22 · Diagnostics

Engine starts with difficulty''

Make: Fiat
Model: Ulysse Factory Service Manual
Year: 2002–2010
Section: Starting › Engine starts with difficulty''

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Fault diagnosisEngine starts with difficulty''

ENGINE STARTS WITH DIFFICULTY''

2.0 16V JTD, 2.2 16V JTD

The engine, particularly when cold, starts with difficulty and only after repeated attempts. When the key is turned the instruments light up as normal, the starter motor turns, but the engine is difficult to start.

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the following, in order: that there are no obstructions in the air filter condition of the air intake circuit; diesel pipe seal absence of fuel, water, paraffin or dirt in the diesel filter. correct operation of the exhaust manifolds	Move on to Step	1. Air filter faulty	1. Replace the filter
			2. Air intake circuit faulty	2. Restore correct operation
			3. Leaks from the diesel pipes	3. Adjust pipe tightness to correct setting and replace if necessary
			4. Water, petrol, paraffin or dirt found to be present	4. Clean the tank and pipes and replace the diesel filter cartridge
			5. Obstruction in the exhaust system	5. Replace the damaged system component
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; 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	HIGH PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the diagnostic equipment connected to the diagnostic socket, check that the diesel pressure parameter is correct following the instructions in test 1060D	Move on to Step	Pressure not correct	Move on to Step
3	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	Repair the pipe and replace if necessary
4	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check, as described in test 1060B, that the diesel pressure between the air filter and the low 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
5	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Close the return pipe downstream of the low pressure relief valve, located on the fuel filter cover, using the special tool and carry out test 1060B again with the pipe closed, checking that the filter outlet pressure remains below 2 bar	Move on to Step	Pressure rises to 5 bar: pressure regulator valve on filter mounting incorrectly adjusted	Replace the diesel filter cover
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 diesel filter cartridge
7	LOW SUPPLY PRESSURE CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the pressure downstream of the supply pump at the diesel 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 checking 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 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 and clean the fuel tank
			3. Current < 2 Amps: pump obstructed
10	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Replace the high 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 pressure pump and check that the fault is no longer present.		Fault persists	Move on to Step
12	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
13	CHECK ON CAUSE OF INSUFFICIENT COMPRESSION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	R/R head for valve leakage test Check the condition of the cylinders	Move on to Step	1. Valve seal insufficient	1. Overhaul the head
		Move on to Step	2. Cylinders worn/damaged	2. Overhaul engine
14	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present		Fault persists	Replace the engine management control unit

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Parts & tools for this job Staging For 2002 Fiat Ulysse

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