320D2 Troubleshooting9

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Troubleshooting SMCS - 1000

Introduction Troubleshooting can be difficult. To make a repair to a problem, refer to the possible cause and the corrective action. The most common problems are identified in this troubleshooting manual. The symptoms, causes, and guidance for solving the problems are given. The list of problems, causes, and corrections will only give an indication of the location of a possible problem. There is also a list that shows some of the repairs that are required. Sometimes additional repair work is required beyond the repair which is recommended. Frequently, a problem does not exist in isolation. The problem can be a result of wear or of damage to several parts which operate together as part of a system. Service personnel may remember similar complaints which were corrected by a previous method of troubleshooting. A similar complaint can have a different cause. Get a good description of the problem from the operator and/or the person that owns the vehicle. Knowing the details of the problem can save time. This will make the repair job faster and easier. All possible problems and the probable causes cannot be listed. The technician must follow a logical process of eliminating possible causes and of identifying the specific causes of the problems.

Troubleshooting The Fuel Injection Nozzles On The Engine Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and threads are clean.

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Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel that have the proper training should perform repairs to the fuel injection nozzle. Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly. Refer to Specifications, "Fuel Injection Nozzles" for additional information.

The Engine is Difficult to Start or the Engine Runs Rough Probable Cause Table 1 Troubleshooting Test Steps

Values

Results Result: The fuel injection nozzle does not seal correctly in the cylinder head. Make sure that the gaskets, the insert, and the mating surface of the cylinder head are clean.

1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head A. Verify that the fuel injection nozzle is sealed correctly in the cylinder head.

Fuel Injection Nozzle

Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head. Verify that the problem is resolved. Result: The fuel injection nozzle is sealed correctly in the cylinder head. Proceed to Test Step 2.

Result: There is debris on the mounting surface of the cylinder head or extra gaskets were left in the cylinder head for the fuel injection nozzle.

2. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert A. Check for debris on the mating surface of the cylinder head. B. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.

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Remove any extra gaskets or debris. Debris

Verify that the problem is resolved. Result: There is no debris on the mounting surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection nozzle.

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Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking. Repair or replace the high-pressure fuel line that is leaking.

3. Check the Connections of the High Pressure Fuel Line A. Check for a damaged or leaking highpressure fuel line.

Fuel leak

Verify that the problem is resolved. Result: A high-pressure fuel line is not leaking. Proceed to Test Step 4.

Result: The correct fuel nozzles are not installed.

4. Check that the Correct Fuel Nozzles are Installed A. Verify that all fuel injection nozzles are the correct replacement parts for the engine.

Fuel Nozzle

Install the correct fuel nozzles. Refer to the Parts Manual for the correct replacement part. Verify that the problem is resolved.

The Engine Exhaust has too Much Black Smoke Probable Cause Table 2 Troubleshooting Test Steps

Values

Results

1. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert


A. Check for debris on the mating surface of the cylinder head.

Remove any extra gaskets or debris. Debris Verify that the problem is resolved.

B. Make sure that extra gaskets were removed from the threaded recess in the cylinder head for the fuel injection nozzle.

Result: There is no debris on the mounting surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection

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nozzle. Proceed to Test Step 2.

2. Check for Correct Operation of the Fuel Nozzle A. Make sure that the components of the fuel injection nozzle are tightened to the correct torques. B. Make sure that the gaskets and the insert are positioned correctly.

Result: The fuel nozzle is not operating properly. Replace the fuel nozzle. Fuel Nozzle

Result: The fuel nozzle is operating properly. Proceed to Test Step 3.

C. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.

Result: The correct fuel nozzles are not installed.

3. Check that the Correct Fuel Nozzles are Installed A. Verify that all fuel injection nozzles are the correct replacement parts for the engine.

Verify that the problem is resolved.

Fuel Nozzle

Install the correct fuel nozzles. Refer to the Parts Manual for the correct replacement part. Verify that the problem is resolved.

The Engine has Lost Power and the Engine Uses too Much Fuel Probable Cause Table 3 Troubleshooting Test Steps

1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head A. Verify that the fuel injection nozzle is sealed correctly in the cylinder head.

Values

Results Result: The fuel injection nozzle does not seal correctly in the cylinder head.


Make sure that the gaskets, the insert, and the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded

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hole of the cylinder head. Verify that the problem is resolved. Result: The fuel injection nozzle is sealed correctly in the cylinder head. Proceed to Test Step 2.


2. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert A. Check for debris on the mating surface of the cylinder head.






3. Check the Connections of the High Pressure Fuel Line A. Check for a damaged or leaking highpressure fuel line.

Fuel leak


4. Check for Correct Operation of the Fuel Nozzle A. Make sure that the components of the fuel injection nozzle are tightened to the

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Fuel Nozzle

Result: The fuel nozzle is not operating properly. Replace the fuel nozzle.

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correct torques. Verify that the problem is resolved.

B. Make sure that the gaskets and the insert are positioned correctly.

Result: The fuel nozzle is operating properly.



Result: The correct fuel nozzles are not installed. Install the correct fuel nozzles. 5. Check that the Correct Fuel Nozzles are Installed A. Verify that that all fuel injection nozzles have the correct code for the engine.

Fuel Nozzle

Refer to the Parts Manual for the correct replacement part. Verify that the problem is resolved. Result: The correct fuel nozzles are installed. Proceed to Test Step 6.

Result: A low-pressure fuel line is leaking.

6. Check the Connections of the Low Pressure Fuel Line A. Check for a damaged or leaking lowpressure fuel line.

Fuel Leak

Repair or replace the low-pressure fuel line that is leaking. Verify that the problem is resolved.

The Engine is Misfiring, Running Rough, or Running Poorly Probable Cause Table 4 Troubleshooting Test Steps 1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head

Values


Results Result: The fuel injection nozzle does not seal correctly in the cylinder head. Make sure that the gaskets, the insert, and

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the mating surface of the cylinder head are clean. Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head.

A. Verify that the fuel injection nozzle is sealed correctly in the cylinder head.

Verify that the problem is resolved. Result: The fuel injection nozzle is sealed correctly in the cylinder head. Proceed to Test Step 2.


2. Check for Debris on the Mating Surface of the Cylinder Head with the Gaskets or the Insert A. Check for debris on the mating surface of the cylinder head.






3. Check the Connections of the High Pressure Fuel Line A. Check for a leaking high-pressure fuel line.

Fuel leak


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4. Check for Correct Operation of the Fuel Nozzle

Result: The fuel nozzle is not operating properly.

A. Make sure that the components of the fuel injection nozzle are tightened to the correct torques. B. Make sure that the gaskets and the insert are positioned correctly.

Replace the fuel nozzle. Fuel Nozzle

Verify that the problem is resolved. Result: The fuel nozzle is operating properly.



Result: The correct fuel nozzles are not installed. Install the correct fuel nozzles. 5. Check that the Correct Fuel Nozzles are Installed A. Verify that all fuel injection nozzles have the correct code for the engine.

Refer to the Parts Manual for the correct replacement part. Fuel Nozzle Verify that the problem is resolved. Result: The correct fuel nozzles are installed. Proceed to Test Step 6.

Result: A high-pressure fuel line is restricted or damaged. 6. Check for a Restriction in the Highpressure Fuel Line A. Check for a damaged or restricted high-pressure fuel line.

Repair or replace the high-pressure fuel line that is restricted or damaged. High-pressure fuel line restriction

Verify that the problem is resolved. Result: A high-pressure fuel line is not restricted or damaged. Proceed to Test Step 7.

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Result: The seat washer is not 2.0 mm (0.08 inch) thick.

7. Check for the Correct Seat Washer A. Verify that the seat washer is 2.0 mm (0.08 inch) thick.

2.0 mm (0.08 inch) seat washer

Replace the seat washer with the correct seat washer. Verify that the problem is resolved.

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure that all surfaces and threads are clean. Only personnel that have the proper training should disassemble the fuel injection nozzles. Only personnel that have the proper training should perform repairs to the fuel injection nozzles. Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate correctly. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

Back Leakage Table 5 Troubleshooting Test Steps

Values

Results Result: There are fuel leaks.through the threaded connection of the body and the nozzle nut.

1. Check for Fuel Leaks through the Threaded Connection of the Body and the Nozzle Nut

Make sure that the threads are clean. Tighten the body to the correct torque. Fuel leaks

A. Check for fuel leaks.through the threaded connection of the body and the nozzle nut.

Verify that the problem is resolved. Result: There are no fuel leaks.through the threaded connection of the body and the nozzle nut. Proceed to Test Step 2.

2. Check for Debris or Damage on the

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Damage or

Result: The valve has debris or is damaged.

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Orifices A.Visually inspect the components of the valve for carbon pitting, for scoring, or for other damage.

Clean the surface of the orifices with solvent. Replace the fuel injection nozzles if corrosion exists.

Debris


The fuel injection nozzle does not inject fuel in the correct quantity or in the correct pattern. Probable Cause Table 6 Troubleshooting Test Steps

Values

Results Result: The opening pressure is not correct.

1. Check the Setting for the Opening Pressure A. Test the setting of the opening pressure.

Adjust the setting to the correct pressure. Opening pressure

Verify that the problem is resolved. Result: The opening pressure is correct. Proceed to Test Step 2.

Result: The fuel injection nozzle is stuck. Debris or damage exists on the fuel injection nozzle. 2. Verify the Operation of the Fuel Injection Nozzle

The fuel injection nozzle must be cleaned or replaced.

Fuel injection A.Verify that the fuel injection nozzle nozzle is not stuck.

Verify that the problem is resolved. Result: The fuel injection nozzle is not stuck. Proceed to Test Step 3.

3. Check for a Blockage or Restriction in the Orifices A.Inspect the orifices for carbon

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Result: The orifices are blocked or restricted. Orifice blockage

The fuel injection nozzle must be cleaned or replaced.

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Verify that the problem is resolved. buildup.

Result: The orifices are not blocked or restricted. Proceed to Test Step 4.

4. Check for a Blockage or Restriction in the Fuel Return A.Inspect the fuel return passage.

Result: The fuel return passage is blocked or restricted. Fuel return passage

Clean the passage in order to remove any carbon buildup or other debris. Verify that the problem is resolved.

Troubleshooting the Turbocharger The engine lacks power. Probable Cause Table 7 Troubleshooting Test Steps

Values

Results Result: The air filter element is dirty or has restrictions. The air filter element must be cleaned or replaced.

1. Check for Restrictions in the Air Filter Element A. Check the condition of the air filter element.

Air filter element

Verify that the problem is resolved. Result: The air filter element is not dirty or does not have restrictions. Proceed to Test Step 2.

2. Check for a Restriction in the Tube between the Air Filter and the Turbocharger

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Restriction/damage

Result: There is damage or a restriction to the tube between the air filter and the turbocharger.

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Find the restriction and repair or replace the component. Verify that the problem is resolved.

A. Check for damage or a restriction in the tube between the air filter and the turbocharger.

Result: There is not damage or a restriction to the tube between the air filter and the turbocharger. Proceed to Test Step 3.

Result: There is a leak or a restriction to the tube between the intake manifold and the turbocharger. 3. Check for an Air Leak or Restriction in the Tube between the Intake Manifold and the Turbocharger A. Check for a leak or a restriction in the tube between the intake manifold and the turbocharger.

Find the leak or restriction and repair or replace the component. Air leak or restriction

Verify that the problem is resolved. Result: There is not a leak or a restriction to the tube between the intake manifold and the turbocharger. Proceed to Test Step 4.

Result: There is damage or a restriction in the exhaust system components. The component must be repaired or replaced.

4. Check for Restriction in the Exhaust System A. Check for damage or a restriction in the exhaust system components.

Restriction/damage

Verify that the problem is resolved. Result: There is not damage or a restriction in the exhaust system components. Proceed to Test Step 5.

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Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. 5. Check for Proper Installation of the Turbocharger A. Verify that turbocharger is not loose or the clamps and bolts on the turbocharger are not loose.

Correctly position the turbocharger and tighten the clamps and bolts. Turbocharger

Verify that the problem is resolved. Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 6.

Result: The intake manifold has cracks, loose bolts, or a distorted flange. The intake manifold must be repaired or replaced.

6. Inspect the Intake Manifold A. Inspect the intake manifold for cracks, loose bolts, or a distorted flange.

Intake manifold

Verify that the problem is resolved. Result: The intake manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 7. Result: The exhaust manifold has cracks, loose bolts, or a distorted flange. The exhaust manifold must be repaired or replaced.

7. Inspect the Exhaust Manifold A. Inspect the exhaust manifold for cracks, loose bolts, or a distorted flange.

Exhaust manifold

Verify that the problem is resolved. Result: The exhaust manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 8.

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Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced. 8. Inspect the Turbocharger Verify that the problem is resolved. A. Inspect the turbine housing for damage or a restriction.

Restriction/damage Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 9. Result: The turbocharger bearings are not OK. Replace the turbocharger.

9. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.

Turbocharger Bearings

Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 10. Result: The compressor housing contains debris. Clean the compressor housing.

10. Inspect the Compressor for Debris Verify that the problem is resolved. A. Inspect the compressor housing for debris.

Debris Result: The compressor housing does not contain debris. Proceed to Test Step 11.

11. Inspect the Turbocharger Rotor A. Inspect the turbocharger rotor for carbon Carbon build-up build-up.

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Result: The turbocharger rotor has carbon build-up. Remove the carbon.

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Verify that the problem is resolved. Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 12. Result: The fuel injection pump is not operating properly. The fuel injection pump must be repaired or replaced.

12. Inspect the Fuel Injection Pump A. Verify proper operation of the fuel injection pump.

Fuel injection pump

Verify that the problem is resolved. Result: The fuel injection pump is operating properly. Proceed to Test Step 13. Result: The fuel injection nozzles have wear or damage. The fuel injection nozzles must be repaired or replaced.

13. Inspect the Fuel Injection Nozzles A. Inspect the fuel injection nozzles for wear or damage.

Damage/wear

Verify that the problem is resolved. Result: The fuel injection nozzles do not have wear or damage. Proceed to Test Step 14. Result: The intake and exhaust valves are burned.

14. Inspect the Intake and Exhaust Valves A. Inspect the intake and exhaust valves.

Intake/exhaust valves

Replace the inlet valves and the exhaust valves. Determine the cause of the damage to the valves. Verify that the problem is resolved. Result: The intake and exhaust valves are not burned.

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Proceed to Test Step 15. Result: The piston rings have wear. 15. Inspect the Piston Rings A. Inspect the piston rings for wear.

Replace the piston rings. Piston rings Verify that the problem is resolved.

The engine exhaust has excessive black smoke. Probable Cause Table 8 Troubleshooting Test Steps

Values



Air filter element


Result: There is damage or a restriction to the tube between the air filter and the turbocharger. 2. Check for a Restriction in the Tube between the Air Filter and the Turbocharger A. Check for damage or a restriction in the tube between the air filter and the turbocharger.

Find the restriction and repair or replace the component. Restriction/damage

Verify that the problem is resolved. Result: There is not damage or a restriction to the tube between the air filter and the turbocharger. Proceed to Test Step 3.

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4. Inspect the Intake Manifold A. Inspect the intake manifold for cracks, loose bolts, or a distorted flange.

Intake manifold

Verify that the problem is resolved. Result: The intake manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 5.

Result: The engine oil pipe has restrictions. The drain pipe must be repaired or replaced.

5. Inspect the Engine Oil Drain Pipe A. Inspect the engine oil drain pipe for restrictions.

Restrictions Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions.

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Result: The turbocharger has combustion gas or air leaks. Replace the turbocharger.

6. Inspect the Turbocharger Seals A. Inspect the turbocharger for combustion gas or air leaks.

Leaks

Verify that the problem is resolved. Result: The turbocharger does not have combustion gas or air leaks. Proceed to Test Step 7. Result: The turbocharger bearings are not OK. Replace the turbocharger.





Debris Result: The compressor housing does not contain debris. Proceed to Test Step 9. Result: The turbocharger rotor has carbon build-up.

9. Inspect the Turbocharger Rotor A. Inspect the turbocharger rotor for carbon build-up.

Carbon build-up

Remove the carbon.

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The engine exhaust has excessive blue smoke. Probable Cause Table 9 Troubleshooting Test Steps

Values


1. Check for Restrictions in the Air Filter Element Air filter element


A. Check the condition of the air filter element. Result: The air filter element is not dirty or does not have restrictions. Proceed to Test Step 2.

Result: The crankcase breather has restrictions. The crankcase breather (if equipped), or the tubing must be cleaned or replaced.

2. Check for Restrictions in the Crankcase Breather Restrictions A. Check the crankcase breather for restrictions.

Verify that the problem is resolved. Result: The crankcase breather does not have restrictions. Proceed to Test Step 3.

3. Check for a Restriction in the Tube between the Air Filter and the Turbocharger Restriction/damage

Result: There is damage or a restriction to the tube between the

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air filter and the turbocharger. Find the restriction and repair or replace the component. Verify that the problem is resolved.

A. Check for damage or a restriction in the tube between the air filter and the turbocharger.


Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. Correctly position the turbocharger and tighten the clamps and bolts.

4. Check for Proper Installation of the Turbocharger A. Verify that turbocharger is not loose or the clamps and bolts on the turbocharger are not loose.

Turbocharger


Result: The intake manifold has cracks, loose bolts, or a distorted flange. 5. Inspect the Intake Manifold A. Inspect the intake manifold for cracks, loose Intake manifold bolts, or a distorted flange.

The intake manifold must be repaired or replaced. Verify that the problem is resolved. Result: The intake manifold does not have cracks, loose bolts, or a distorted flange.

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Restrictions

Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions. Proceed to Test Step 7.

Result: The turbocharger has combustion gas or air leaks. Replace the turbocharger. 7. Inspect the Turbocharger Seals A. Inspect the turbocharger for combustion gas or air leaks.

Leaks




Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 9.

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Result: The compressor housing contains debris. Clean the compressor housing. 9. Inspect the Compressor for Debris A. Inspect the compressor housing for debris.

Debris

Verify that the problem is resolved. Result: The compressor housing does not contain debris. Proceed to Test Step 10. Result: The turbocharger rotor has carbon build-up. Remove the carbon.


Carbon build-up

Verify that the problem is resolved. Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 11. Result: The turbocharger has excessive anti-corrosion fluid. Clean the turbocharger in order to remove the anti-corrosion fluid.

11. Inspect the Turbocharger for Fluid A. Inspect the turbocharger for excessive anticorrosion fluid. This condition only exists on a new engine which has not been operated.

Anti-corrosion fluid

Verify that the problem is resolved. Result: The turbocharger does not have excessive anti-corrosion fluid. Proceed to Test Step 12. Result: The high idle operates for an excessive time.

12. Verify the High Idle Speed High idle A. Verify the high idle speed of the engine.

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The fuel injection pump must be

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repaired or replaced. Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 13. Result: The turbocharger has a restriction in the bearing housing. 13. Inspect the Turbocharger for a Restriction A. Inspect the turbocharger for a restriction in the bearing housing.

Restriction

The bearing housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved.

The engine uses an excessive amount of engine oil. Probable Cause Table 10 Troubleshooting Test Steps

Values



Air filter element


2. Check for Restrictions in the Crankcase Breather

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Restrictions

Result: The crankcase breather has restrictions.

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The crankcase breather (if equipped), or the tubing must be cleaned or replaced. A. Check the crankcase breather for restrictions.





Result: The incorrect type of engine oil is being used. Drain the engine oil. Install the correct quantity and type of engine oil.

4. Check the Engine Oil A. Verify that the correct type of engine oil is being used.

Engine oil

Verify that the problem is resolved. Result: The correct type of engine oil is being used. Proceed to Test Step 5.

5. Inspect the Engine Oil Drain Pipe

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Restrictions

Result: The engine oil pipe has restrictions.

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The drain pipe must be repaired or replaced. A. Inspect the engine oil drain pipe for restrictions.




Restrictions

Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions. Proceed to Test Step 7. Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced.

7. Inspect the Turbocharger A. Inspect the turbine housing for damage or a restriction.

Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 8. Result: The turbocharger bearings are not OK.



Replace the turbocharger. Verify that the problem is resolved.

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Result: The turbocharger bearings are OK. Proceed to Test Step 9. Result: The piston rings have wear. Replace the piston rings. 9. Inspect the Piston Rings A. Inspect the piston rings for wear.

Verify that the problem is resolved. Piston rings

Result: The piston rings do not have wear. Proceed to Test Step 10. Result: The oil supply line has leaks. The supply line must be repaired or replaced.

10. Inspect the Oil Supply Line A. Inspect the oil supply line for leaks.

Verify that the problem is resolved. Leaks Result: The oil supply line does not have leaks. Proceed to Test Step 11. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.

11. Verify the High Idle Speed A. Verify the high idle speed of the engine.

High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 12.

12. Inspect the Turbocharger for a Restriction

Result: The turbocharger has a restriction in the bearing housing. Restriction

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The bearing housing must be repaired or the turbocharger must be replaced.

A. Inspect the turbocharger for a restriction in the bearing housing.


Excessive engine oil exists at the end of the turbine. Probable Cause Table 11 Troubleshooting Test Steps

Values

Results Result: The crankcase breather has restrictions. The crankcase breather (if equipped), or the tubing must be cleaned or replaced.

1. Check for Restrictions in the Crankcase Breather A. Check the crankcase breather for restrictions.

Restrictions



2. Check for a Restriction in the Exhaust System A. Check for damage or a restriction in the exhaust system components.

Restriction/damage


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Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. Correctly position the turbocharger and tighten the clamps and bolts.


Turbocharger




Restrictions



Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction.

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Proceed to Test Step 6. Result: The turbocharger bearings are not OK. Replace the turbocharger. 6. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.


Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 7. Result: The turbocharger rotor has carbon build-up. Remove the carbon.


Carbon build-up

Verify that the problem is resolved. Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 8. Result: The piston rings have wear. Replace the piston rings.

8. Inspect the Piston Rings A. Inspect the piston rings for wear.

Piston rings

Verify that the problem is resolved. Result: The piston rings do not have wear. Proceed to Test Step 9.

9. Inspect the Turbocharger for Fluid

Anti-corrosion fluid

Result: The turbocharger has excessive anti-corrosion fluid.

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Clean the turbocharger in order to remove the anti-corrosion fluid. Verify that the problem is resolved.

A. Inspect the turbocharger for excessive anticorrosion fluid. This condition only exists on a new engine which has not been operated.

Result: The turbocharger does not have excessive anti-corrosion fluid. Proceed to Test Step 10. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.


High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 11. Result: The turbocharger has a restriction in the bearing housing.

11. Inspect the Turbocharger for a Restriction A. Inspect the turbocharger for a restriction in the bearing housing.

Restriction


Excessive engine oil exists at the compressor end of the turbocharger. Probable Cause Table 12 Troubleshooting Test Steps

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Values

Results

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Result: The air filter element is dirty or has restrictions. The air filter element must be cleaned or replaced.


Air filter element








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Correctly position the turbocharger and tighten the clamps and bolts. Fuel Nozzle




Leaks

Verify that the problem is resolved. Result: The turbocharger does not have combustion gas or air leaks. Proceed to Test Step 7.

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Result: The turbocharger bearings are not OK. Replace the turbocharger. 7. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.



8. Inspect the Compressor for Debris A. Inspect the compressor housing for debris.

Verify that the problem is resolved. Debris Result: The compressor housing does not contain debris. Proceed to Test Step 9. Result: The piston rings have wear. Replace the piston rings.



Result: The piston rings do not have wear. Proceed to Test Step 10. Result: The turbocharger has excessive anti-corrosion fluid.

10. Inspect the Turbocharger for Fluid A. Inspect the turbocharger for excessive antiAnti-corrosion fluid corrosion fluid. This condition only exists on a new engine which has not been operated.

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Clean the turbocharger in order to remove the anti-corrosion fluid. Verify that the problem is resolved.

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Result: The turbocharger does not have excessive anti-corrosion fluid. Proceed to Test Step 11. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced. 11. Verify the High Idle Speed A. Verify the high idle speed of the engine.

High idle



Restriction


Engine oil exists in the exhaust manifold. Probable Cause Table 13 Troubleshooting Test Steps

Values

Result: The crankcase breather has restrictions.


Results

The crankcase breather (if equipped), or the tubing must be cleaned or replaced. Verify that the problem is resolved. Result: The crankcase breather does not

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have restrictions. Proceed to Test Step 2.



Restriction/damage




Restrictions



Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 5.

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Result: The turbocharger bearings are not OK. Replace the turbocharger. 5. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.




Debris Result: The compressor housing does not contain debris. Proceed to Test Step 7. Result: The turbocharger rotor has carbon build-up. Remove the carbon.

7. Inspect the Turbocharger Rotor Verify that the problem is resolved. A. Inspect the turbocharger rotor for carbon build-up.

Carbon build-up Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 8. Result: The piston rings have wear. Replace the piston rings.


Piston rings

Verify that the problem is resolved. Result: The piston rings do not have

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wear. Proceed to Test Step 9. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.


High idle



Restriction


Lack of lubrication to the turbocharger Probable Cause Table 14 Troubleshooting Test Steps

Values

Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose.


Results

Turbocharger

Correctly position the turbocharger and tighten the clamps and bolts. Verify that the problem is resolved. Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not

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loose. Proceed to Test Step 2.

2. Check for Turbocharger for Proper Lubrication Result: The components listed are not operating properly.

The flow of engine oil is delayed to the turbocharger when the engine is started. Insufficient oil flows to the turbocharger when the engine is running. A. Check the following components for correct operation: · · · · ·

The component must be repaired or replaced. Turbocharger lubrication

Verify that the problem is resolved. Result: The components listed are operating properly.

Engine oil pump Engine oil bypass valve Engine oil filter Viscosity of the engine oil Restrictions in oil lines


Result: The engine oil is dirty. Drain the engine oil. Install the correct type of engine oil. Replace the engine oil filter.

3. Inspect the Engine Oil A. Inspect the engine oil.

Engine Oil

Verify that the problem is resolved. Result: The engine oil is not dirty. Proceed to Test Step 4.

Result: The incorrect type of engine oil is being used. 4. Check the Engine Oil A. Verify that the correct type of engine oil is being used.

Engine oil

Drain the engine oil. Install the correct quantity and type of engine oil. Verify that the problem is resolved. Result: The correct type of engine oil is being used.

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Result: The oil supply line is restricted. The oil supply line must be repaired or replaced.

5. Check the Engine Oil Supply Line A. Inspect the oil supply line from the engine oil pan for a restriction.

Restrictions

Verify that the problem is resolved. Result: The oil supply line is not restricted. Proceed to Test Step 6.

Result: The engine rpm increases too rapidly when the engine is started. Check the fuel injection pump for correct operation and settings.

6. Verify the Engine RPM Engine RPM A. Verify the engine RPM during start-up.

Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 7. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.


High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 8. Result: The oil supply line has leaks.

8. Inspect the Oil Supply Line

Leaks

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The supply line must be repaired or replaced. Verify that the problem is resolved. A. Inspect the oil supply line for leaks.

Result: The oil supply line does not have leaks. Proceed to Test Step 9. Result: The piston rings have wear. Replace the piston rings.


Verify that the problem is resolved. Piston rings Result: The piston rings do not have wear. Proceed to Test Step 10. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.


High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 11. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.


Restriction

Verify that the problem is resolved. Result: The turbocharger has a restriction in the bearing housing. Proceed to Test Step 12.

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Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.

12. Inspect the Engine Oil Filter A. Inspect the engine oil filter for a restriction.

Oil Filter Verify that the problem is resolved. Result: The engine oil filter does not have a restriction. Proceed to Test Step 13.

13. Correct Engine Operation The engine may have stopped too soon from a high load condition. A. Check the following components for correct operation or damage: · · · · · ·

Compressor impeller of the turbocharger Cooling system Fuel injection pump Air/fuel ratio control Valve lash Fuel injection nozzles

Result: The components listed are not operating properly. Engine operation

The component must be repaired or replaced. Verify that the problem is resolved.

The inside of the intake manifold is wet. Probable Cause Table 15 Troubleshooting Test Steps 1. Check for Restrictions in the Air Filter Element A. Check the condition of the air filter

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Values

Air filter element

Results Result: The air filter element is dirty or has restrictions. The air filter element must be cleaned

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or replaced. Verify that the problem is resolved. element.

Result: The air filter element is not dirty or does not have restrictions. Proceed to Test Step 2.




Result: The air filter element is not sealed properly. Inspect the air filter element and the air supply line to the turbocharger for correct installation.

3. Check for Proper Installation of the Air Filter Element A. Verify that the air filter element is sealed properly.

Air filter

Verify that the problem is resolved. Result: The air filter element is sealed properly. Proceed to Test Step 4.

4. Check for a Restriction in the Tube between the Air Filter and the Turbocharger A. Check for damage or a restriction in the

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Restriction/damage

Result: There is damage or a restriction to the tube between the air filter and the turbocharger. Find the restriction and repair or

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replace the component. Verify that the problem is resolved. tube between the air filter and the turbocharger.







Restriction/damage


7. Check for Proper Installation of the Turbocharger

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Turbocharger

Result: The turbocharger is loose or the clamps and bolts on the

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turbocharger are loose. Correctly position the turbocharger and tighten the clamps and bolts. Verify that the problem is resolved.

A. Verify that turbocharger is not loose or the clamps and bolts on the turbocharger are not loose.

Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 8. Result: The exhaust manifold has cracks, loose bolts, or a distorted flange. The exhaust manifold must be repaired or replaced.

8. Inspect the Exhaust Manifold A. Inspect the exhaust manifold for cracks, loose bolts, or a distorted flange.

Exhaust manifold

Verify that the problem is resolved. Result: The exhaust manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 9.



Restrictions


10. Inspect the Turbocharger

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Restriction/damage

Result: The turbine housing is damaged or has a restriction.

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The turbine housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved. A. Inspect the turbine housing for damage or a restriction.

Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 11.



Leaks




Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 13. Result: The compressor housing contains debris.


Clean the compressor housing. Debris

Verify that the problem is resolved. Result: The compressor housing does not contain debris.

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Proceed to Test Step 14. Result: The piston rings have wear. Replace the piston rings. 14. Inspect the Piston Rings A. Inspect the piston rings for wear.


Result: The piston rings do not have wear. Proceed to Test Step 15. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.


Verify that the problem is resolved. Restriction Result: The turbocharger does not have a restriction in the bearing housing. Proceed to Test Step 16. Result: The air inlet heater has fuel leaks. Repair the leaks.

16. Inspect the Air Inlet Heater A. Test the air inlet heater for leakage.

Verify that the problem is resolved. Leaks Result: The air inlet heater does not have fuel leaks. Proceed to Test Step 17. Result: The back plate of the compressor is cracked.

17. Inspect the Compressor A. Inspect the back plate of the

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Compressor

The back plate of the compressor must

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be repaired or the turbocharger must be replaced.

compressor.


Damaged compressor impeller of the turbocharger Probable Cause Table 16 Troubleshooting Test Steps

Values

Results Result: The air filter element is not sealed properly. Inspect the air filter element and the air supply line to the turbocharger for correct installation.


Air filter





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Result: The incorrect oil is being used. Drain the engine oil. Replace the engine oil filter. Install the correct type of engine oil.


Engine oil Verify that the problem is resolved. Result: The correct oil is being used. Proceed to Test Step 6.

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Restrictions

Verify that the problem is resolved. Result: The oil supply line is not restricted. Proceed to Test Step 7. Result: The turbocharger bearings are not OK. Replace the turbocharger.





Debris Result: The compressor housing does not contain debris. Proceed to Test Step 9.

Result: The engine rpm increases too rapidly when the engine is started.

9. Verify the Engine RPM A. Verify the engine RPM during startup.

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Engine RPM Check the fuel injection pump for correct operation and settings.

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Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 10. Result: The high idle operates for an excessive time. Check the fuel injection pump for correct operation and settings.


High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 11. Result: The oil supply line has leaks. The supply line must be repaired or replaced.


Verify that the problem is resolved. Leaks Result: The oil supply line does not have leaks. Proceed to Test Step 12. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.


Restriction

Verify that the problem is resolved. Result: The turbocharger does not have a restriction in the bearing housing. Proceed to Test Step 13.

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Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.



14. Correct Engine Operation The engine may have stopped too soon from a high load condition. Result: The components listed are not operating properly.

A. Check the following components for correct operation or damage: · Compressor impeller of the turbocharger · Cooling system · Fuel injection pump · Air/fuel ratio control · Valve lash · Fuel injection nozzles

Engine operation


Damage to the turbine Probable Cause Table 17 Troubleshooting Test Steps 1. Check for Restriction in the Exhaust System

Values

Restriction/damage

Results Result: There is damage or a restriction in the exhaust system components.

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The component must be repaired or replaced. Verify that the problem is resolved. A. Check for damage or a restriction in the exhaust system components.

Result: There is not damage or a restriction in the exhaust system components. Proceed to Test Step 2.






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Verify that the problem is resolved. Result: The components listed are operating properly. Proceed to Test Step 4.

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Engine Oil




Engine oil

Verify that the problem is resolved. Result: The correct oil is being used. Proceed to Test Step 6.



Restrictions

Verify that the problem is resolved. Result: The oil supply line is not restricted. Proceed to Test Step 7. Result: The turbine housing is damaged or has a restriction.


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Restriction/damage

The turbine housing must be repaired or the turbocharger must be replaced.

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Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 8. Result: The turbocharger bearings are not OK. Replace the turbocharger. 8. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.


Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 9. Result: The turbocharger rotor has carbon build-up. Remove the carbon.


Carbon build-up Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 10.



Engine RPM

Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 11.

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Result: The high idle operates for an excessive time. Check the fuel injection pump for correct operation and settings.


High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 12. Result: The fuel injection pump is not operating correctly. The fuel injection pump must be repaired or replaced.

12. Inspect the Fuel Injection Pump for Proper Operation A. Test the fuel injection pump for proper operation.

Fuel pump

Verify that the problem is resolved. Result: The fuel injection pump is operating correctly. Proceed to Test Step 13. Result: The inlet valves and the exhaust valves are burned. Replace the inlet valves and the exhaust valves. Determine the cause of the damage to the valves.

13. Inspect the Intake and Exhaust Valves A. Inspect the intake and exhaust valves.

Burned valves

Verify that the problem is resolved. Result: The inlet valves and the exhaust valves are not burned. Proceed to Test Step 14. Result: The oil supply line has leaks.


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Leaks

The supply line must be repaired or replaced.

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Verify that the problem is resolved. Result: The oil supply line does not have leaks. Proceed to Test Step 15. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.


Restriction

Verify that the problem is resolved. Result: The turbocharger has a restriction in the bearing housing. Proceed to Test Step 16. Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.



17. Correct Engine Operation Result: The components listed are not operating properly.

The engine may have stopped too soon from a high load condition. A. Check the following components for correct operation or damage:

Engine operation


· Compressor impeller of the

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turbocharger · Cooling system · Fuel injection pump · Air/fuel ratio control · Valve lash · Fuel injection nozzles

The rotating assembly of the turbocharger does not rotate freely. Probable Cause Table 18 Troubleshooting Test Steps

Values

Results Result: The air filter element is not sealed properly. Inspect the air filter element and the air supply line to the turbocharger for correct installation.


Air filter





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Restriction/damage





5. Check for Turbocharger for Proper Lubrication The flow of engine oil is delayed to the turbocharger when the engine is started. Insufficient oil flows to the turbocharger when the engine is running. Turbocharger lubrication A. Check the following components for correct operation: · Engine oil pump · Engine oil bypass valve · Engine oil filter

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Result: The components listed are not operating properly. The component must be repaired or replaced. Verify that the problem is resolved. Result: The components listed are operating properly. Proceed to Test Step 6.

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· Viscosity of the engine oil · Restrictions in oil lines



Engine oil




Restrictions




Engine Oil


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Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced.


Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 10. Result: The turbocharger bearings are not OK. Replace the turbocharger.





Debris Result: The compressor housing does not contain debris. Proceed to Test Step 12. Result: The turbocharger rotor has carbon build-up.

12. Inspect the Turbocharger Rotor Remove the carbon. A. Inspect the turbocharger rotor for carbon build-up.

Carbon build-up Verify that the problem is resolved. Result: The turbocharger rotor does not

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have carbon build-up. Proceed to Test Step 13.



Engine RPM



High idle



Verify that the problem is resolved. Leaks Result: The oil supply line does not have leaks. Proceed to Test Step 16.

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Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.


Restriction

Verify that the problem is resolved. Result: The turbocharger has a restriction in the bearing housing. Proceed to Test Step 17. Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.





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Engine operation


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Worn bearings, bearing bores, and journals Probable Cause Table 19 Troubleshooting Test Steps

Values

Results Result: There is damage or a restriction to the tube between the air filter and the turbocharger.

1. Check for a Restriction in the Tube between the Air Filter and the Turbocharger A. Check for damage or a restriction in the tube between the air filter and the turbocharger.





Restriction/damage




Turbocharger Correctly position the turbocharger and tighten the clamps and bolts.

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Engine oil



Result: The oil supply line is restricted. Restrictions

The oil supply line must be repaired or replaced.

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Engine Oil




Engine RPM



High idle Verify that the problem is resolved. Result: The high idle does not operate for an excessive time.

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Proceed to Test Step 10. Result: The oil supply line has leaks. The supply line must be repaired or replaced. 10. Inspect the Oil Supply Line A. Inspect the oil supply line for leaks.

Verify that the problem is resolved. Leaks Result: The oil supply line does not have leaks. Proceed to Test Step 11. Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.



12. Correct Engine Operation The engine may have stopped too soon from a high load condition.

Result: The components listed are not operating properly.

A. Check the following components for correct operation or damage: Engine operation · Compressor impeller of the turbocharger · Cooling system · Fuel injection pump · Air/fuel ratio control · Valve lash


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· Fuel injection nozzles

The turbocharger makes excessive noise. Probable Cause Table 20 Troubleshooting Test Steps

Values



Air filter element


Result: The air filter element is not sealed properly. Inspect the air filter element and the air supply line to the turbocharger for correct installation.


Air filter


3. Check for a Restriction in the Tube between the Air Filter and the Turbocharger A. Check for damage or a restriction in

Restriction/damage

Result: There is damage or a restriction to the tube between the air filter and the turbocharger. Find the restriction and repair or replace

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the component. Verify that the problem is resolved. the tube between the air filter and the turbocharger.







Restriction/damage


6. Check for Proper Installation of the Turbocharger

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Turbocharger


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Correctly position the turbocharger and tighten the clamps and bolts. A. Verify that turbocharger is not loose or the clamps and bolts on the turbocharger are not loose.



7. Inspect the Intake Manifold A. Inspect the intake manifold for Intake manifold cracks, loose bolts, or a distorted flange.

Verify that the problem is resolved. Result: The intake manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 8. Result: The exhaust manifold has cracks, loose bolts, or a distorted flange. The exhaust manifold must be repaired or replaced.

8. Inspect the Exhaust Manifold Verify that the problem is resolved. A. Inspect the exhaust manifold for Exhaust manifold cracks, loose bolts, or a distorted flange.

Result: The exhaust manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 9.

9. Check for Turbocharger for Proper Lubrication

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Turbocharger lubrication

Result: The components listed are not operating properly.

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The flow of engine oil is delayed to the turbocharger when the engine is started. Insufficient oil flows to the turbocharger when the engine is running.


A. Check the following components for correct operation: · · · · ·

Result: The components listed are operating properly.





Engine oil

Verify that the problem is resolved. Result: The correct oil is being used. Proceed to Test Step 11.



Restrictions


12. Inspect the Turbocharger Bearings

Result: The turbocharger bearings are not OK. Turbocharger Bearings

Replace the turbocharger.

A. Inspect the turbocharger bearings.

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Verify that the problem is resolved. Debris Result: The compressor housing does not contain debris. Proceed to Test Step 14. Result: The turbocharger rotor has carbon build-up. Remove the carbon.


Carbon build-up Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 15.



Engine RPM

Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 16.

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Result: The high idle operates for an excessive time. Check the fuel injection pump for correct operation and settings.


High idle



Verify that the problem is resolved. Leaks Result: The oil supply line does not have leaks. Proceed to Test Step 18. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.


Restriction

Verify that the problem is resolved. Result: The turbocharger does not have a restriction in the bearing housing. Proceed to Test Step 19. Result: The engine oil filter has a restriction.


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Oil Filter

Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace

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the engine oil filter. Verify that the problem is resolved. Result: The engine oil filter does not have a restriction. Proceed to Test Step 20. 20. Correct Engine Operation The engine may have stopped too soon from a high load condition. Result: The components listed are not operating properly.


Engine operation


Sludge or carbon deposits in the bearing housing Probable Cause Table 21 Troubleshooting Test Steps

Values

Results Result: The crankcase breather has restrictions.

1. Check for Restrictions in the Crankcase Breather A. Check the crankcase breather for restrictions.

The crankcase breather (if equipped), or the tubing must be cleaned or replaced. Restrictions


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Engine oil




Engine Oil Verify that the problem is resolved. Result: The engine oil is not dirty. Proceed to Test Step 5.

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Restrictions

Verify that the problem is resolved. Result: The oil supply line is not restricted. Proceed to Test Step 6. Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced.


Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 7.



Engine RPM

Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 8. Result: The oil supply line has leaks.

8. Inspect the Oil Supply Line Leaks

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The supply line must be repaired or

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replaced. Verify that the problem is resolved. A. Inspect the oil supply line for leaks.

Result: The oil supply line does not have leaks. Proceed to Test Step 9. Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.





Engine operation


Troubleshooting the Engine When you are troubleshooting the engine, refer to the Specifications Module and the Systems Operation,

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Testing and Adjusting Module for additional information.

The engine will not start. Probable Cause Table 22 Troubleshooting Test Steps

Values

Results Result: The engine starting procedure was incorrectly followed. Ensure that the engine starting procedure is correctly followed.

1. Interview the Operator A. Ensure the engine starting procedure was followed.

Starting procedures

Verify that the problem is resolved. Result: The engine starting procedure was correctly followed. Proceed to Test Step 2.

Result: The manual valve in the fuel line is closed. Open the valve. 2. Check the Fuel Shutoff Valve A. Make sure the fuel shutoff valve is Open.

Fuel valve

Verify that the problem is resolved. Result: The manual valve in the fuel line is open. Proceed to Test Step 3.

3. Check the Fuel Level A. Check the fuel level.

Fuel level

Result: The fuel level is low in the fuel tank. Fill the fuel tank with fuel.

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Remove the air from the fuel system. Verify that the problem is resolved. Result: The fuel level is not low in the fuel tank. Proceed to Test Step 4.

Result: The fuel contains water, dirt, ice, or wax. Replace the fuel filters. Replace the fuel in the fuel tank with clean fuel.

4. Check the Fuel Quality A. Check the fuel for contamination.

Contamination

Verify that the problem is resolved. Result: The fuel does not contain water, dirt, ice, or wax. Proceed to Test Step 5.

Result: Engine cranking speed is too slow. 5. Check the Engine Crank Speed Make the necessary repairs. A. Check the engine cranking speed. Conditions that cause low cranking speed: 1. The engine oil is too thick. 2. The connections of the battery cables to the starting motor are loose.

Crank Speed

Verify that the problem is resolved. Result: Engine cranking speed is OK. Proceed to Test Step 6.

6. Check the Engine Glow Plugs A. Inspect the cable connections and the electrical

Engine Glow Plugs

Result: The glow plugs for the fuel injection pump do not operate correctly.

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Make the necessary repairs. Verify that the problem is resolved.

connections of the glow plugs and the electrical components of the starting aid circuit. Test the glow plugs for correct operation.

Result: The glow plugs for the fuel injection pump operate correctly. Proceed to Test Step 7.

Result: The fuel shutoff solenoid is not operating correctly. Replace a fuel shutoff solenoid that is suspect.

7. Check the Fuel Shutoff Solenoid A. Ensure that the fuel shutoff solenoid operates correctly.

Solenoid

Verify that the problem is resolved. Result: The fuel shutoff solenoid is operating correctly. Proceed to Test Step 8.

Result: The operation of the fuel transfer pump is not correct.

8. Check the Operation of the Fuel Transfer Pump A. Check the fuel pressure when the engine is cranking. Refer to the Specifications Module, "Fuel Transfer Pump" topic for additional information.

Fuel transfer pump

Remove the fuel transfer pump if the fuel pressure is too low. The fuel transfer pump must be repaired or replaced. Verify that the problem is resolved. Result: The operation of the fuel transfer pump is correct. Proceed to Test Step 9.

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Result: The fuel filter or the fuel lines are restricted. Replace the suspect component.

9. Check the Fuel Filter A. Check the fuel filter and fuel lines for restrictions. Drain any water from the fuel filter.

Fuel filter/fuel lines

Verify that the problem is resolved. Result: The fuel filter or the fuel lines are not restricted. Proceed to Test Step 10.

10. Check the Timing for the Fuel Injection Pump Result: The operation of the fuel injection pump is not correct.

A. Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information.

The fuel injection pump must be repaired or replaced.

B. Check the operation of the fuel rack linkage. C. Make sure that the high-pressure fuel lines are connected to the fuel injection nozzles in the correct order.

Fuel injection pump timing

Result: The operation of the fuel injection pump is correct.

D. Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque. Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.


Result: There is a problem with the governor or the fuel injection linkage.

11. Inspect the Fuel Injection Linkage and the Governor A. Inspect the governor and the fuel injection linkage for damage or the fuel injection linkage for incorrect assembly in the timing gear case.


Governor and fuel injection linkage

Make the necessary repairs. Verify that the problem is resolved. Result: There is not a problem

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with the governor or the fuel injection linkage. Proceed to Test Step 12.

12. Inspect the Fuel Injection Nozzles

Result: A fuel injection nozzle is not operating correctly.

A. Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder. B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Fuel Injection Nozzles

Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved. Result: The fuel injection nozzles are operating correctly. Proceed to Test Step 13.

13. Check the Cylinder Compression A. Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: · Piston rings are worn or broken. · The piston height is incorrect. · The piston is damaged. · The fuel injection nozzles are not seated correctly. · The valve lash requires adjustment. · The fuel injection pump timing is incorrect. · The engine timing is incorrect. · When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

Result: The cylinders have low compression. Cylinder compression


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The engine starts and the engine runs for a brief period of time and the engine stops. Probable Cause Table 23 Troubleshooting Test Steps

Values

Results Result: The fuel filter or the fuel lines are restricted. Check the fuel lines and the fuel filter. Replace the fuel filter. Drain any water from the fuel filter.

1. Inspect the Fuel System A. Check the fuel filter or the fuel lines for restrictions. Excess water can build up in the fuel filter.

Fuel System

Verify that the problem is resolved. Result: The fuel filter or the fuel lines are not restricted. Proceed to Test Step 2.

Result: The operation of the fuel transfer pump is not correct. 2. Check the Operation of the Fuel Transfer Pump A. Check the fuel pressure when the engine is cranking. Refer to the Specifications Module, "Fuel Transfer Pump" topic for additional information.

Fuel transfer pump

Remove the fuel transfer pump if the fuel pressure is too low. The fuel transfer pump must be repaired or replaced. Verify that the problem is resolved. Result: The operation of the fuel transfer pump is correct. Proceed to Test Step 3.

Result: The air inlet or the exhaust system is restricted.

3. Inspect the Air Inlet and Exhaust System A. Check the air inlet and exhaust system for restrictions..

Air inlet and exhaust system

Remove any restrictions. Verify that the problem is resolved.

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Result: The air inlet or the exhaust system is not restricted. Proceed to Test Step 4.

Result: Air is in the fuel system. 4. Check for Air in the Fuel System Air in the fuel system

A. Inspect the fuel system for air leaks in the system.

Find the air leak in the fuel system. Repair the fuel system. Verify that the problem is resolved.

The engine misfires or the engine runs rough. Probable Cause Table 24 Troubleshooting Test Steps

Values

Result: The fuel pressure is low.

1. Measure the Fuel Pressure

Make the necessary repairs.

A. Make sure that sufficient fuel is in the fuel tank. Remove any air in the fuel system. B. Look for leaks or suspect bends in the fuel line between the fuel tank and the fuel transfer pump.

Results

Fuel Pressure

Verify that the problem is resolved. Result: The fuel pressure is not low.

C. Check the outlet pressure of the fuel transfer pump.


Result: Air is in the fuel system. 2. Check for Air in the Fuel System A. Inspect the fuel system for air leaks in the system.

Air in the fuel system

Find the air leak in the fuel system. Repair the fuel system. Verify that the problem is resolved.

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Result: Air is not in the fuel system. Proceed to Test Step 3.

Result: The valve lash is not correct. Adjust the valve lash. 3. Check the Valve Lash A. Check the engine valve lash.

Valve lash

Verify that the problem is resolved. Result: The valve lash is correct. Proceed to Test Step 4.









5. Inspect the Fuel Injection Nozzles A. Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut

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Result: A fuel injection nozzle is not operating correctly. Replace the suspect fuel injection nozzle.

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at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder.

Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information.

B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Verify that the problem is resolved. Result: The fuel injection nozzles are operating correctly. Proceed to Test Step 6.

Result: The engine mounts are not correctly tightened or the engine mounts are not mounted correctly.

6. Check the Engine Mounts

Repair or replace the suspect components.

A. Check the engine mounts for proper installation. B. Check the engine mounts for correct positioning. Engine mounts C. Check the bolts of the engine mounts for correct tightening.

Verify that the problem is resolved. Result: The engine mounts are correctly tightened and the engine mounts are mounted correctly.

These conditions will cause a vibration.


Result: The fuel contains water, dirt, ice, or wax. 7. Check the Fuel Quality A. Check the fuel for contamination.

Contamination

Replace the fuel filters. Replace the fuel in the fuel tank with clean fuel. Verify that the problem is resolved.

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Result: The fuel does not contain water, dirt, ice, or wax. Proceed to Test Step 8.

8. Check the Cylinder Compression A. Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: · Piston rings are worn or broken. · The piston height is incorrect. · The piston is damaged. · The fuel injection nozzles are not seated correctly. · The valve lash requires adjustment. · The fuel injection pump timing is incorrect. · The engine timing is incorrect. · When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

Result: The cylinders have low compression. Cylinder compression


The engine runs evenly, but the engine loses power. Probable Cause Table 25 Troubleshooting Test Steps

Values

Result: The cylinders have low compression.

1. Check the Engine for Low Compression A. Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: · · · · · ·

Cylinder walls are worn or damaged. Piston rings are worn or broken. The piston height is incorrect. The piston height is incorrect. The fuel injection nozzles are not seated correctly. The valve lash requires adjustment.

Results

Low compression

Repair or replace the engine component causing low compression. Verify that the problem is resolved. Result: The cylinders do not have low compression.

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· The fuel injection pump timing is incorrect. · The engine timing is incorrect. · When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.







Verify that the problem is resolved. Result: The operation of the fuel injection pump is correct.




Valve lash



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Air filter element

Result: The air filter element is dirty or has restrictions. The air filter element must be cleaned or replaced.

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Result: Air is in the fuel system. Find the air leak in the fuel system. Repair the fuel system. 5. Check for Air in the Fuel System A. Inspect the fuel system for air leaks in the system.

Air in the fuel system

Verify that the problem is resolved. Result: Air is not in the fuel system. Proceed to Test Step 6.

Result: The fuel transfer pump is not operating correctly. 6. Check the Fuel Transfer Pump for Proper Operation A. Check the fuel pressure when the engine is cranking. Refer to the Specifications Module, "Fuel Transfer Pump" topic for additional information. Remove the fuel transfer pump if the fuel pressure is too low.

Fuel pressure

The fuel transfer pump must be repaired or replaced. Install the fuel transfer pump with the lobe of the camshaft on minimum lift. Tighten the mounting bolts evenly. Verify that the problem is resolved.

The engine lacks power. Probable Cause

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Table 26 Troubleshooting Test Steps

Values

Results Result: The fuel quality does not meet the engine specifications.

1. Test the Quality of the Fuel A. Test the quality level of the fuel, make sure the fuel quality meets the engine specifications.

Fuel quality

Remove the fuel from the fuel tank. Install a new fuel filter. Put a good grade of clean fuel in the fuel tank. Verify that the problem is resolved. Result: The fuel quality meets the engine specifications. Proceed to Test Step 2.

Result: The fuel pressure is low. 2. Measure the Fuel Pressure Make the necessary repairs. A. Make sure that sufficient fuel is in the fuel tank. Remove any air in the fuel system. Fuel B. Look for leaks or suspect bends in the fuel line between Pressure the fuel tank and the fuel transfer pump.

Verify that the problem is resolved. Result: The fuel pressure is not low.

C. Check the outlet pressure of the fuel transfer pump. Proceed to Test Step 3.

Result: There is a problem with the governor or the fuel injection linkage.

3. Inspect the Fuel Injection Linkage and the Governor A. Inspect the governor and the fuel injection linkage for damage or the fuel injection linkage for incorrect assembly in the timing gear case.

Governor and fuel injection linkage

Make the necessary repairs. Verify that the problem is resolved. Result: There is not a problem with the governor or the fuel

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injection linkage. Proceed to Test Step 4.

Result: The valve lash exceeds the specification. Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting.

4. Measure the Valve Lash A. Measure the valve lash.

Valve lash

Verify that the problem is resolved. Result: The valve lash is within the specification. Proceed to Test Step 5.

5. Inspect the Operation of the Fuel Injection Pump A. Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced. B. Make sure that the linkage of the fuel rack operates correctly.

Result: The operation of the fuel injection pump is not correct. Make the necessary repairs. Fuel Injection Pump

C. Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.



6. Inspect the Fuel Injection Nozzles A. Run the engine at the rpm that gives maximum




Result: A fuel injection nozzle is not operating correctly.

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misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder. B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved.

The engine has excessive vibration. Probable Cause Table 27 Troubleshooting Test Steps

Values

Results Result: The bolts for the pulleys are loose or the pulley is damaged.

1. Inspect the Engine Pulleys A. Inspect the engine pulleys for damage or loose bolts. Pulleys Refer to the Specifications Module, "Crankshaft Pulley" topic for additional information.

Tighten the bolts. If the pulley is worn or damaged, use new parts for replacement. Verify that the problem is resolved. Result: The bolts for the pulleys are not loose or the pulley is not damaged. Proceed to Test Step 2.

2. Inspect the Engine Mounts A. Inspect the engine mounts for loose bolts or damage.

Engine mounts

Result: The engine mounts are loose, worn, or suspect. Tighten all mounting bolts. Inspect the engine mounts for wear or for damage. Use new parts

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for replacement. Verify that the problem is resolved.

The engine has excessive combustion noise. Probable Cause Table 28 Troubleshooting Test Steps

Values

Results Result: The fuel quality does not meet the engine specifications. Remove the fuel from the fuel tank. Install a new fuel filter. Put a good grade of clean fuel in the fuel tank.

1. Test the Quality of the Fuel A. Test the quality level of the fuel, make sure the fuel quality meets the engine specifications.

Fuel quality

Verify that the problem is resolved. Result: The fuel quality meets the engine specifications. Proceed to Test Step 2.

2. Inspect the Fuel Injection Nozzles A. Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the Fuel operation of the engine, the fuel injection nozzle is Injection probably suspect. Test the fuel injection nozzle for that Nozzles cylinder. B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat

Result: A fuel injection nozzle is not operating correctly. Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved.

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washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Result: The fuel injection nozzles are operating correctly. Proceed to Test Step 3.

Result: The piston height is incorrect. 3. Measure the Piston Height Piston height

A. Measure the engine piston height.

To obtain the correct piston height, the piston, the piston pin, the bearings, or the connecting rod should be replaced. Verify that the problem is resolved.

The engine has excessive valve compartment noise. Probable Cause Table 29 Troubleshooting Test Steps

Values

Results Result: Valve springs or locks are broken. Install new parts. Broken locks can cause the valve to slide into the cylinder. Major damage to the engine can occur.

1. Inspect the Valve Springs and Locks A. Inspect the valve springs and locks for damage.

Valve springs and locks

Verify that the problem is resolved. Result: Valve springs or locks are not broken. Proceed to Test Step 2.

2. Inspect the Rocker Arms A. Inspect the rocker arm assemblies for damage.

Rocker arm assemblies

Result: The bolts and nuts, which hold the rocker arm assembly, are loose. Tighten the bolts or nuts. Refer to the Specifications Module, "Rocker Shaft" topic for additional

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information. Verify that the problem is resolved. Result: The bolts and nuts, which hold the rocker arm assembly, are not loose. Proceed to Test Step 3.

Result: The valve lash exceeds the specification. 3. Measure the Valve Lash A. Measure the valve lash.

Valve lash

Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting. Verify that the problem is resolved.

Engine oil is in the cooling system. Probable Cause Table 30 Troubleshooting Test Steps

Values

Results Result: The engine oil cooler has leaks.

1. Inspect the Engine Oil Cooler Core A. Drain the coolant from the engine and the radiator. Drain the lubricating engine oil from the engine oil cooler. Refer to the Operation and Maintenance Manual for more Engine Oil information. Cooler Core B. Inspect the engine oil cooler core for leaks. Refer to Systems Operation, Testing and Adjusting, "Cooling System - Inspect" for the correct procedure.

Replace the oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" and Disassembly and Assembly, "Engine Oil Cooler - Install". Fit new seals between the oil cooler and the oil cooler cover. Refill the crankcase with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual for more information. Verify that the problem is resolved. Result: The engine oil cooler does not have leaks. Proceed to Test Step 2.

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Result: The cylinder head gasket has faults or signs of leakage.

2. Inspect the Cylinder Head Gasket A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure.

Replace the cylinder head gasket. Head gasket

Verify that the problem is resolved. Result: The cylinder head gasket does not have faults or signs of leakage.

B. Inspect the cylinder head gasket for faults and any signs of leakage.


Result: The cylinder head is not flat or has cracks. 3. Inspect the Cylinder Head Repair the cylinder head and/or replace the cylinder head.

A. Check the cylinder head for cracks. B. Check the cylinder head for flatness. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the correct procedure.

Cylinder head

Verify that the problem is resolved. Result: The cylinder head is flat and does not have cracks. Proceed to Test Step 4.

Result: The cylinder block has faults or signs of leakage. 4. Inspect the Cylinder Block A. Inspect the top face of the cylinder block for faults and signs of leakage.

Cylinder block

Replace the cylinder block. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation, Testing and Adjusting, "Cylinder Block - Inspect" for the correct procedure. Verify that the problem is resolved.

After the Repair A. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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B. Replenish the engine with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual, "Engine Oil and Filter - Change" for more information. C. Thoroughly flush the coolant system in order to remove all traces of the engine lubricating oil from the coolant system. Fill the coolant system with coolant. Refer to the Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

Engine knock occurs. Probable Cause Table 31 Troubleshooting Test Steps

Values

Results Result: The main bearings are damaged. Replace damaged parts.

1. Inspect the Main Bearings A. Inspect the main bearings and the bearing surfaces of the crankshaft.

Main Bearings

Verify that the problem is resolved. Result: The main bearings are not damaged. Proceed to Test Step 2.

Result: The crankshaft is damaged. Replace the crankshaft. Clean the engine thoroughly. 2. Inspect the Crankshaft A. Inspect the crankshaft for damage..

Crankshaft

Verify that the problem is resolved. Result: The crankshaft is not damaged. Proceed to Test Step 3.

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Result: The piston height is not correct. Replace the damaged component.

3. Inspect the Piston Height A. Check the piston height. B. Inspect the piston, the connecting rod, and the crankshaft for wear. Check for correct installation.

Piston Height

Verify that the problem is resolved. Result: The piston height is correct. Proceed to Test Step 4.

4. Inspect the Fuel Injection Nozzles A. Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder. B. Make sure that the fuel injection nozzles are properly Fuel sealed in the threaded ports. Make sure that the fuel Injection injection nozzles are correctly aligned in the threaded Nozzles ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Result: A fuel injection nozzle is not operating correctly. Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved.

C. Ensure the projection of the fuel injection nozzles are positioned correctly in the precombustion chamber.

The rocker arm has insufficient movement and the valve lash exceeds the specification. Probable Cause

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Values

Results Result: Lubrication of internal engine components is inadequate. Make the necessary repairs.

1. Check the Lubrication of Internal Components A. Check lubrication of the valves. There must be a strong flow of oil at high rpm. There must be a small flow of oil at low rpm. Oil passages in the engine must be clean.

Lubrication

Verify that the problem is resolved. Result: Lubrication of internal engine components is adequate. Proceed to Test Step 2.

Result: Rocker arm parts are worn. If there is too much wear, install new parts or rocker arms. Adjust the valve lash.

2. Check the Rocker Arms for Wear or Damage A.Visually inspect the rocker arms for wear or damage.

Damage or wear

Verify that the problem is resolved. Result: Rocker arm parts are not worn. Proceed to Test Step 3.

Result: The end of the valve stem is worn. 3. Inspect the Valve Stems A. Inspect the valve stems for wear.

Damage or wear

Install new valves. Adjust the valve lash. Verify that the problem is resolved. Result:The end of the valve

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stem is not worn. Proceed to Test Step 4.


Valve lash


Result: The pushrods are worn. If there is too much wear, install new pushrods. Adjust the valve lash.

5. Inspect the Engine Pushrods A. Visually inspect the pushrods for wear or damage.

Damage or wear

Verify that the problem is resolved. Result: The pushrods are not worn. Proceed to Test Step 6.

Result: The valve lifters are worn. 6. Inspect the Valve Lifters A. Visually inspect the valve lifters for wear or damage.

Damage or wear

If there is too much wear, install new valve lifters. Adjust the valve lash. Verify that the problem is resolved.

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Result: The valve lifters are not worn. Proceed to Test Step 7.

Result: The components are worn. 7. Inspect the Camshaft Replace suspect parts. Adjust the valve lash.

A. Measure the valve lash. B. Check for free movement of the valves.

Damage or wear


C. Check for bent valve stems. Result: The components are not worn.

D. Check for wear on the valve lifters.


Result: The bolts and the nuts that hold the rocker arm assembly are loose.

8. Inspect the Rocker Arm Assembly A. Visually inspect the rocker arms for wear, damage or loose bolts..

Damage or wear

Tighten the bolts and the nuts. Verify that the problem is resolved.

A cylinder head valve is loose. Probable Cause Table 33 Troubleshooting Test Steps

Values

Result: The valve keeper for the valve is broken.

1. Inspect the Valve Keepers A. Inspect the engine valve keepers for damage.

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Results

Valve keepers

Replace the valve keeper. Broken keepers can cause the valve to slide into the cylinder. Major engine damage can result.

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Verify that the problem is resolved. Result: The valve keeper for the valve is not broken. Proceed to Test Step 2.

Result: The valve springs are broken or damaged.

2. Inspect the Valve Springs Valve A. Inspect the valve springs for springs damage..

Install new valve springs. Verify that the problem is resolved.

Oil condenses at the exhaust. Probable Cause

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Values

Results Result: The valve compartment contains too much oil. Look at both ends of the rocker arm shaft. Be sure that a plug is installed in each end.

1. Inspect the Valve Compartment A. Inspect the valve compartment for excessive oil..

Valve compartment

Verify that the problem is resolved. Result: The valve compartment does not contain too much oil. Proceed to Test Step 2.

Result: The valve guides are worn. Install new valve guides. Recondition the cylinder head.

2. Inspect the Valve Guides A. Measure the timing of the fuel injection pump.

Timing

Verify that the problem is resolved. Result: The valve guides are not worn.. Proceed to Test Step 3.

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Result: The piston rings are worn. 3. Inspect the Engine Piston Rings A. Inspect the engine piston rings for wear.

Replace worn parts. The piston rings are worn. Refer to the Specifications Module, "Pistons and Rings" topic for additional information.

Piston rings


The valve lash is less than the required specification. Probable Cause Table 35 Troubleshooting Test Steps

Values

Result: The valve seat or the face of the valve is worn.

1. Inspect the Engine Valves A. Inspect the engine valve seats and valves.

Results

Valves

Adjust the valve lash. Verify that the problem is resolved.

Engine components have early wear. Probable Cause Table 36 Troubleshooting Test Steps

Values

Results Result: Dirt is in the engine oil.


Oil

Remove the dirty engine oil. Install a new oil filter. Put clean oil in the engine. Verify that the problem is resolved. Result: Dirt is not in the engine oil.

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Result: Leaks exist in the air inlet system. The components must be repaired or replaced.

2. Inspect the Air Inlet System Air inlet system

A. Inspect all gaskets and connections.

Verify that the problem is resolved. Result: Leaks do not exist in the air inlet system. Proceed to Test Step 3.

3. Inspect the Engine Oil for Fuel A. Fuel leaks will cause high fuel consumption and low engine oil pressure. Inspect the engine for the following leaks: · Fuel leaks into the crankcase from the fuel transfer pump. · Fuel leaks past the valve in a fuel injection nozzle. · The pressure setting of the fuel injection nozzles is too high. · The drive is broken on the fuel injection pump.

Result: Fuel is in the engine oil. Fuel leak

Replace the damaged component. Verify that the problem is resolved.

Coolant is in the engine oil. Probable Cause Table 37 Troubleshooting Test Steps

Values

Result: The cylinder head gasket is damaged.

1. Inspect the Cylinder Head Gasket A. Inspect the cylinder head gasket for damage.

Results

Head gasket

Install a new cylinder head gasket. Verify that the problem is resolved.

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Result: The cylinder head gasket is not damaged. Proceed to Test Step 2.

Result: The cylinder head is cracked or damaged. Install a new cylinder head. 2. Inspect the Cylinder Head A. Inspect the cylinder head for damage.

Cylinder head

Verify that the problem is resolved. Result: The cylinder head is not cracked or damaged. Proceed to Test Step 3.

Result: The cylinder block is cracked or damaged.

3. Inspect the Cylinder Block A. Inspect the cylinder block for damage.

Cylinder block

Install a new cylinder block. Verify that the problem is resolved.

The engine exhaust has too much black smoke or too much gray smoke. Probable Cause Table 38 Troubleshooting Test Steps

Values

Result: The cylinders have low compression.

1. Check the Engine for Low Compression A. Starting the engine may be difficult in warm weather. The engine may not start in cold weather. Low compression is most frequently caused by the following conditions: · Cylinder walls are worn or damaged. · Piston rings are worn or broken.

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Results

Low compression

Repair or replace the engine component causing low compression. Verify that the problem is resolved.

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· The piston height is incorrect. · The piston height is incorrect. · The fuel injection nozzles are not seated correctly. · The valve lash requires adjustment. · The fuel injection pump timing is incorrect. · The engine timing is incorrect. · When an inlet valve or an exhaust valve is fully seated, gases leak past the valve head.

2. Inspect the Fuel Injection Nozzles A. Run the engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder. Loosen one nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder. B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

3. Inspect the Operation of the Fuel Injection Pump A. Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced. B. Make sure that the linkage of the fuel rack operates correctly. C. Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct

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Result: The cylinders do not have low compression. Proceed to Test Step 2.

Result: A fuel injection nozzle is not operating correctly. Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Fuel Injection Specifications Module, "Fuel Nozzles Injection Nozzles" topic for additional information. Verify that the problem is resolved. Result: The fuel injection nozzles are operating correctly. Proceed to Test Step 3.

Result: The operation of the fuel injection pump is not correct. Make the necessary repairs. Fuel Injection Verify that the problem is Pump resolved. Result: The operation of the fuel injection pump is correct. Proceed to Test Step 4.

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order. D. Make sure that the mounting bolts of the fuel injection pump are tightened to the correct torque. Inspect the fuel lines for leaks or for restrictions. The damaged fuel lines or fittings must be repaired or replaced.

Result: There is a restriction in the air inlet system. 4. Inspect the Air Inlet System Restriction

A. Check the air cleaner for restrictions.

The air cleaner must be cleaned or replaced. Verify that the problem is resolved.

The engine exhaust has too much white smoke or too much blue smoke. Probable Cause Table 39 Troubleshooting Test Steps

Values

Results Result: The engine contains too much engine oil. Drain the excess engine oil from the engine oil pan.

1. Check the Oil Level A. Check the engine oil level.

Oil level

Verify that the problem is resolved. Result: The engine does not contain too much engine oil. Proceed to Test Step 2.

2. Inspect the Fuel Injection Pump Timing A. Check the fuel injection pump for the

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Timing

Result: The timing of fuel injection pump is incorrect. Adjust the timing. Refer to the

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Specifications Module, "Fuel Injection Pump" topic for additional information. Verify that the problem is resolved. correct timing. Result: The timing of fuel injection pump is correct. Proceed to Test Step 3.

Result: The valve guides are worn. Replace the valve guides. 3. Inspect the Engine Valve Guides A. Inspect the engine valve guides for wear.

Valve guides

Verify that the problem is resolved. Result: The valve guides are not worn. Proceed to Test Step 4.

Result: The piston rings are worn. Replace worn parts. The piston rings are worn. Refer to the Specifications Module, "Pistons and Rings" topic for additional information.

4. Inspect the Engine Piston Rings A. Inspect the engine piston rings for wear.

Piston rings Verify that the problem is resolved. Result: The piston rings are not worn. Proceed to Test Step 5.

Result: The water temperature regulator is suspect.

5. Operating Conditions A. If the engine consistently runs below the normal operating temperature, inspect the water temperature regulator.

Operating Temperature

Replace the water temperature regulator. Verify that the problem is resolved. Result: The water temperature regulator is not suspect.

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Result: The breather hose or the vent hole in the breather assembly is obstructed.

6. Inspect the Breather Hose or the Vent Hole in the Breather Assembly Restrictions A.Visually inspect the components.

Clean the vent hole, the breather assembly, and the breather hose. Verify that the problem is resolved.

The engine has low oil pressure. Probable Cause

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Values

Results Result: The engine oil level is low. Fill the engine oil to the correct level.


Oil level

Verify that the problem is resolved. Result: The engine oil level is not low. Proceed to Test Step 2.

Result: The engine oil filter is restricted.

2. Inspect the Engine Oil Filter A. Inspect the engine oil filter for restrictions.

Oil filter

Install a new engine oil filter. Replace the oil in the engine with clean engine oil. Check the operation of the engine oil bypass valve for the engine oil filter. Verify that the problem is resolved. Result: The engine oil filter is not restricted.

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3. Inspect the Engine Oil for Fuel A. Fuel leaks will cause high fuel consumption and low engine oil pressure. Inspect the engine for the following leaks:

Result: Fuel is in the engine oil.

· Fuel leaks into the crankcase from the fuel Fuel leak transfer pump. · Fuel leaks past the valve in a fuel injection nozzle. · The pressure setting of the fuel injection nozzles is too high. · The drive is broken on the fuel injection pump.


Replace the damaged component.

Result: Fuel is not in the engine oil. Proceed to Test Step 4.

Result: The clearance is not within specifications. Make the necessary repairs.

4. Inspect the Clearance of the Rocker Arm A. Measure the clearance.between the bore of the rocker arm and the rocker shaft.

Clearance

Verify that the problem is resolved. Result: The clearance is within specifications. Proceed to Test Step 5.

Result: The rocker assembly does not have proper lubrication. Replace parts which are worn. Refer to the Specifications Module, "Rocker Shaft" topic for additional information.

5. Inspect the Rocker Assembly A. Inspect the rocker assembly for proper lubrication.

Lubrication Verify that the problem is resolved. Result: The rocker assembly has proper lubrication. Proceed to Test Step 6.

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Result: The suction tube is loose or damaged. The suction tube must be repaired or replaced.

6. Inspect the Oil Pump Suction Tube A. Inspect the oil pump suction tube for damage or a loose connection.

Suction tube

Verify that the problem is resolved. Result: The suction tube is not loose or damaged. Proceed to Test Step 7.

Result: The engine oil bypass valve does not operate correctly. Clean the bypass valve. Replace the bypass valve if the spring is broken or the plunger is damaged.

7. Inspect the Oil Pump Bypass Valve A. Inspect oil pump bypass valve for proper operation.

Oil pump bypass valve

Verify that the problem is resolved. Result: The engine oil bypass valve operates correctly. Proceed to Test Step 8.

8. Inspect the Engine Oil Pump

Result: The engine oil pump does not operate correctly.

A. Inspect the engine oil pump for proper operation.

The components must be repaired or replaced.

B. Check the distance of the face of the cover of the oil pump above the face of the idler gear. Refer to the Specifications Module, "Engine Oil Pump" topic. Check the wear of the lobe on the oil pump.

Oil pump

Verify that the problem is resolved. Result: The engine oil pump operates correctly. Proceed to Test Step 9.

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Result: The clearance is not within specifications. Replace the crankshaft or the crankshaft bearings. Refer to the Specifications Module, "Crankshaft" topic for additional information.

9. Inspect the Crankshaft A. Measure the clearance between the crankshaft and the crankshaft bearings.

Clearance Verify that the problem is resolved. Result: The clearance is within specifications. Proceed to Test Step 10.

Result: The clearance is not within specifications.

10. Inspect the Camshaft A. Measure the clearance between the camshaft and the camshaft bearings.

Clearance

Replace the camshaft or the camshaft bearings. Verify that the problem is resolved.

The engine oil pressure is too high. Probable Cause Table 41 Troubleshooting Test Steps

Values

Result: The engine oil bypass valve does not open.

1. Inspect the Engine Oil Bypass Valve A. Inspect the engine oil bypass valve for proper operation.

Results

Bypass valve

The bypass valve must be cleaned or replaced. Verify that the problem is resolved.

The engine uses too much engine oil.

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Probable Cause Table 42 Troubleshooting Test Steps

Values

Results Result: The engine contains too much engine oil. Drain the excess engine oil from the engine oil pan.


Oil level

Verify that the problem is resolved. Result: The engine does not contain too much engine oil. Proceed to Test Step 2.

Result: The engine oil lines have leaks. Find the source of the oil leaks. Repair the line or fitting.

2. Inspect the Engine A. Inspect the engine for oil leaks.

Oil leaks

Verify that the problem is resolved. Result: The engine oil lines do not have leaks. Proceed to Test Step 3.

Result: The valve guides are worn. 3. Inspect the Engine Valve Guides A. Inspect the engine valve guides for wear.

Replace the valve guides. Valve guides

Verify that the problem is resolved. Result: The valve guides are not worn. Proceed to Test Step 4.

Result: The piston rings are worn.

4. Inspect the Engine Piston Rings A. Inspect the engine piston rings for wear.

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Piston rings

Replace worn parts. The piston rings are worn. Refer to the Specifications Module, "Pistons and Rings" topic for additional information.

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The engine overheats. Probable Cause Table 43 Troubleshooting Test Steps

Values

Results Result: The air flow through the radiator is restricted. Clean the exterior of the radiator in order to remove all restrictions.

1. Inspect the Cooling System A. Check the air flow through the radiator for a restriction.

Restriction

Verify that the problem is resolved. Result: The air flow through the radiator is not restricted. Proceed to Test Step 2.

Result: The coolant level in the engine is low. Add coolant into the radiator to the correct level.

2. Check the Coolant Level A. Check the coolant level.

Coolant

Verify that the problem is resolved. Result: The coolant level in the engine is not low. Proceed to Test Step 3.

Result: The coolant pressure cap is not working properly.

3. Inspect the Coolant Pressure Cap A. Test the operation of the pressure cap.

Coolant Pressure Cap

Replace the faulty pressure cap. Verify that the problem is resolved.

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Result: The coolant pressure cap is working properly. Proceed to Test Step 4.

Result: Gases from combustion are in the coolant. Find the source of the entry of the gases from combustion into the coolant system. Repair the source of the problem.

4. Inspect the Cooling System A. Inspect the cooling system for gases from combustion.

Cooling System

Verify that the problem is resolved. Result: Gases from combustion are not in the coolant. Proceed to Test Step 5.

Result: The water temperature regulator is suspect. 5. Inspect the Water Temperarure Regulator A. Test the water temperature regulator for correct operation. Refer to the Systems Operation, Testing and Adjusting Module or the Specifications Module for additional information.

Replace the faulty water temperature regulator. Regulator

Verify that the problem is resolved. Result: The water temperature regulator is not suspect. Proceed to Test Step 6.

Result: The water pump is suspect. The water pump must be repaired or replaced.

6. Inspect the Water Pump A. Test the water pump for proper operation..

Water pump Verify that the problem is resolved. Result: The water pump is not suspect.

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Result: The engine is operating with too much load. Reduce the load.

7. Operating Conditions A. Check the load the engine is operating under.

Load

Verify that the problem is resolved. Result: The engine is not operating with too much load. Proceed to Test Step 8.

Result: The timing of fuel injection pump is incorrect. 8. Inspect the Fuel Injection Pump Timing A. Check the fuel injection pump for the correct timing.

Timing

Adjust the timing. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. Verify that the problem is resolved.

The exhaust temperature is too high. Probable Cause

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Values

Results Result: There is a restriction in the air inlet or exhaust system.

1. Inspect the Air Inlet and Exhaust System A. Inspect the air inlet and exhaust system, look for a restriction.

Remove the restriction. Restriction

Verify that the problem is resolved. Result: There is not a restriction in the air inlet or exhaust system. Proceed to Test Step 2.

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Result: The timing of the fuel injection pump is incorrect.

2. Measure the Fuel Injection Pump Timing A. Measure the timing of the fuel injection pump.


Timing

Adjust the timing of the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. Verify that the problem is resolved.

The starting motor does not turn or the starting motor turns too slowly. Probable Cause Table 45 Troubleshooting Test Steps

Values

Results Result: The battery has a low charge.

1. Measure the Charge of the Battery A. Measure the battery voltage.

Battery voltage

Charge the battery. Replace a faulty battery. Clean all cable terminals and battery posts. Apply the 1U-8267 Battery Saver and Cleaner on the cable clamps and to battery posts. Tighten the cable clamps on the battery posts. Verify that the problem is resolved. Result: The battery does not have a low charge. Proceed to Test Step 2.

Result: A short circuit was found. 2. Inspect the Starting Motor A. Inspect the brushes for the starting motor. Inspect the brushes for a short circuit.

Repair the short circuit. Starting motor brushes

Verify that the problem is resolved. Result: A short circuit was not found. Proceed to Test Step 3.

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Result: The ignition switch, the start relay, or the starting motor solenoid are not operating properly. 3. Inspect the Ignition Switch, the Start Relay, and the Starting Motor Solenoid A. Inspect the ignition switch, the start relay, and the starting motor solenoid for proper operation.

Replace or repair the components that are not operating properly. Starter circuit

Verify that the problem is resolved. Result: The ignition switch, the start relay, or the starting motor solenoid are operating properly. Proceed to Test Step 4.

4. Inspect the Starting Motor Circuit A. Inspect the starting motor circuit for a voltage drop. B. Inspect the battery cables and battery terminals for loose connections, corrosion, or other damage.

Result: An excessive voltage drop exists in the cables or across the terminals in the circuits for the starting motor. Voltage drop

Replace the damaged parts. Verify that the problem is resolved.

The starting motor turns, but the pinion gear does not engage the flywheel ring gear. Probable Cause

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Values

Results Result: The overrunning clutch for the pinion drive slips. Replace the overrunning clutch.

1. Inspect the Pinion Drive A. Inspect the overrunning clutch for the pinion drive.

Pinion drive

Verify that the problem is resolved. Result: The overrunning clutch for the pinion drive does not slip. Proceed to Test Step 2.

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Result: The ring gear of the flywheel is damaged. Replace the flywheel. 2. Inspect the Flywheel Ring Gear A. Inspect the flywheel ring gear for damage..

Flywheel

Verify that the problem is resolved. Result: The ring gear of the flywheel is not damaged. Proceed to Test Step 3.

Result: The shift lever or the linkage is damaged. Replace the shift lever or the linkage.

3. Inspect the Shift Lever A. Inspect the shift lever and linkage for damage.

Shift lever

Verify that the problem is resolved. Result: The shift lever or the linkage is not damaged. Proceed to Test Step 4.

Result: The starting motor solenoid is not operating properly. Replace or repair the components that are not operating properly.

4. Inspect the Starting Motor Solenoid A. Inspect the starting motor solenoid for proper operation.

Starter solenoid

Verify that the problem is resolved. Result: The starting motor solenoid is operating properly. Proceed to Test Step 5.

5. Inspect the Armature or Idler Gear of the Starting Motor

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Starting motor

Result: The armature or idler gear of the starting motor is damaged.

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Replace the starting motor.

A. Inspect the armature or idler gear of the starting motor for damage.


The engine does not crank or the engine rotates slowly when the keyswitch is in the start position. Probable Cause

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Values

Results Result: The battery has a low charge.

1. Measure the Charge of the Battery A. Measure the battery voltage.

Battery voltage

Charge the battery. Replace a faulty battery. Clean all cable terminals and battery posts. Apply the 1U-8267 Battery Saver and Cleaner on the cable clamps and to battery posts. Tighten the cable clamps on the battery posts. Verify that the problem is resolved. Result: The battery does not have a low charge. Proceed to Test Step 2.

Result: The start relay is not operation properly. Replace the start relay.

2. Inspect the Start Relay A. Check the start relay for proper operation.

Start relay

Verify that the problem is resolved. Result: The start relay is operation properly. Proceed to Test Step 3.

3. Inspect the Starting Motor Circuit A. Inspect the starting motor circuit

Voltage drop

Result: An excessive voltage drop exists in the cables or across the terminals in the circuits for the starting motor. Replace the damaged parts.

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for a voltage drop.


B. Inspect the battery cables and battery terminals for loose connections, corrosion, or other damage.

Result: An excessive voltage drop does not exist in the cables or across the terminals in the circuits for the starting motor. Proceed to Test Step 4.

Result: The overrunning clutch for the pinion drive slips.

4. Inspect the Pinion Drive A. Inspect the overrunning clutch for the pinion drive.

Pinion drive

Replace the overrunning clutch. Verify that the problem is resolved.

The starting motor continues to run after the ignition switch is released. Probable Cause Table 48 Troubleshooting Test Steps

Values

Result: The ignition switch, the start relay, or the starting motor solenoid are not operating properly.

1. Inspect the Ignition Switch, the Start Relay, and the Starting Motor Solenoid A. Inspect the ignition switch, the start relay, and the starting motor solenoid for proper operation.

Results

Starter circuit

Replace or repair the components that are not operating properly. Verify that the problem is resolved.

The pinion gear does not disengage after the engine starts to run. Probable Cause Table 49 Troubleshooting Test Steps 1. Inspect the Return Spring of the Pinion Solenoid

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Values

Return Spring

Results Result: The return spring of the pinion solenoid is damaged.

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Replace the return spring of the pinion solenoid. Verify that the problem is resolved.

A. Inspect the return spring of the pinion solenoid for damage.

Result: The return spring of the pinion solenoid is not damaged. Proceed to Test Step 2.

Result: The shift lever or the linkage is damaged. Replace the shift lever or the linkage.

2. Inspect the Shift Lever A. Inspect the shift lever and linkage for damage.

Shift lever

Verify that the problem is resolved. Result: The shift lever or the linkage is not damaged. Proceed to Test Step 3.

Result: The ignition switch, the start relay, or the starting motor solenoid are not operating properly.

3. Inspect the Ignition Switch, the Start Relay, and the Starting Motor Solenoid A. Inspect the ignition switch, the start relay, and the starting motor solenoid for proper operation.

Starter circuit

Replace or repair the components that are not operating properly. Verify that the problem is resolved.

The alternator does not charge the battery or the alternator charge rate is slow or irregular. Probable Cause Table 50 Troubleshooting Test Steps 1. Inspect the Alternator Drive

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Values

Drive belt

Results Result: The drive belt for the alternator is loose.

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Belt


The drive belt must be adjusted or replaced.

A. Verify that the tension is correct on the drive belt.

Verify that the problem is resolved. Result: The drive belt for the alternator is not loose.

B. Inspect the drive belt for wear and for damage.


Result: The drive pulley for the alternator is loose or worn. Tighten the nuts of the pulley to the correct torque. Replace a damaged pulley.

2. Inspect the Alternator Drive Pulley A. Inspect the pulley for wear or for damage.

Drive pulley

Verify that the problem is resolved. Result: The drive pulley for the alternator is not loose or worn. Proceed to Test Step 3.

Result: The electrical cables and connections in the charging and starting circuits are loose or damaged. Inspect all cables and connections. All connections must be clean and tight. Apply the 1U-8267 Battery Saver and Cleaner on the cable terminals and the connections. Replace suspect parts.

3. Inspect the Electrical Connections A. Inspect the electrical cables and connections in the charging and starting circuits.

Electrical connections

Verify that the problem is resolved. Result: The electrical cables and connections in the charging and starting circuits are not loose or damaged. Proceed to Test Step 4.

4. Check the Alternator for Proper Operation A. Test the following alternator

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Alternator

Result: One of the components is not operating properly. Replace the component that is not operating properly.

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components: · Regulator or the field winding of the rotor · Brushes · Rectifier


The alternator charges the battery to a voltage that is too high. Probable Cause Table 51 Troubleshooting Test Steps

Values

1. Check the Alternator for Proper Operation

Results

Result: One of the components is not operating properly.

A. Test the following alternator components: Alternator · Regulator or the field winding of the rotor · Brushes · Rectifier

Replace the component that is not operating properly. Verify that the problem is resolved.

The alternator is noisy. Probable Cause

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Values

Results Result: The drive belt for the alternator is loose.

1. Inspect the Alternator Drive Belt The drive belt must be adjusted or replaced. A. Verify that the tension is correct on the drive belt. B. Inspect the drive belt for wear and for damage.

Drive belt

Verify that the problem is resolved. Result: The drive belt for the alternator is not loose.

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Result: The drive pulley for the alternator is loose or worn. Tighten the nuts of the pulley to the correct torque. Replace a damaged pulley.

2. Inspect the Alternator Drive Pulley A. Inspect the pulley for wear or for damage.

Drive pulley

Verify that the problem is resolved. Result: The drive pulley for the alternator is not loose or worn. Proceed to Test Step 3.

Result: The drive belt and the drive pulley are not in alignment. Adjust the alignment.

3. Inspect the Belt Alignment A. Inspect the alignment of the drive pulley and drive belt.

Belt alignment

Verify that the problem is resolved. Result: The drive belt and the drive pulley are in alignment. Proceed to Test Step 4.

Result: The bearings of the alternator are worn or damaged.

4. Check the Alternator for Proper Operation Alternator

Replace the alternator.

A. Inspect the alternator bearings. Verify that the problem is resolved.

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320D2 Troubleshooting9

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