23 · Diagnostics

Engine cuts out whilst driving

Make: Fiat
Model: Panda Factory Service Manual
Year: 2003–2012
Section: Engine › Engine cuts out whilst driving

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Fault diagnosisEngine cuts out whilst driving

ENGINE CUTS OUT WHILST DRIVING

1.1, 1.2 8v

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: that the earth is correctly fixed on the engine that the battery earth is correctly fixed correct fixing of the positive battery terminal and the leads connected to it for any obstructions in the catalyzer that there is no water or other fluids in the fuel tank	Continue to Step 1	Earth leads incorrectly fixed	Renew or, if necessary, replace the battery earth lead Op. 5505A38
			Battery positive earth incorrectly fixed	Restore battery positive lead Op. 5530B26
			Catalyzer obstructed	Replace the catalyzer Op. 1080B62
			Presence of dirt in the fuel tank	Clean the fuel tank Op. 1040A24
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket. check that there are no faults in the engine management control unit; the plausibility of all the parameters.	Continue to Step 2	An error is detected in the control unit	Continue following the instructions for the diagnostic equipment
		Continue to Step 2	Inconsistent parameter	Continue following the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. check that there are no faults in the engine management control unit; the plausibility of all the parameters.	Continue to Step 3	Error arises suddenly in the control unit	Continue following the instructions for the diagnostic equipment
			Error arises suddenly in the control unit	Continue following the instructions for the diagnostic equipment
			Error arises suddenly in the control unit	Restore the control unit circuit supply See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
3	CHECK ON FUEL PRESSURE ON ROAD	All OK	Problems met	Operation
	Road test the vehicle and check the fuel supply pressure Op. 0510C10 Make sure that the conditions in which the problem occurs are reproduced	Continue to Step 4	Pressure not correct: obstructions in fuel delivery pipe	Remove the obstructions in the fuel pipe, and if necessary replace it Op. 1040B30
			Pressure not correct: obstructions in fuel delivery pipe	Restsore the tank ventilation
			Pressure not correct: obstructions in fuel delivery pipe	Repair fuel pump electrical circuit See E5030 PETROL ENGINE ELECTRONIC MANAGEMENT
			Pressure not correct: obstructions in fuel delivery pipe	Replace fuel pump assembly Op. 1040A70
4	Continue as instructed by the tester	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists: control unit faulty	Replace control unit Op. 1056B82

1.3 JTD 16v

The engine cuts out suddenly whilst driving. Later, after starting normally, it works again

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: that there is fuel in the tank the engine wiring is properly connected to earth battery earth correctly fixed correct fixing of positive battery terminal and that all leads are connected no water in the fuel filter	Continue to Step 1	No fuel	Add fuel)
			Fastenings slack or oxidized	Re-attach correctly
			Presence of water in the fuel filter	Clean the tank and pipes and replace the filter element
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the Examiner diagnostic equipment to the diagnostic socket. check for errors in the control unit	Continue to Step 2	Presence of one of the following errors: P0262, P0265, P0268, P0271	Continue to Step 4
			Presence of error P0093	Continue to Step 3
			Simultaneous presence of errors P1191 and P1197	Continue to Step 7
			Simultaneous presence of errors P1194 and P1197	Continue to Step 7
			Presence of error P1191	Continue to Step 5
			Presence of one of the following errors: P1193, P1195, P1196	Continue to Step 5
			Presence of other errors	Continue according to the instructions for the diagnostic equipment
2	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Road test the vehicle, reproducing the conditions in which the fault arises, keeping the diagnostic equipment connected. check that there are no errors in the control unit;	Continue to Step 4	Presence of one of the following errors: P0262, P0265, P0268, P0271	Continue to Step 4
			Presence of error P0093	Continue to Step 3
			Simultaneous presence of errors P1191 and P1197	Continue to Step 6
			Simultaneous presence of errors P1194 and P1197	Continue to Step 6
			Presence of error P1191	Continue to Step 5
			Presence of one of the following errors: P1193, P1195, P1196	Continue to Step 5
			Presence of other errors	Continue according to the instructions for the diagnostic equipment
3	HIGH RESSURE CIRCUIT CHECK	All OK	Problems met	Operation
	Check the condition of and that there are no leaks from the rail, the radial jet pump, the injector pipes and all the high pressure lines.	Continue to Step 4	There are leaks	Eliminate leaks from the system
4	INJECTOR HIGH PRESSURE CHECK	All OK	Problems met	Operation
	Check, as described in the test See Test 1060C Injector high pressure fuel circuit check, that diesel leaks from the injector recirculation connections are small and about the same as one another.	Continue to Step 5	Consistent leak from one injector	Replace the injector
5	HIGH PRESSURE CHECK	All OK	Problems met	Operation
	Connect the Examiner diagnostic equipment to the diagnostic socket. Check as described in the test See Test 1060D Check high pressure fuel circuit that the diesel pressure parameter is correct. Check the operation of the rail high pressure sensor by carrying out the test See Test 1060GE Check on operation of diesel high pressure sensor the operation of the pressure regulator through active diagnosis.	Continue to Step 13	Sensor faulty	Replace sensor.
			Pressure regulator faulty	Replace the pressure regulator
			Pressure not correct	Continue to Step 6
6	CHECK ON RETURN LOW PRESSURE	All OK	Problems met	Operation
	Check as described in the test See Test 1060A Low return fuel pressure circuit checkthat the pressure in the return pipe to the tank is under 1 bar	Continue to Step 7	Pressure above maximum limit: return pipe to tank blocked	Repair the pipe; if necessary replace it
7	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check as described in the test See Test 1060B Low fuel pressure supply circuit checkthat the diesel pressure between filter and pressure pump is between 2 and 3 bar	Continue to Step 13	Pressure below minimum limit or above maximum limit	Continue to Step 8
8	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Choke the return pipe from the pressure regulating valve and repeat the test See Test 1060B Low fuel pressure supply circuit checkwith the pipe choked, checking that the pressure at the filter outlet is below 2 bar	Continue to Step 9	Pressure rises to 5 bar: pressure regulator in filter casing stuck	Replace the filter case with valve
9	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Continue to Step 10	Difference in pressure greater than 1 bar	Replace the diesel filter cartridge Op. 1044B20
10	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check that the supply pump pressure at the filter inlet is over 2.2 bar	Continue to Step 13	Pressure below 2.2 bar	Continue to Step 11
11	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Measure the difference in pressure between electric pump outlet and filter inlet, checking that it is less than 0.3 bar	Continue to Step 12	Difference in pressure greater than 0.3 bar	Replace the pipe
12	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check as described in the test See Test 1040AA Check supply voltage and absorption currentthat the pump's supply voltage is 13V and that the absorbed current is less than or equal to 4.6 amps	Continue to Step 13	Voltage below 12 V	Check electric wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
		Continue to Step 13	Current greater than 4.6 amps: pump faulty	Replace the fuel pump assembly Op. 1040A70
13	CORRECT OPERATION CHECK	All OK	Problems met	Operation
	Replace the pressure pump and check that the fault is no longer present	End of diagnosis End of diagnosis	Fault persists	Continue to Step 14
14	CORRECT OPERATION CHECK	All OK	Problems met	Operation
	Replace the pressure pump and check that the fault is no longer present	End of diagnosis End of diagnosis	Fault persists	Contact Technical Service for further information on the problem

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