Engine cuts out whilst running (then not restarting)

Make: Alfa Romeo
Model: Brera and Spider Factory Service Manual
Year: 2005–2010
Section: Engine › Engine cuts out whilst running (then not restarting)

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Fault diagnosisEngine cuts out whilst running (then not restarting)

ENGINE CUTS OUT WHILST RUNNING (THEN NOT RESTARTING)

2.4 JTD 20v

The customer complains of: The engine cuts out whilst idling, it is impossible to restart it

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Results of the tests
	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 by carrying out the Op. 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 Also check 1. wiring on engine correctly fastened to earth; 2. battery correctly fastened to earth; 3. positive battery pole and all leads connected to it correctly fastened	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
			Supply fastenings slack or oxidized	Restore correct fastenings See E1010 POWER SUPPLY
			Earth fastenings slack or oxidized	Restore correct fastenings See E1010 POWER SUPPLY
1	AMBIENT PARAMETERS CHECK	All OK	Problems encountered	Operation
	Select the following control unit at the diagnostic equipment: EDC16C39 Diesel electronic injection control unit. Check the value of the following parameters: . Battery voltage See Test 5530BB BATTERY VOLTAGE CHECK . Engine rpm See Test 1060GI ENGINE SPEED CHECK . Objective Diesel pressure . Measured Diesel pressure See Test 1060GH DIESEL FUEL PRESSURE CHECK	Move on to Step 2
2	PARTICLE FILTRATION SYSTEM CHECKS	All OK	Problems encountered	Operation
	Check that the DPF system is working properly See Test 1080BE PARTICULATE FILTER SATURATION CHECK	Move on to Step 3
3	PREHEATING RELAY ACTIVE DIAGNOSIS	All OK	Problems encountered	Operation
	Carry out the active diagnosis for 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 5	The result of the active diagnosis is negative	Move on to Step 4
4	HEATER PLUGS CHECK	All OK	Problems encountered	Operation
	Check that the heater plugs are working properly See Test 5520CA GLOW PLUGS FUNCTIONAL TEST	Move on to Step 5
5	ELECTRICAL EQUIPMENT CHECK	All OK	Problems encountered	Operation
	Check that fuse F1 has not blown (it is the last one at the bottom of the veritical row)	Move on to Step 6	Fuse F1 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.
		Move on to Step 6	Fuse F20 has blown	Move on to Step 6
6	INJECTOR HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the diesel leaks from the injector recirculation connections are small (seepage) and roughly equal to one another. See Test 1060OC INJECTORS SEAL TEST	Move on to Step 7	Significant leak from one injector	Replace the injector Op. 1060F10 FUEL INJECTORS - R.R.
7	HIGH PRESSURE CHECK	All OK	Problems encountered	Operation
	Check that the diesel pressure parameter is correct. See Test 1060OD INSPECTION OF THE HIGH PRESSURE FUEL CIRCUIT	Move on to Step 16	Pressure not correct	Move on to Step 8
8	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 CHECK ON RETURN LOW PRESSURE FUEL CIRCUIT	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 that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar See Test 1060OB CHECK ON SUPPLY LOW PRESSURE FUEL CIRCUIT	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 vlve and carry out the test 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 Op. 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 Op. 1044B20
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 that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 A See Test 1040AA SUPPLY VOLTAGE AND ABSORPTION CURRENT CHECKS	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 regulation valve and check that the fault is no longer present. Op. 1060E50 PRESSURE REGULATOR ON PRESSURE PUMP - R.R.	End of diagnosis	Fault persists	Move on to Step 16
16	CHECK ON CORRECT OPERATION	All OK	Problems encountered	Operation
	Replace the engine management control unit and check that the fault is no longer present Op. 1060G80 DIESEL ELECTRONIC INJECTION CONTROL UNIT - .R	End of diagnosis	Fault persists	Contact technical service for further information on the problem

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