in which the fault occurs, keeping the diagnostic equipment connected.Check: that there are no errors memorized in the control unit; that there are no errors memorized in the control unit;	Move on to Step	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
3	INJECTOR HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060C, that the diesel leaks from the injector recirculation connections are small (seepage) and about the same as one another.	Move on to Step	Persistent leak from one injector	Replace the injector
4	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check, as described in test 1060D, that the diesel pressure parameter is correct	Move on to Step	Pressure not correct	Move on to Step
5	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060A, that the pressure in the 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
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060B, that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step	Pressure below the minimum limit or above the maximum limit	Move on to Step
7	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Constrict the return pipe from the pressure regulator valve and carry out test 1060B again with the pipe constricted checking that the pressure at the filter outlet remains below 2 bar	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.
8	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	Difference in pressure more than 1 bar	Replace the diesel filter cartridge, See in Op. 1044B20 fuel filter filtering element - replace
9	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	Pressure below 2.2 bar	Move on to Step
10	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	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	Difference in pressure more than 0.3 bar	Replace the pipe
11	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	Move on to Step	1. Voltage < 12 volt	1. Check electrical wiring (Wiring Diagram ) E5050 DIESEL ENGINE ELECTRONIC MANAGEMENT
		Move on to Step	2. Current > 10 Amps: pump defective	2. Replace the fuel pump assembly See in Op. 1040A70 SUBMERGED PUMP ASSEMBLY complete with level gauge - R.R.
12	CHECK CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the DRV high pressure valve and check that the fault is no longer present		Fault persists	Move on to Step
13	CHECK CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure pump and check that the fault is no longer present		Fault persists	Contact the Service Department for further information on the problem

2.0 TB, 2.4 20V, 3.0 V6

The engine cuts out unexpectedly whilst driving. It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	First, check: correct earth fastening on engine; correct battery earth fastening (Wiring Diagram ) E1020 EARTHS positive battery pole and all leads connected to it correctly fastened (Wiring Diagram ) E1010 POWER SUPPLY no water in the fuel	Move on to Step	1. Earth leads fastening not correct	1. Restore or, if necessary, replace the battery earth lead See in Op. 5530B22 battery earth lead - r+r
			2. Positive battery lead fastenings not correct	2. Restore the positive battery lead See in Op. 5530B26 LEAD between battery and starter motor - R.R.
			3. Water in the fuel	3. Replace the fuel
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic test equipment (Examiner or other instruments) to the tester input.Check: that there are no faults in the engine management control unit; the plausibility of all the parameters	Move on to Step	1. Error detected in the control unit	1. Continue following the instructions in the diagnostic table
		Move on to Step	2. Parameter not consistent	2. Continue following the instructions in the diagnostic table
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test reproducing the conditions in which the fault occurs, keeping the diagnostic equipment connected.Check: that there are no faults in the engine management control unit; the plausibility of all the parameters	Move on to Step	1. The sudden onset of an error in the control unit is detected	1. Continue following the instructions in the diagnostic table
			2. Parameter not consistent	2. Continue following the instructions in the diagnostic table
			3. Loss of dialogue between the control unit and the diagnostic equipment	3. Restore the control unit circuit supply (Wiring Diagram ) E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
3	FUEL PRESSURE ROAD TEST	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test and check the fuel supply pressure See in Op. 0510C10 FUEL SYSTEM - Check DELIVERY PRESSURE Make sure that the conditions in which the problem occurs are reproduced	Move on to Step	1. Pressure not correct: obstructions in the pipe	1. Remove the obstructions in the fuel pipe, replace it if necessary
		Move on to Step	2. Pressure not correct: petrol pump damaged	2. Replace the petrol pump assembly See in Op. 1040A70 SUBMERGED PUMP ASSEMBLY complete with level gauge - R.R.
4	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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Parts & tools for this job For 2002 Lancia Thesis

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