		Test results
0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
	Check the following, in order: that there are no obstructions in the air filter; the condition of the air intake circuit diesel pipe seal; absence of fuel, water, paraffin or dirt in the diesel filter. correct operation of the exhaust manifolds the condition of the wiring and the operation of the preheating system (heater plugs)	Move on to Step 1	Air intake circuit component	Repair or replace the damaged component
			Filter blocked	Replace the air filter Op. 1048A10
			Leaks from the diesel pipes	Adjust pipe tightness to correct setting and replace if necessary.
			Water, petrol, paraffin or dirt found to be present	Clean the tank and pipes and replace the diesel filter cartridge Op. 1044B20
			Obstruction in exhaust system	Replace the damaged system component
			Preheating wiring faulty	Restore wiring See E5050 GESTIONE ELETTRONICA MOTORI DIESEL
			Heater plugs faulty	Replace damaged heater plugs
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;	Move on to Step 2	Presence of error P0093	Move on to Step 2
			Simultaneous presence of errors P1191 and P1197	Move on to Step 4
			Simultaneous presence of errors P1194 and P1197	Move on to Step 4
			Presence of error P1191	Move on to Step 3
			Presence of error P1194	Move on to Step 3
			Other errors present	Proceed as instructed by the diagnostic equipment
2	HIGH PRESSURE CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check the condition of the rail and check that there are no leaks from the rail, the radial jet pump, the injector pipes and the high pressure pipes.	Move on to Step 3	Presence of leaks	Restore the correct seal for the system
3	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Connect the Examiner diagnostic equipment to the diagnostic socket. Check as described in the test See Test 1060D Verifica circuito combustibile alta pressione that the diesel pressure parameter is correct; Check the operation of the high pressure sensor on the rail by carrying out the test See Test 1060GE Verifica funzionalità sensore alta pressione gasolio The operation of the pressure regulator through active diagnosis.	Move on to Step 11	Sensor faulty	Replace the sensor
			Pressure regulator fault	Replace the pressure regulator
			Pressure not correct	Move on to Step 4
4	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the test See Test 1060A Verifica circuito combustibile bassa pressione di ritorno that the pressure in the return pipe to the tank is less than 1 bar	Move on to Step 5	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe; if necessary, replace it
5	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the test See Test 1060B Verifica circuito combustibile bassa pressione di mandata check that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step 11	Pressure below the minimum limit or above the maximum limit	Move on to Step 6
6	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Clse the return pipe downstream of the low pressure regulator valve, in the fuel filter cover, using the special tool, and carry out the test again See Test 1060B Verifica circuito combustibile bassa pressione di mandata with the pipe closed, checking that the filter outlet pressure remains below 2 bar	Move on to Step 7	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the diesel filter cover
7	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 8	Difference in pressure more than 1 bar	Replace the diesel filter cartridge
8	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 11	Pressure below 2 bar	Move on to Step 9
9	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 10	Difference in pressure more than 0.3 bar	Replace the pipe
10	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the test See Test 1040AA Verifica della tensione di alimentazione e della corrente di assorbimento that pump supply voltage is equal to 13 Volts and that current uptake is less than or equal to 4.6 Amps.	Move on to Step 11	Voltage lower than 12 volts	Check electrical wiring See E5050 GESTIONE ELETTRONICA MOTORI DIESEL
		Move on to Step 11	Current greater than 4.6 Amps: pump defective	Replace the fuel pump assembly Op. 1040A70
11	CHECK CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the high pressure regulator and check that the fault is no longer present	End of diagnosis	Fault persists	Move on to Step 12
12	CHECK CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the high pressure pump and check that the fault is no longer present	End of diagnosis	Fault persists	Move on to Step 13
1.3 JTD Climate control	R/R head Op. 1016C11 to check the valve seal Check condition of cylinders/piston rings	Move on to Step 13	Valve seal insufficient	Overhaul the cylinder head Op. 1016E10
13	CYLINDER COMPRESSION CHECK	All OK	Problems encountered	Operation
	Carry out the cylinder compression check	Move on to Step 15	Cylinder compression insufficient	Move on to Step 14
14	CAUSE OF INSUFFICIENT COMPRESSION CHECK	All OK	Problems encountered	Operation
	R/R head for valve leakage test Check condition of cylinders/piston rings	Move on to Step 15	Valve seal insufficient	Overhaul the cylinder head Op. 1016E10
		Move on to Step 15	Cylinders/piston rings worn	Restore the seal
15	CORRECT OPERATION CHECK	All OK	Problems encountered	Operation
	Check that the fault is no longer present	End of diagnosis End of diagnosis	Fault persists: control unit defective	Replace the engine management control unit Op. 1060G80

APPLICABLE TO VERSIONS WITH: Euro 5

		Test results
0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
	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 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
		Move on to Step 1	Air vacuum circuit fault	Replace vacuum pump. Eliminate the intake air via the intake manifold gasket or the tappet cover gasket and engine block. Restore a perfect seal for the engine.
1	MODE PARAMETERS CHECK	All OK	Problems encountered	Operation
	Select the engine management control unit on the diagnosis equipment. Check the value of the following parameters: · Battery voltage · Target Diesel pressure · Measured Diesel pressure · Atmospheric pressure · Engine rpm · Engine coolant temperature	Move on to Step 2
2	PARTICULATE FILTRATION SYSTEM CHECKS	All OK	Problems encountered	Operation
	Select the engine management control unit on the diagnosis equipment. Check that the DPF system is working properly	Move on to Step 3	Errors present	Continue as instructed by the diagnostic equipment
3	PREHEATING RELAY ACTIVE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis of the preheating relay, checking that the result is positive	Move on to Step 5	The result of the active diagnosis is negative	Move on to Step 4
4	GLOW HEATER PLUGS CHECK	All OK	Problems encountered	Operation
	Check that the glow heater plugs are working properly See Test 5520CA CHECK GLOW PLUG OPERATION See Test	Move on to Step 5	1.Glow heater plugs defective Wiring defective 3.Preheating control unit defective 4.Engine control unit defective	1.Replace the glow heater plugs Op. 5520C10 HEATER PLUGS - R+R Restore the wiring See E5050 DIESEL ENGINE ELECTRONIC MANAGEMENT - DESCRIPTION 3.Replace preheating control unit Op. 5520C20 HEATER PLUGS CONTROL UNIT - R.R 4.Replace the engine management control unit Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - R.R
5	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 6	Pressure not correct	Move on to Step 12
6	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 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 as described in the test See Test 1060OB LOW FUEL DELIVERY PRESSURE CIRCUIT CHECK that the diesel pressure between the filter and the pressure pump is between 4.5 and 6 bar	Move on to Step 8	Pressure below the minimum limit or above the maximum limit	Move on to Step 10
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 diesel 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 4.5 bar	Move on to Step 10	Pressure below 4.5 bar	Move on to Step 12
10	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 11	Difference in pressure more than 0.3 bar	Replace the pipe
11	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check as described in the test See Test 1040AA that the pump supply voltage is equal to 12V and that the current uptake is between 4 and 8 Amps	Move on to Step 12	Voltage less than 12 volt	Check electrical wiring See E5050 DIESEL ENGINE ELECTRONIC MANAGEMENT - DESCRIPTION
			Current greater than 8 A: pump defective	Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GAUGE CONTROL - R + R
			Current less than 4 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 CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the high pressure pump Op. 1060E10 PRESSURE PUMP FOR DIESEL INJECTION - R.R. and check that the fault is no longer present	End of diagnosis	Fault persists	Go to Step 13
13	CYLINDER COMPRESSION CHECK	All OK	Problems encountered	Operation
	Carry out the cylinder compression test Op. 0520G15 COMPRESSION TEST - CHECK WITH EXAMINER WITH SPARK PLUGS/INJECTORS REMOVED	Move on to Step 15	Cylinder compression insufficient	Move on to Step 14
14	CAUSE OF INSUFFICIENT COMPRESSION CHECK	All OK	Problems encountered	Operation
	Implement 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 15	Valve seal insufficient	Overhaul the head Op. 1016E10 SINGLE CYLINDER HEAD - DETACHED - OVERHAUL
		Move on to Step 15	Cylinders/piston rings worn	Restore the seal
15	CORRECT OPERATION CHECK	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.R

APPLICABLE TO VERSIONS WITH: Euro 5

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