Engine does not produce best performance

Make: Fiat
Model: Panda Factory Service Manual
Year: 2003–2012
Section: Engine › Engine does not produce best performance

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Fault diagnosisEngine does not produce best performance

ENGINE DOES NOT PRODUCE BEST PERFORMANCE

1.1, 1.2 8v

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily check: the state of the spark plugs and leads; full accelerator pedal travel the condition of air filter the condition of the air intake circuit; absence of obstructions in the catalytic converter	Continue to Step 1	Spark plugs dirty or damaged	Replace the spark plugs Op. 5510D10
			Cables damaged	Replace spark plug leads Op. 5510D14
			Insufficient accelerator pedal travel	Restore pedal travel
			Air intake circuit fault	Eliminate the problem
			Catalyzer obstructed	Replace the exhaust manifold Op. 1072C16
1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the Examiner diagnostic equipment to the diagnostic socket. check that there are no faults in the engine management control unit; plausibility of all the parameters	Continue to Step 2	'Supply system' error detected	Coolant leaks detected See table Z50
			Another error dectected in the control unit	Another error dectected in the control unit
			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; plausibility of all the parameters	Continue to Step 3	'Supply system' error detected	Coolant leaks detected See table Z50
			Sudden occurrence of another error detected	Continue following the instructions for the diagnostic equipment
			Parameters inconsistent	Continue following the instructions for the diagnostic equipment
3	FUEL PRESSURE ROAD TEST	All OK	Problems met	Operation
	Road test the vehicle and check the fuel supply pressure Op. 0510C10in the conditions that lead to the anomaly	Continue to Step 4	Insufficient fuel pressure: pipes obstructed	Remove restrictions
			Insufficient fuel pressure: valve obstructed	Replace the tank cap
			Insufficient fuel pressure: regulator out of calibration	Replace the pump assembly Op. 1040A70
			Insufficient fuel pressure: regulator out of calibration	Replace the pump assembly Op. 1040A70
			Insufficient fuel pressure: regulator out of calibration	Replace the pump assembly Op. 1040A70
4	CHECK ON TIMING	All OK	Problems met	Operation
	Check that the timing is correct Op. 0510A20	Continue to Step 5	Timing not correct	Restore the correct timing
5	CHECK ON CYLINDER COMPRESSION	All OK	Problems met	Operation
	Carry out the cylinder compression test Op. 0510A10	Continue to Step 7	Cylinder compression insufficient	Continue to Step 6
6	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems met	Operation
	Carry out R/R on head to check the valve seal Op. 1016C10 Check the condition of the cylinders/piston rings	Continue to Step 7	Insufficient valve seal	Overhaul the cylinder head Op. 1016E10
		Continue to Step 7	Cylinders/piston rings worn	Repair the leak
7	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

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Check, in order: the condition of the air intake circuit no faults in the air filter; seal of the diesel pipes; accelerator pedal travel; that there no obstructions in the exhaust system	Continue to Step 1	Fault in air intake circuit	Repair the air intake circuit
			Air filter blocked	Replace the filter element Op. 1048A14
			Leaks from the diesel pipes	stop the leak
			Accelerator pedal travel incomplete	Eliminate the cause of the problem
			Exhaust system obstructed	Replace the defective system component
1	CHECK TURBOCHARGER ADJUSTMENT	All OK	Problems met	Operation
	Check the operation of the turbocharger as described in the Test See Test 1064BA Check turbo presure	Continue to Step 2	Actuator does not work correctly	Check the condition of the vacuum circuit and, if necessary, replace the damaged components
		Continue to Step 2	Turbocharger faulty	Replace the turbocharger Op. 1064B24
2	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the Examiner diagnostic equipment to the diagnostic socket. and check: for errors in the control unit	Continue to Step 3	Presence of error P0093	Continue to Step 9
			Simultaneous presence of errors P1191 and P1197	Continue to Step 11
			Simultaneous presence of errors P1194 and P1197	Continue to Step 11
			Presence of error P1191	Continue to Step 10
			Presence of one of the following errors: P1193, P1195, P1196	Continue to Step 10
			Presence of error P0180	Continue to Step 8
			Presence of error P0168	Continue to Step 8
			Presence of one of the following errors: P0101, P1102	Continue to Step 4
			Presence of error P1237	Continue to Step 4
			Presence of one of the following errors: P0120, P0220, P0226	Continue to Step 6
			Presence of error P0504	Continue to Step 7
			Presence of error P0400	Continue to Step 5
			Presence of other errors	Continue according to the instructions for the diagnostic equipment
3	ROAD TEST WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	ROAD TEST WITH DIAGNOSTIC EQUIPMENT Make sure that the conditions in which the problem occurs are reproduced check for errors in the control unit	Continue to Step 4	Presence of error P0093	Continue to Step 9
			Simultaneous presence of errors P1191 and P1197	Continue to Step 11
			Simultaneous presence of errors P1194 and P1197	Continue to Step 11
			Presence of error P1191	Continue to Step 10
			Presence of one of the following errors: P1193, P1195, P1196	Continue to Step 10
			Presence of error P0180	Continue to Step 8
			Presence of error P0168	Continue to Step 8
			Presence of one of the following errors: P0101, P1102	Continue to Step 4
			Presence of error P1237	Continue to Step 4
			Presence of one of the following errors: P0120, P0220, P0226	Continue to Step 6
			Presence of error P0504	Continue to Step 7
			Presence of error P0400	Continue to Step 5
			Presence of other errors	Continue according to the instructions for the diagnostic equipment
4	CHECK FLOW METER	All OK	Problems met	Operation
	Using an Examiner, check that the sensor is working properly by carrying out the test See Test 1060GB Check on operation of air flow meter	Continue to Step 5	Debimeter signal incorrect	Replace the flow meter
5	CHECK EGR	All OK	Problems met	Operation
	With an Examiner connected to the tester output, perform: active testing of the electric EGR valve Check the condition of the EGR system, particularly to ensure that the EGR is not blocked open	Continue to Step 6	EGR wiring broken	Restore correct operation See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			EGR valve fault	Replace EGR Op. 1080C74
			EGR system mechanical fault	Restore correct operation
6	CHECK ACCELERATOR PEDAL POTENTIOMETER	All OK	Problems met	Operation
	Check the correct operation of the accelerator pedal potentiometer as described in the test See Test 1068AB Check operation of accelerator pedal potentiometer	Continue to Step 7	Anomalous potentiometer operation	Replace potentiometer
		Continue to Step 7	Electrical wiring defective	Renew the wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
7	CHECK ON BRAKE PEDAL SWITCH	All OK	Problems met	Operation
	Check the operation of the brake pedal switch (using the tester to check the status of the relevant parameter has changed correctly)	Continue to Step 8	Brake pedal does not return	Eliminate the cause of the sticking
			Switch stuck in closed position	Replace the switch Op. 1060G38
			Wiring short circuited	Restore the correct connection
8	CHECK DIESEL HEATING SYSTEM	All OK	Problems met	Operation
	Check the condition of the heating system and record the temperature of the diesel fuel and the condition of the wiring Perform active diagnosis on the diesel filter heater	Continue to Step 9	System fault	Restore correct operation
		Continue to Step 9	Wiring faulty	Renew the wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
9	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 10	There are leaks	Eliminate leaks from the system
10	HIGH PRESSURE CHECK	All OK	Problems met	Operation
	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. Check the operation of the high pressure sensor on the rail by carrying out See Test 1060GE Check on operation of diesel high pressure sensor; the operation of the pressure regulator through active diagnosis.	Continue to Step 18	Sensor faulty	Replace sensor.
			Pressure regulator faulty	Replace the pressure regulator
			Pressure not correct	Continue to Step 11
11	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 12	Pressure above maximum limit: return pipe to tank blocked	Repair the pipe, if necessary, replace it.
12	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 18	Pressure below minimum limit or above maximum value	Continue to Step 13
13	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Choke the return pipe and repeat the test See Test 1060B Low fuel pressure supply circuit checkwith the pipe choked, checking that the pressure at the filter outlet remains below 2 bar	Continue to Step 14	Pressure rises to 5 bar: blocked pressure regulation valve on filter support	Replace the valve Op. 1044B16
14	CHECK DELIVERY LOW PRESSURE	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 15	Difference in pressure greater than 1 bar	Replace the fuel filter cartridge Op. 1044B20
15	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Check that the pressure downstream of the supply pump is over 2.2 bar	Continue to Step 18	Pressure below 2 bar	Continue to Step 16
16	LOW SUPPLY PRESSUR CHECK	All OK	Problems met	Operation
	Measure the difference in pressure between the electric pump outlet and filter inlet, checking that it is less than 0.3 bar	Continue to Step 17	Difference in pressure greater than 0.3 bar	Replace the pipe
17	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 18	Voltage below 12 V	Check electric wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
		Continue to Step 18	Current greater than 4.6 amps: pump faulty	Replace fuel pump assembly Op. 1040A70and clean the fuel tank
18	Continue as instructed by the tester	All OK	Problems met	Operation
	Replace the high-pressure regulating valve and check that the fault is no longer present.	End of diagnosis End of diagnosis	Fault persists	Continue to Step 19
19	Continue as instructed by the tester	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 20
20	CHECK ON TIMING	All OK	Problems met	Operation
	Check that the timing is correct	Continue to Step 21	Timing not correct	Restore the correct timing Op. 1032B14
21	TAPPET CHECK	All OK	Problems met	Operation
	Check the operation of the hydraulic tappets	Continue to Step 22	Tappet defective	Replace the defective tappet
22	CHECK ON CYLINDER COMPRESSION	All OK	Problems met	Operation
	Carry out the cylinder compression test	Continue to Step 24	Cylinder compression insufficient	Continue to Step 23
23	CHECKING CAUSE OF INSUFFICIENT COMPRESSION	All OK	Problems met	Operation
	Carry out R.R. on head to check the valve seal and check the condition of the cylinders/piston rings	Continue to Step 24	Insufficient valve seal	Overhaul the cylinder head Op. 1016E10
24	Continue as instructed by the tester	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis End of diagnosis	Fault persists: control unit faulty	Replace engine management control unit Op. 1060G80

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