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| Service News | ||
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Alfa various models
Version: 1.4 Turbo Jet 120 HP LPG Euro 5 (MiTo and Giulietta) |
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| 1043 1 021 RA |
LPG INJECTION CONTROL UNIT
Spontaneous switching to petrol with DTC P0087/P0088 errors - Service Solution |
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NOTE Cancels and replaces the following Service News: • SN 10.02.13 of 22/11/2013 for the introduction of a new solenoid valve part number 71776582. • SN 10.06.14 of 11/04/2014 for update of the pressure sensor control. |
CLAIMED FAULT
The Customer complains of one or both of the following faults:
- Spontaneous switching to petrol.
- EOBD warning light in instrument panel coming on.
During the fault diagnosis using the Examiner or wiTECH Plus (Examiner Emulator) one or both errors are found:
- P0087 - Gas low pressure sensor.
- P0088 - Rail gas pressure.
TECHNICAL CAUSE
Irregular operation of the LPG system.
OPERATIONS AT THE DEALERSHIPS
DEALERSHIP BEHAVIOUR STANDARDS TOWARDS THE CUSTOMER
- Once the customer's claimed fault is confirmed, reassure the Customer that the problem will be solved by performing a diagnosis about the correct working conditions of the LPG system and by replacing the malfunctioning components if any.
- After the intervention, check the work done and make sure that the customer is satisfied.
Service Solution
Once the customer's claimed fault is confirmed, perform a diagnosis on the correct operating conditions of the LPG system, replacing any faulty component according to the Operating Cycle below.
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The procedures below specifically refer to LPG Euro 5 versions with Turbo engines. |
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Before starting any diagnosis activity, make sure that the list of components does not require any Tutorship action for the dedicated area, otherwise open directly a Tutorship ticket. |
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Always follow all the steps of the controls listed below even if a faulty component is found during the first step of the control. |
OPERATION CYCLE
Once the customer's claimed fault is confirmed, before replacing any component of the system, use the diagnosis equipment to perform the following controls.
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It is strictly forbidden to adjust the supply pressure at the pressure regulator output. In the case of malfunction, replace the component. |
CHECK PRESSURE SENSOR ON LPG INJECTOR RAIL
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Close the cock on the LPG tank to interrupt any gas flow to the circuit. Start the engine, wait until the LPG circuit is completely drained; then, switch the engine off. |
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TEST |
Correct values |
OK |
KO |
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1 - Check whether the pressure detected by the sensor located at free air is the ambient one |
«Rail gas pressure» 0.9 ÷ 1.0 bar. If necessary, with engine off, compare the value with the one of the pressure at the intake manifold; these values should be similar |
End of LPG pressure sensor diagnosis |
Replacement of pressure sensor on injector rail. Op. 1057B70 of the Service Manual |
CHECK OPERATION OF LPG CUT-OUT SOLENOID VALVE ON PRESSURE REGULATOR
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Open the cock on the LPG tank again |
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TEST |
Correct values |
OK |
KO |
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1 - With engine off, measure the parameter «rail gas pressure» |
«Rail gas pressure» 0.9 ÷ 1.0 bar |
Go to Step 2 |
Replacement of solenoid valve on pressure regulator with a new one, part number 71776582 Op. 1040B45 of the Service Manual |
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2 - In «Active diagnosis» perform the «gas solenoid valve relay» test |
Correct opening of the gas solenoid valve relay |
Go to Step 3 |
Check whether the relay supply is correct; if the electrical continuity is OK, continue with: replacement of solenoid valve on pressure regulator with a new one, part number 71776582 Op. 1040B45 of the Service Manual |
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3 - Go back to the parameter function and measure the «rail gas pressure» |
«Rail gas pressure» 1.8 ÷1.9 bar |
End of cut-out solenoid valve diagnosis |
Replacement of solenoid valve on pressure regulator with a new one, part number 71776582 Op. 1040B45 of the Service Manual |
CHECK LPG PRESSURE REGULATOR SEALING
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Before starting disconnect the pipe between overpressure valve of the reduction unit and the air cleaner housing. |
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If the pressure regulator was replaced as a result of the above control and, during the subsequent control, it is still faulty, open a Te.Se.O. ticket before any further replacement. |
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TEST |
Correct values |
OK |
KO |
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1 - In «Active diagnosis» perform the «gas solenoid valve relay» test |
«Rail gas pressure» 1.9 bar |
Go to Step 2 |
Pressure regulator replacement. Op. 1043B40 of the Service Manual |
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2 - Use leak detecting foam / electronic detector to locate possible gas leaks (perform the test on the whole LPG supply line) |
No leak found |
Go to Step 3 |
Pressure regulator replacement. Op. 1043B40 of the Service Manual |
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3 - Wait 10 minutes to make sure that the pressure is steady |
No leak found and rail gas pressure steady at 1.9 bar |
End of pressure regulator diagnosis |
Pressure regulator replacement. Op. 1043B40 of the Service Manual |
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At the end of the test, reconnect the pipe between overpressure valve of the reduction unit and the air cleaner housing. |
CHECK LEVEL SENSOR AND FLOAT ON LPG TANK
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Before starting the diagnosis, refuel with LPG. |
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TEST |
Correct values |
OK |
KO |
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1 - Make sure that both the level gauge on the tank and the gauge on the instrument panel show «full» |
Both level gauges show «full» |
Go to Step 2 |
LPG level sensor replacement Op. 1043A63 of the Service Manual |
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2 - Disconnect the harness on the tank and measure the consistency of the ohm signal of the level sensor using a multimeter |
Conductance ranging between: 19620 - 23980 ohm |
Go to Step 3 |
LPG level sensor replacement Op. 1043A63 of the Service Manual |
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3 - Remove the level gauge on the tank, rotating it by 180° |
- Check that the instrument panel displays «refuel» and only the reserve mark is switched on. - Check that the reference mark on the tank gauge shows the reserve |
End of LPG level sensor diagnosis |
LPG level sensor replacement Op. 1043A63 of the Service Manual |
CHECK LPG INJECTORS ON RAIL
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Start the engine and wait until it switches to LPG, switch the engine off and then make a key-ON, read the rail gas pressure parameter. |
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TEST |
Correct values |
OK |
KO |
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1 - Using a suitable equipment (leak detector) make sure that there are no leaks |
No gas leak |
Go to Step 2 |
LPG injector unit replacement Op. 1057B66 of the Service Manual |
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2 - After switching the ignition off, wait 5 hours; never touch the vehicle and never rotate the ignition key. After the stop, turn the key to ON and read the rail gas pressure parameter |
Variation of the «rail gas pressure» lower than 0.3 bar |
End of LPG injector diagnosis |
LPG injector unit replacement Op. 1057B66 of the Service Manual |
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If the diagnosis on the LPG system components does not show any malfunction and the claimed fault persists, open a Te.Se.O. ticket. |
CLAIM REPORT DATA
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Version |
Operation |
Part |
Fault |
Position |
Time allowance |
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Alfa MiTo |
1043102 (1) |
1 |
RA |
- |
1.30 |
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Alfa Giulietta |
1043102 (1) |
1 |
RA |
- |
1.20 |
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Alfa MiTo |
1043103 (2) |
1 |
RA |
- |
2.40 |
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Alfa Giulietta |
1043103 (2) |
1 |
RA |
- |
2.05 |
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Alfa MiTo |
1043104 (3) |
1 |
RA |
- |
2.40 |
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Alfa Giulietta |
1043104 (3) |
1 |
RA |
- |
2.05 |
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Alfa MiTo |
1057109 (4) |
1 |
RA |
- |
0.55 |
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Alfa Giulietta |
1057109 (4) |
1 |
RA |
- |
0.55 |
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Alfa MiTo |
1057110 (5) |
1 |
RA |
- |
1.35 |
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Alfa Giulietta |
1057110 (5) |
1 |
RA |
- |
1.40 |
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Alfa MiTo |
1043105 (6) |
1 |
RA |
- |
1.20 |
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Alfa Giulietta |
1043105 (6) |
1 |
RA |
- |
0.95 |
(1) - Operation Code and Time allowance for the controls with diagnosis equipment plus checking for leaks without replacing any component.
(2) - Operation Code and Time allowance for the controls with diagnosis equipment plus replacement of the pressure regulator.
(3) - Operation Code and Time allowance for the controls with diagnosis equipment plus replacement of the LPG level sensor.
(4) - Operation Code and Time allowance for the controls with diagnosis equipment plus replacement of the injector rail pressure sensor.
(5) - Operation Code and Time allowance for the controls with diagnosis equipment plus replacement of the LPG injector unit.
(6) - Operation Code and Time allowance for the controls with diagnosis equipment plus replacement of the solenoid valve on the pressure regulator.