Fiat Bravo Quiz
Diesel injection system

Diesel injection system fault diagnosis

In this manual: Diesel injection system
Dear Reader — 1Engine — 35Engine lubrication — 3Engine cooling — 10Ignition/spark plugs — 14Fuel system — 10Petrol fuel injection — 13Diesel injection system — 13Exhaust system — 7Clutch — 7Transmission / Gearshift / Automatic Transmission — 5Front Axle — 11Rear axle — 4Steering — 9Wheel alignment — 1Brake system — 22Wheels and tyres — 10Body — 34Heating — 6Electrical system — 39Lighting system — 14Instruments — 7Windscreen wiper system — 8Vehicle care / tools — 6Jump Starting / Towing the Vehicle — 3Jacking up the vehicle — 1Fiat Bravo / Brava Maintenance Schedule — 1Maintenance — 38Wiring diagrams — 5
18steps
~108min
4/5difficulty
Done 0 of 18
55/74 kW engine (75/100 hp) up to 9/98

Before locating the fault using fault diagnosis, the following preconditions must be met: operating error when starting ruled out. Fuel in the tank, engine mechanically sound, battery charged, starter turns at sufficient speed. Caution: if fuel lines are disconnected, they must first be cleaned with cold cleaner.

Fault Cause Remedy
Engine does not start or starts poorly.
  1. Engine does not glow plug preheat.
  2. Electromagnetic shut-off solenoid receives no voltage.
  3. Fuel supply faulty.
  4. Fuel lines kinked, blocked, fuel lines leaking, porous.
  5. Fuel filter clogged.
  6. Tank vent blocked. Fuel strainer in tank contaminated.
  7. Injection nozzles faulty.
  8. Idle speed, injection timing incorrect.
  9. Injection pump faulty.
  • Check the glow plug system.
  • Switch ignition on and off alternately, the shut-off solenoid on the injection pump must click.
  • Check whether fuel is being delivered.
  • Clean fuel lines, replace if necessary.
  • Replace fuel filter.
  • Clean.
  • Check injection nozzles: loosen the union nuts one after another and check whether the cylinders are firing.
  • Check and adjust idle speed and injection timing (workshop work).
  • Temporarily fit a new pump.
Engine runs unevenly at idle, when pulling away.
  1. Fuel hoses loose at the fuel pump or at the fuel filter.
  2. Idle adjustment incorrect.
  3. As under 1.3-6.
  • Replace fuel hoses.
  • Adjust idle speed.
  • As under 1.3-6.
Fuel consumption too high.
  1. Air filter contaminated.
  2. Fuel system leaking.
  3. Return line blocked.
  4. Injection timing of injection pump out of adjustment.
  • Replace filter element.
  • Carry out visual inspection of all fuel lines (suction, return and injection lines), fuel filter and injection pump.
  • Blow out return line from injection pump to fuel tank with compressed air.

Replace overflow restrictor in the banjo bolt of the return line.

  • Adjust injection timing.
    • Glow plug indicator lamp does not light up.
    1. Bulb in instrument cluster defective.
    2. Glow system/glow plugs defective.
    • Replace bulb.
    • Check glow plugs, replace if necessary.

    Have control unit checked.

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