22 · Diagnostics

Engine cuts out whilst driving

Make: Fiat
Model: Ulysse Factory Service Manual
Year: 2002–2010
Section: Engine › Engine cuts out whilst driving

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Fault diagnosisEngine cuts out whilst driving

ENGINE CUTS OUT WHILST DRIVING

2.0 16V JTD, 2.2 16V JTD

The engine cuts out unexpectedly whilst driving. It works later on after starting normally.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	presence of fuel in the tank; wiring on engine correctly fastened to earth; battery correctly fastened to earth; positive battery pole and all leads connected to it correctly fastened; no water in the fuel filter	Move on to Step	1. No fuel	1. Introduce fuel
			2. Fastenings slack or oxidized	2. Restore correct fastenings
			3. Presence of water in the fuel filter	3. Clean the tank and pipes and replace the filter element
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check: that there are no errors in the control unit;	Move on to Step	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test reproducing the conditions in which the fault occurs, keeping the diagnostic equipment connected.Check: that there are no errors memorized in the control unit;	Move on to Step	Error detected in the control unit	Continue following the instructions for the diagnostic equipment
3	INJECTOR HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060C, that the diesel leaks from the injector recirculation connections are small (seepage) and about the same as one another.	Move on to Step	Persistent leak from one injector	Replace the injector
4	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	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	Move on to Step	Pressure not correct	Move on to Step
5	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060A, that the pressure in the return pipe to the tank is less than 1 bar	Move on to Step	Pressure above the maximum limit: return pipe to the tank obstructed
6	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060B, that the diesel pressure between the filter and the pressure pump is between 2 and 3 bar	Move on to Step	Pressure below the minimum limit or above the maximum limit	Move on to Step
7	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Constrict the return pipe from the pressure regulator valve and carry out test 1060B again with the pipe constricted checking that the pressure at the filter outlet remains below 2 bar	Move on to Step	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the valve
8	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the difference in pressure upstream and downstream of the filter is less than 1 bar	Move on to Step	Difference in pressure more than 1 bar	Replace the diesel filter cartridge, Op. 1044B20 FUEL FILTER FILTERING ELEMENT - REPLACE
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the supply pump pressure at the filter inlet is more than 2.2 bar	Move on to Step	Pressure below 2,2 bar	Move on to Step
10	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	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	Difference in pressure more than 0,3 bar	Replace the pipe
11	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1040AA, that the pump supply voltage is equal to 12 volt and that the current absorbed is between 2 and 10 Ampere	Move on to Step	1. Voltage < 12 volt	1. Check electrical wiring See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			2. Current > 10 Amps: pump defective	2. Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
			3. Current < 2 Amps: pump obstructed	3. Replace the fuel pump assembly < R1 > and clean the fuel tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
12	CHECK CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure pump and check that the fault is no longer present.		Fault persists	Move on to Step
13	CHECK CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure pump and check that the fault is no longer present		Fault persists	Contact the Service Department for further information on the problem

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Parts & tools for this job Staging For 2002 Fiat Ulysse

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