Engine starts, and cuts out straight away

Make: Fiat
Model: Ulysse Factory Service Manual
Year: 2002–2010
Section: Starting › Engine starts, and cuts out straight away

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Fault diagnosisEngine starts, and cuts out straight away

ENGINE STARTS, AND CUTS OUT STRAIGHT AWAY

2.0 16V JTD, 2.2 16V JTD

The engine starts normally, though possibly with difficulty, then suddenly stalls

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: no water, other fluids or dirt in the fuel filter no water, other fluids or dirt in the fuel tank that there are no obstructions in the exhaust system	Move on to Step	1. Water, other fluids or dirt in the fuel filter	1. Replace the filter element
			2. Water, other fluids or dirt in the fuel tank	2. Clean tank
			3. obstructions in the exhaust system	3. Replace the exhaust system damaged component
1	CHECK USING DIAGNOSTIC EQUIPMENT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Connect the diagnostic equipment (Examiner or other instruments) to the diagnostic socket.Re-create the conditions under which the fault occurs and check: that there are no errors in the control unit; parameter plausibility	Move on to Step	1. Errors detected in control unit	1. Continue following the instructions for the diagnostic equipment
			2. Parameters not plausible	2. Continue following the instructions for the diagnostic equipment
			3. No communication with the control unit	3. Restore the correct connections See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
2	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic socket, check as described < R1 > that the diesel pressure parameter is correct See Test 1060D ELECTRONIC DIESEL INJECTION CONTROL	Move on to Step	Pressure not correct	Move on to Step
3	LOW RETURN PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check as described < R1 > that the diesel 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 greater than maximum limit (return pipe to tank blocked)	Repair the pipe and replace if necessary
4	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the diesel pressure between the filter and radial jet pump < R1 > 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
5	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Constrict the return pipe, downstream of the low pressure regulation valve, and carry out < R1 > 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
6	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
7	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
8	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	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	Difference in pressure more than 0,3 bar	Replace the pipe
9	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described < R1 >, that the pump supply voltage is equal to 12 volt and that the current absorbed is between 2 and 10 Ampere See Test 1040AA CHECK ON THE SUPPLY VOLTAGE AND THE ABSORPTION CURRENT FOR THE SUBMERGED PUMP	Move on to Step	1. Voltage lower than 12 volts	1. Check the wiring at the connection leads See E5050 DIESEL ENGINES ELECTRONIC MANAGEMENT
			2. Current greater than 10 Amps: pump defective	2. Replace the fuel pump assembly Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
			3. Current less than 2 Amps: Jet pump blocked	3. Change fuel pump assembly < R1 > and clean tank Op. 1040A70 SUBMERGED PUMP ASSEMBLY COMPLETE WITH LEVEL GUAGE CONTROL - R + R
10	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the pressure regulator and check that the fault is no longer present.		Fault persists	Move on to Step
11	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the high pressure pump and check that the fault is no longer present		Fault persists control unit defective	Replace the engine management control unit Op. 1060G80 DS ELECTRIC INJECTION CONTROL UNIT - R R

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Parts & tools for this job Staging For 2002 Fiat Ulysse

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