Engine does not produce best performance

Make: Fiat
Model: Ulysse Factory Service Manual
Year: 2002–2010
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

2.0 16V JTD, 2.2 16V JTD

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: condition of the air intake circuit; that there are no faults in the air filter; the seal of the diesel pipes; accelerator pedal travel; that there are no obstructions in the exhaust pipe.	Move on to Step	1. Air intake circuit faulty	1. Repair the air intake circuit
			2. Air filter blocked	2. Replace the filter element
			3. Leaks from diesel pipes	3. Eliminate the leaks
			4. Accelerator pedal does not complete its full travel	4. Eliminate the cause of the problem
			5. Obstructions in the exhaust system	5. Replace the damaged component of the exhaust system
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic test equipment (Examiner or other instruments) to the tester input.Check: that there are no errors in the control unit; parameter plausibility.	Move on to Step	1. Error detected in the control unit	1. Continue following the instructions for the diagnostic equipment
		Move on to Step	2. Parameters not plausible	2. Continue following the instructions for the diagnostic equipment
2	ROAD TEST USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out a road test keeping the diagnostic equipment connected. Check: that there are no errors in the control unit; parameter plausibility.	Move on to Step	1. The sudden onset of errors in the control unit is detected	1. Continue following the instructions for the diagnostic equipment
			2. Parameters off the scale	2. Continue following the instructions for the diagnostic equipment
			3. No communication with the control unit	3. Restore the connection between the engine management control unit and the diagnostic connector (see Wiring Diagrams)
3	CHECK PRESSURE PUMP THIRD PISTON DEACTIVATION DEVICE	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check operation of the third pressure pump piston deactivation device.	Move on to Step	1. Electrical connections not correct	1. Repair the electrical connections
		Move on to Step	2. Device not working (locked closed even above 2/3 of full engine load)	2. Replace the pressure pump at the end of diagnosis
4	BRAKE PEDAL SWITCH CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the brake pedal switch is working properly	Move on to Step	1. Brake pedal does not return	1. Eliminate the cause of the sticking
			2. Switch stuck closed	2. Replace the switch
			3. Wiring short circuited	3. Eliminate the cause of the problem
5	TURBOCHARGER CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check turbocharger operation as described < R1 > See Test 1064BA SUPERCHARGING PRESSURE CHECK	Move on to Step	Turbocharger faulty	Replace the turbocharger
6	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Check that the diesel pressure parameter is correct as described < R1 > See Test 1060D ELECTRONIC DIESEL INJECTION CONTROL	Move on to Step	Pressure not correct	Move on to Step
7	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 See Test 1060A LOW RETURN FUEL PRESSURE CIRCUIT CHECK	Move on to Step	Pressure above the maximum limit: return pipe to the tank obstructed	Repair the pipe and replace if necessary
8	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 See Test 1060B LOW FUEL PRESSURE SUPPLY CIRCUIT CHECK	Move on to Step	Pressure below the minimum limit or above the maximum limit	Move on to Step
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Constrict the return pipe, downstream of the valve, and carry out test 1060B again with the pipe constricted checking that the pressure at the filter outlet stays below 2 bar See Test 1060B LOW FUEL PRESSURE SUPPLY CIRCUIT CHECK	Move on to Step	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the valve
10	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 fuel filter cartridge
11	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the supply pump pressure is more than 2.2 bar	Move on to Step	Pressure below 2 bar	Move on to Step
12	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure difference between pump outlet and filter inlet is less than 0.3 bar	Move on to Step	1. Difference in pressure more than 0,3 bar	1. Replace pipe, end of fault diagnosis
13	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as decribed in test 1040AA, that the pump supply voltage is equal to 12V and that the current uptake is between 2 and 10 Amps	Move on to Step	1. Voltage < 12 volt	1. Check electrical wiring (see wiring diagram)
			2. Current > 10 Amps: pump not running smoothly	2. Replace the fuel pump assembly
			3. Current < 2 Amps: pump obstructed	3. Replace the fuel pump assembly and clean the fuel tank
14	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the DRV pressure regulator and check that the fault is no longer present.		Fault persists	Move on to Step
15	CHECK ON 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
16	TIMING CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the valve gear timing is correct	Move on to Step	Valve gear timing not correct	Restore the correct valve gear timing
17	CYLINDER COMPRESSION CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Carry out the cylinder compression check	Move on to Step	Cylinder compression insufficient	Move on to Step
18	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	R/R head for valve leakage testCheck cylinder conditions	Move on to Step	1. Valve seal insufficient	1. Restore the seal
	R/R head for valve leakage testCheck cylinder conditions	Move on to Step	2. Cylinders worn/damaged	2. Overhaul engine
19	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present		Fault persists control unit defective	Replace the engine management control unit

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Parts & tools for this job Staging For 2002 Fiat Ulysse

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