Engine does not start (under any circumstances)

Make: Alfa Romeo
Model: 159 Factory Service Manual
Year: 2005–2011
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 JTD 8V, 1.9 JTD 16V, 2.4 JTD 20V

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
		Results of the tests
	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 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 IGNITION SYSTEM CHECK	Move on to Step 2
2	PARTICLE FILTER SATURATION CHECK	All OK	Problems encountered	Operation
	Select the following control unit at the diagnostic equipment: EDC16C39 Diesel electronic injection control unit. Check the saturation level of the dust in the particle filter See Test 1080BE PARTICULATE FILTER SATURATION CHECK	Move on to Step 3
3	CHECK USING DIAGNOSTIC EQUIPMENT	All OK	Problems encountered	Operation
	Carry out active diagnosis of flow modification valve	Move on to Step 4	Solenoid valve not working	Check the wiring continuity See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT Replace the solenoid valve if necessary Op. 1060G72 SOLENOID FOR THROTTLE BODY PNEUMATIC VALVE - R.R.
4	FLOW MODIFICATION VALVE ACTUATOR CHECK	All OK	Problems encountered	Operation
	Check operation of the pneumatic actuator	Move on to Step 5	Actuator not working	Replace electro-pneumatically controlled throttle casing Op. 1060G52
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 1	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 See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUIT that the diesel pressure parameter is correct.	Move on to Step 17	Pressure not correct	Move on to Step 7
7	INJECTOR HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Check, See Test 1060OC INJECTORS SEAL TEST that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another.	Move on to Step 8	Significant leak from one injector	Replace the injector Op. 1060F10 FUEL INJECTORS - R.R.
8	LOW RETURN PRESSURE CHECK	All OK	Problems encountered	Operation
	Check, See Test 1060OA CHECK ON RETURN LOW PRESSURE FUEL CIRCUIT 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
	Check See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step 15	Pressure below the minimum limit or above the maximum limit	Move on to Step 10
10	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Constrict the return pipe downstream of the valve and carry out once again See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT with the pipe constricted, checking that the filter outlet pressure remains below 2 bar	Move on to Step 11	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the valve See Test 1044B16 FUEL SUPPLY/RETURN REGULATION VALVE ON FUEL FILTER - R.R.
11	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 12	Difference in pressure more than 1 bar	Replace the fuel filter cartridge See Test 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
12	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 15	Pressure below 2,2 bar	Move on to Step 13
13	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 14	Difference in pressure more than 0.3 bar	Replace the pipe
14	LOW SUPPLY PRESSURE CHECK	All OK	Problems encountered	Operation
	Check See Test 1040AA SUPPLY VOLTAGE AND ABSORPTION CURRENT CHECKS that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A	Move on to Step 15	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
15	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 16
16	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
17	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

1.9 JTS, 2.2 JTS, 3.2 JTS

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
	Attempt start-up for 15 seconds. Press the START/STOP button to turn on the panel. Check whether any of the following errors are present using the diagnostic equipment: P0115, P0230, P0301, P0302, P0303, P0304, P0335, P0336, P0603, P0604, P0605, P0606, P0638	Move on to Step 1	One or more of the errors indicated is present	Continue as described by the diagnostic equipment
1	CHECK VEHICLE PROTECTION SYSTEM ERRORS	All OK	Problems encountered	Operation
	Check the body computer for errors in the vehicle protection system.	Move on to Step 2	One or more errors in the vehicle protection system is indicated	Continue as described by the diagnostic equipment
2	FUEL PUMP RELAY CHECK	All OK	Problems encountered	Operation
	Insert the ignition key and check the pump comes on for 2 seconds	Move on to Step 3	The pump is not activated	Check that the fuel pump relay is working properly See Test 1040AD FUEL PUMP RELAY CHECK
3	POWER SUPPLY CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check there are no faults in the fuel supply circuit by carrying out test See Test 1040OA FUEL SUPPLY CIRCUIT CHECK	Move on to Step 4	Faults present	The test indicates the solution
4	RPM SENSOR ERROR CHECK	All OK	Problems encountered	Operation
	Connect the diagnostic equipment and check that error P0335 is not present	Move on to Step 5	Error P0335 is present	Continue as described by the diagnostic equipment
5	AIR INTAKE CIRCUIT CHECK	All OK	Problems encountered	Operation
	Check there are no faults in the air intake circuit In particular, check: - that the air filter is not blocked or fitted incorrectly - that the air intake circuit does not contain abnormal restrictions or leaks or is not incorrectly fitted	Move on to Step 6	Air filter blocked	Replace the filter element Op. 1048A14 AIR CLEANER FILTER ELEMENT - REPLACE.
			Faulty component	Replace the faulty component Op. 1048 ENGINE AIR SUPPLY CIRCUIT
			Components incorrectly positioned	Refit the faulty component correctly Op. 1048 ENGINE AIR SUPPLY CIRCUIT
6	CHECK FOR IMPURITIES IN THE FUEL	All OK	Problems encountered	Operation
	Check that the fuel does not contain impurities such as water, alcohol or suspended particles by performing test See Test	Move on to Step 7	Faults present	The test indicates the solution
7	SPARK PLUG CHECK	All OK	Problems encountered	Operation
	Remove the spark plugs. Op. 5510D10 SPARK PLUGS - R+R and check that they do not display signs of faults as indicated in the test See Test	Move on to Step 8	Faults present	The test indicates the solution
8	FLOW METER CHECK	All OK	Problems encountered	Operation
	Disconnect the flow meter so that the engine control unit enters recovery mode and calculates air flow using default values. Check that the fault persists under these conditions	Move on to Step 9	The engine starts normally when the flow meter is disconnected	The flow meter is faulty: delete the errors and replace the flow meter Op. 1056F09 HOT FILM AIRFLOW METER DEBIMETER R R
9	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 11	Cylinder compression insufficient	Move on to Step 10
10	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 11	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
11	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 12	Valve gear timing not correct	Restore the correct valve gear timing
12	EXHAUST PIPE CHECK	All OK	Problems encountered	Operation
	Check the exhaust circuit for leaks, loose connections, restrictions, deformations or damage	Move on to Step 13	Faults present	Restore correct fastening of faulty parts. Replace them if necessary.
13	CHECK WATER TEMPERATURE SENSOR ERRORS	All OK	Problems encountered	Operation
	Connect the diagnostic equipment and check that error P0115 is not present	Move on to Step 14	Error P0115 present	Continue as described by the diagnostic equipment
14	ERROR DELETION	All OK	Problems encountered	Operation
	Use the diagnostic instrument to delete the errors and check start-up is successful	Move on to Step 15	The engine still will not start	Move on to Step 0
15	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Allow the engine to warm up while idling. Check that the diagnostic instrument has not detected any more errors in the control unit	End of diagnosis	Errors still present in control unit	Continue as described by the diagnostic equipment

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