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
Make sure that the fuel injection nozzle is
Sealed Correctly in the Cylinder Head
Fuel tightened to the correct torque in the threaded
Injection hole of the cylinder head.
A. Verify that the fuel injection nozzle is
Nozzle
sealed correctly in the cylinder head.
Verify that the problem is resolved.
Result: The fuel injection nozzle is sealed

Proceed to Test Step 2.
Result: There is debris on the mounting

surface of the cylinder head or extra gaskets
2. Check for Debris on the Mating were left in the cylinder head for the fuel
Surface of the Cylinder Head with the injection nozzle.
Gaskets or the Insert
Remove any extra gaskets or debris.
A. Check for debris on the mating surface
of the cylinder head. Debris Verify that the problem is resolved.
B. Make sure that extra gaskets were Result: There is no debris on the mounting
removed from the threaded recess in the surface of the cylinder head or extra gaskets
cylinder head for the fuel injection nozzle. left in the cylinder head for the fuel injection
nozzle.
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Result: A high-pressure fuel line is leaking.
Repair or replace the high-pressure fuel line

3. Check the Connections of the High that is leaking.
Pressure Fuel Line
Fuel leak
A. Check for a damaged or leaking high-
pressure fuel line. Result: A high-pressure fuel line is not
leaking.
Result: The correct fuel nozzles are not

installed.
4. Check that the Correct Fuel Nozzles
are Installed
Install the correct fuel nozzles.
Fuel
Refer to the Parts Manual for the correct
A. Verify that all fuel injection nozzles are Nozzle
replacement part.
the correct replacement parts for the engine.
The Engine Exhaust has too Much Black Smoke
Probable Cause
Table 2
1. Check for Debris on the Mating Surface Result: There is debris on the mounting surface
of the Cylinder Head with the Gaskets or of the cylinder head or extra gaskets were left in
the Insert the cylinder head for the fuel injection nozzle.
A. Check for debris on the mating surface of Remove any extra gaskets or debris.
the cylinder head. Debris
B. Make sure that extra gaskets were
removed from the threaded recess in the Result: There is no debris on the mounting
cylinder head for the fuel injection nozzle. surface of the cylinder head or extra gaskets left
in the cylinder head for the fuel injection
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nozzle.
2. 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 Replace the fuel nozzle.
torques.
Fuel
Nozzle
B. Make sure that the gaskets and the insert
are positioned correctly. Result: The fuel nozzle is operating properly.
C. Test the fuel injection nozzle on a nozzle Proceed to Test Step 3.

tester in order to measure the pressure setting.

installed.
3. Check that the Correct Fuel Nozzles are
Installed
Fuel
A. Verify that all fuel injection nozzles are Nozzle
replacement part.
the correct replacement parts for the engine.
The Engine has Lost Power and the Engine Uses too Much Fuel
Probable Cause
Table 3
Result: The fuel injection nozzle does not seal

1. Check that the Fuel Injection Nozzle is correctly in the cylinder head.
Sealed Correctly in the Cylinder Head
Fuel Make sure that the gaskets, the insert, and the
Injection mating surface of the cylinder head are clean.
Nozzle
tightened to the correct torque in the threaded
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hole of the cylinder head.


were left in the cylinder head for the fuel
2. Check for Debris on the Mating
injection nozzle.
Surface of the Cylinder Head with the
of the cylinder head. Debris
Result: There is no debris on the mounting
removed from the threaded recess in the
left in the cylinder head for the fuel injection
cylinder head for the fuel injection nozzle.
nozzle.

Pressure Fuel Line
Fuel leak
A. Check for a damaged or leaking high-
pressure fuel line. Result: A high-pressure fuel line is not
leaking.
4. Check for Correct Operation of the Result: The fuel nozzle is not operating
Fuel Nozzle properly.
Fuel
A. Make sure that the components of the Nozzle Replace the fuel nozzle.
fuel injection nozzle are tightened to the
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correct torques.
B. Make sure that the gaskets and the insert
are positioned correctly.
Result: The fuel nozzle is operating properly.
C. Test the fuel injection nozzle on a nozzle
tester in order to measure the pressure
setting.

installed.

are Installed Refer to the Parts Manual for the correct
Fuel replacement part.
A. Verify that that all fuel injection nozzles Nozzle
have the correct code for the engine. Verify that the problem is resolved.
Result: The correct fuel nozzles are installed.
Result: A low-pressure fuel line is leaking.

6. Check the Connections of the Low
Pressure Fuel Line
Repair or replace the low-pressure fuel line
Fuel Leak that is leaking.
A. Check for a damaged or leaking low-
pressure fuel line.
The Engine is Misfiring, Running Rough, or Running Poorly
Probable Cause
Table 4
1. Check that the Fuel Injection Nozzle Result: The fuel injection nozzle does not
is Sealed Correctly in the Cylinder Fuel Injection seal correctly in the cylinder head.
Head Nozzle
Make sure that the gaskets, the insert, and
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the mating surface of the cylinder head are

clean.

tightened to the correct torque in the
threaded hole of the cylinder head.


were left in the cylinder head for the fuel
2. Check for Debris on the Mating
injection nozzle.
Surface of the Cylinder Head with the
of the cylinder head. Debris
Result: There is no debris on the mounting
removed from the threaded recess in the
left in the cylinder head for the fuel
cylinder head for the fuel injection nozzle.
injection nozzle.

Pressure Fuel Line
Fuel leak
A. Check for a leaking high-pressure fuel
line. Result: A high-pressure fuel line is not
leaking.
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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 Replace the fuel nozzle.
correct torques.
Fuel Nozzle
B. Make sure that the gaskets and the
insert are positioned correctly. Result: The fuel nozzle is operating
properly.
C. Test the fuel injection nozzle on a
nozzle tester in order to measure the Proceed to Test Step 5.
pressure setting.

installed.

are Installed
replacement part.
Fuel Nozzle
A. Verify that all fuel injection nozzles
have the correct code for the engine.
Result: The correct fuel nozzles are
installed.
Result: A high-pressure fuel line is

restricted or damaged.

6. Check for a Restriction in the High-
that is restricted or damaged.
pressure Fuel Line
High-pressure
fuel line Verify that the problem is resolved.
A. Check for a damaged or restricted
restriction
high-pressure fuel line.
Result: A high-pressure fuel line is not
restricted or damaged.
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Result: The seat washer is not 2.0 mm

(0.08 inch) thick.
7. Check for the Correct Seat Washer
2.0 mm
Replace the seat washer with the correct
A. Verify that the seat washer is 2.0 mm (0.08 inch) seat
seat washer.
(0.08 inch) thick. washer
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
Result: There are fuel leaks.through the

threaded connection of the body and the
nozzle nut.
1. Check for Fuel Leaks through the Make sure that the threads are clean.
Threaded Connection of the Body and the Tighten the body to the correct torque.
Nozzle Nut
Fuel leaks Verify that the problem is resolved.
A. Check for fuel leaks.through the threaded
connection of the body and the nozzle nut. Result: There are no fuel leaks.through the
threaded connection of the body and the
nozzle nut.
2. Check for Debris or Damage on the Damage or Result: The valve has debris or is damaged.
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Orifices
Clean the surface of the orifices with
solvent. Replace the fuel injection nozzles if
A.Visually inspect the components of the
Debris corrosion exists.
valve for carbon pitting, for scoring, or for
other damage.
The fuel injection nozzle does not inject fuel in the correct quantity or in the correct
pattern.
Probable Cause
Table 6
Result: The opening pressure is not correct.
1. Check the Setting for the Adjust the setting to the correct pressure.
Opening Pressure
Opening Verify that the problem is resolved.
A. Test the setting of the opening pressure
pressure. Result: The opening pressure is correct.
Result: The fuel injection nozzle is stuck. Debris

or damage exists on the fuel injection nozzle.
2. Verify the Operation of the Fuel The fuel injection nozzle must be cleaned or
Injection Nozzle replaced.
Fuel injection
A.Verify that the fuel injection nozzle nozzle Verify that the problem is resolved.
is not stuck.
Result: The fuel injection nozzle is not stuck.
3. Check for a Blockage or Result: The orifices are blocked or restricted.

Restriction in the Orifices Orifice
blockage The fuel injection nozzle must be cleaned or
A.Inspect the orifices for carbon replaced.
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buildup.
Result: The orifices are not blocked or restricted.
Result: The fuel return passage is blocked or

restricted.
4. Check for a Blockage or
Restriction in the Fuel Return
Fuel return Clean the passage in order to remove any carbon
passage buildup or other debris.
A.Inspect the fuel return passage.
Troubleshooting the Turbocharger

The engine lacks power.
Probable Cause
Table 7
Result: The air filter element is dirty

or has restrictions.
The air filter element must be cleaned

1. Check for Restrictions in the Air
or replaced.
Filter Element
Air filter element Verify that the problem is resolved.
A. Check the condition of the air filter
element.
Result: The air filter element is not
dirty or does not have restrictions.
2. Check for a Restriction in the Tube Result: There is damage or a

between the Air Filter and the restriction to the tube between the air
Restriction/damage
Turbocharger filter and the turbocharger.
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Find the restriction and repair or

replace the component.

A. Check for damage or a restriction in the
tube between the air filter and the
Result: There is not damage or a
turbocharger.
restriction to the tube between the air
filter and the turbocharger.
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
Find the leak or restriction and repair
in the Tube between the Intake Manifold
or replace the component.
and the Turbocharger
Air leak or
A. Check for a leak or a restriction in the restriction
tube between the intake manifold and the
Result: There is not a leak or a
turbocharger.
restriction to the tube between the
intake manifold and the turbocharger.
Result: There is damage or a

restriction in the exhaust system
components.
The component must be repaired or

4. Check for Restriction in the Exhaust
replaced.
System
Restriction/damage Verify that the problem is resolved.
exhaust system components.
components.
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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 Correctly position the turbocharger

Turbocharger and tighten the clamps and bolts.
A. Verify that turbocharger is not loose or Turbocharger Verify that the problem is resolved.
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.
Result: The intake manifold has

cracks, loose bolts, or a distorted
flange.
The intake manifold must be repaired

6. Inspect the Intake Manifold or replaced.
A. Inspect the intake manifold for cracks, Intake manifold Verify that the problem is resolved.
loose bolts, or a distorted flange.
Result: The intake manifold does not
have cracks, loose bolts, or a distorted
flange.
Result: The exhaust manifold has

flange.
The exhaust manifold must be

7. Inspect the Exhaust Manifold repaired or replaced.
A. Inspect the exhaust manifold for cracks, Exhaust manifold Verify that the problem is resolved.
Result: The exhaust manifold does
not have cracks, loose bolts, or a
distorted flange.
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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
A. Inspect the turbine housing for damage Restriction/damage
or a restriction. Result: The turbine housing is not
damaged or does not have a
restriction.
Result: The turbocharger bearings are

not OK.
Replace the turbocharger.

9. Inspect the Turbocharger Bearings
Turbocharger
A. Inspect the turbocharger bearings. Bearings
OK.
Result: The compressor housing

contains debris.
Clean the compressor housing.

10. Inspect the Compressor for Debris
A. Inspect the compressor housing for Debris
debris. Result: The compressor housing does
not contain debris.
Result: The turbocharger rotor has

11. Inspect the Turbocharger Rotor carbon build-up.
A. Inspect the turbocharger rotor for carbon Carbon build-up Remove the carbon.
build-up.
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Result: The turbocharger rotor does

not have carbon build-up.
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 Fuel injection pump
injection pump.
Result: The fuel injection pump is
operating properly.
Result: The fuel injection nozzles

have wear or damage.
The fuel injection nozzles must be

13. Inspect the Fuel Injection Nozzles
A. Inspect the fuel injection nozzles for Damage/wear
wear or damage.
Result: The fuel injection nozzles do
not have wear or damage.
Result: The intake and exhaust valves

are burned.
Replace the inlet valves and the

14. Inspect the Intake and Exhaust exhaust valves. Determine the cause
Valves of the damage to the valves.
Intake/exhaust
valves Verify that the problem is resolved.
A. Inspect the intake and exhaust valves.
Result: The intake and exhaust valves

are not burned.
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Result: The piston rings have wear.

15. Inspect the Piston Rings
Replace the piston rings.
Piston rings
A. Inspect the piston rings for wear.
The engine exhaust has excessive black smoke.
Probable Cause
Table 8
Result: The air filter element is dirty or

has restrictions.

or replaced.
Filter Element
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 Find the restriction and repair or
Turbocharger replace the component.

A. Check for damage or a restriction in
the tube between the air filter and the
turbocharger. Result: There is not damage or a
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3. Check for Proper Installation of the Correctly position the turbocharger and
Turbocharger tighten the clamps and bolts.

flange.
The intake manifold must be repaired

4. Inspect the Intake Manifold or replaced.
A. Inspect the intake manifold for cracks, Intake manifold Verify that the problem is resolved.
flange.
Result: The engine oil pipe has

restrictions.
5. Inspect the Engine Oil Drain Pipe 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.
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Result: The turbocharger has

combustion gas or air leaks.

6. Inspect the Turbocharger Seals
A. Inspect the turbocharger for Leaks
Result: The turbocharger does not have

not OK.

Turbocharger
OK.

contains debris.

not contain debris.

9. Inspect the Turbocharger Rotor carbon build-up.
A. Inspect the turbocharger rotor for Carbon build-up Remove the carbon.
carbon build-up.
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The engine exhaust has excessive blue smoke.
Probable Cause
Table 9
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 Verify that the problem is
Air filter element resolved.
A. Check the condition of the air filter element.
not dirty or does not have
restrictions.
Result: The crankcase breather

has restrictions.
The crankcase breather (if

equipped), or the tubing must be
2. Check for Restrictions in the Crankcase
Breather
Restrictions
Verify that the problem is
A. Check the crankcase breather for
resolved.
restrictions.
does not have restrictions.

between the Air Filter and the Turbocharger Restriction/damage restriction to the tube between the
19 of 124 10/4/2017, 10:18 AM

air filter and the turbocharger.


A. Check for damage or a restriction in the resolved.
tube between the air filter and the turbocharger.
Result: The turbocharger is loose

Correctly position the

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

flange.
5. Inspect the Intake Manifold The intake manifold must be

A. Inspect the intake manifold for cracks, loose Intake manifold
bolts, or a distorted flange. Verify that the problem is
resolved.
Result: The intake manifold does

distorted flange.
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restrictions.
The drain pipe must be repaired or

replaced.
6. Inspect the Engine Oil Drain Pipe
resolved.
restrictions.
Result: The engine oil pipe does
not have restrictions.


A. Inspect the turbocharger for combustion gas Leaks resolved.
or air leaks.
Result: The turbocharger does not
have combustion gas or air leaks.
Result: The turbocharger bearings

are not OK.
8. Inspect the Turbocharger Bearings Verify that the problem is

Turbocharger resolved.
are OK.
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contains debris.
9. Inspect the Compressor for Debris Verify that the problem is

resolved.
Debris
A. Inspect the compressor housing for debris.
does not contain debris.

carbon build-up.
Remove the carbon.

10. Inspect the Turbocharger Rotor
resolved.
A. Inspect the turbocharger rotor for carbon Carbon build-up
build-up.
Result: The turbocharger rotor
does not have carbon build-up.

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 anti- resolved.
Anti-corrosion fluid
corrosion fluid. This condition only exists on a
new engine which has not been operated. Result: The turbocharger does not
have excessive anti-corrosion
fluid.
Result: The high idle operates for

12. Verify the High Idle Speed an excessive time.
High idle
A. Verify the high idle speed of the engine. The fuel injection pump must be
22 of 124 10/4/2017, 10:18 AM


resolved.
Result: The high idle does not

operate for an excessive time.
Result: The turbocharger has a

restriction in the bearing housing.
13. Inspect the Turbocharger for a
The bearing housing must be
Restriction
repaired or the turbocharger must
Restriction be replaced.
A. Inspect the turbocharger for a restriction in
the bearing housing.
resolved.
The engine uses an excessive amount of engine oil.
Probable Cause
Table 10
Result: The air filter element is dirty

or has restrictions.

or replaced.
Filter Element
element.
2. Check for Restrictions in the Restrictions Result: The crankcase breather has
Crankcase Breather restrictions.
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The crankcase breather (if equipped),

or the tubing must be cleaned or
replaced.
A. Check the crankcase breather for Verify that the problem is resolved.
restrictions.
Result: The crankcase breather does

3. Check for Proper Installation of the Correctly position the turbocharger and
Turbocharger tighten the clamps and bolts.
Result: The incorrect type of engine

oil is being used.
Drain the engine oil. Install the correct

4. Check the Engine Oil quantity and type of engine oil.
A. Verify that the correct type of engine Engine oil Verify that the problem is resolved.
oil is being used.
Result: The correct type of engine oil
is being used.
5. Inspect the Engine Oil Drain Pipe Result: The engine oil pipe has
Restrictions restrictions.
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replaced.
A. Inspect the engine oil drain pipe for Verify that the problem is resolved.
restrictions.
have restrictions.

restrictions.

6. Inspect the Engine Oil Drain Pipe replaced.
A. Inspect the engine oil drain pipe for Restrictions Verify that the problem is resolved.
restrictions.
have restrictions.


A. Inspect the turbine housing for damage Restriction/damage
or a restriction.
Result: The turbine housing is not
damaged or does not have a restriction.

not OK.
Turbocharger Replace the turbocharger.
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OK.
9. Inspect the Piston Rings Verify that the problem is resolved.

Piston rings
A. Inspect the piston rings for wear. Result: The piston rings do not have
wear.
Result: The oil supply line has leaks.
The supply line must be repaired or

replaced.
10. Inspect the Oil Supply Line
Leaks
A. Inspect the oil supply line for leaks.
Result: The oil supply line does not
have leaks.
Result: The high idle operates for an

excessive time.

11. Verify the High Idle Speed
A. Verify the high idle speed of the High idle
engine.
Result: The high idle does not operate
for an excessive time.

12. Inspect the Turbocharger for a restriction in the bearing housing.
Restriction Restriction
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The bearing housing must be repaired

A. Inspect the turbocharger for a
Excessive engine oil exists at the end of the turbine.
Probable Cause
Table 11

has restrictions.

equipped), or the tubing must be
1. Check for Restrictions in the Crankcase
Breather
Restrictions Verify that the problem is
resolved.
restrictions.

components.
The component must be repaired

2. Check for a Restriction in the Exhaust or replaced.
System
Restriction/damage
A. Check for damage or a restriction in the resolved.
components.
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Correctly position the

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

restrictions.

replaced.
4. Inspect the Engine Oil Drain Pipe
resolved.
restrictions.
Result: The engine oil pipe does

The turbine housing must be

be replaced.
A. Inspect the turbine housing for damage or a Restriction/damage
restriction.
resolved.

restriction.
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are not OK.
6. Inspect the Turbocharger Bearings Verify that the problem is

Turbocharger resolved.
are OK.

has carbon build-up.
Remove the carbon.

resolved.
A. Inspect the turbocharger rotor for carbon Carbon build-up
build-up.
does not have carbon build-up.
Result: The piston rings have

wear.
8. Inspect the Piston Rings Verify that the problem is

resolved.
Piston rings
Result: The piston rings do not
have wear.

9. Inspect the Turbocharger for Fluid Anti-corrosion fluid excessive anti-corrosion fluid.
29 of 124 10/4/2017, 10:18 AM


remove the anti-corrosion fluid.

A. Inspect the turbocharger for excessive anti- resolved.
new engine which has not been operated. Result: The turbocharger does not
have excessive anti-corrosion
fluid.

an excessive time.

High idle resolved.
A. Verify the high idle speed of the engine.

The bearing housing must be
Restriction
Restriction be replaced.
A. Inspect the turbocharger for a restriction in
resolved.
Excessive engine oil exists at the compressor end of the turbocharger.
Probable Cause
Table 12
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dirty or has restrictions.
The air filter element must be

1. Check for Restrictions in the Air Filter
Element
element.
Result: The crankcase breather has

restrictions.

2. Check for Restrictions in the Crankcase equipped), or the tubing must be
Breather cleaned or replaced.
Restrictions
restrictions.

between the Air Filter and the
Turbocharger
turbocharger.
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Result: There is a leak or a

intake manifold and the
turbocharger.
4. Check for an Air Leak or Restriction in
Find the leak or restriction and
the Tube between the Intake Manifold and
repair or replace the component.
the Turbocharger
Air leak or
A. Check for a leak or a restriction in the tube restriction
between the intake manifold and the
turbocharger.
intake manifold and the
turbocharger.

5. Check for Proper Installation of the Correctly position the turbocharger

Turbocharger and tighten the clamps and bolts.
A. Verify that turbocharger is not loose or the Fuel Nozzle Verify that the problem is resolved.
clamps and bolts on the turbocharger are not
loose. Result: The turbocharger is not
loose or the clamps and bolts on the

6. Inspect the Turbocharger Seals Replace the turbocharger.
A. Inspect the turbocharger for combustion Leaks Verify that the problem is resolved.
gas or air leaks.
32 of 124 10/4/2017, 10:18 AM


are not OK.

Turbocharger
are OK.

contains debris.

Debris
A. Inspect the compressor housing for debris.
does not contain debris.

Piston rings
A. Inspect the piston rings for wear. Result: The piston rings do not
have wear.

excessive anti-corrosion fluid.
10. Inspect the Turbocharger for Fluid
A. Inspect the turbocharger for excessive anti- remove the anti-corrosion fluid.
Anti-corrosion fluid
new engine which has not been operated. Verify that the problem is resolved.
33 of 124 10/4/2017, 10:18 AM


have excessive anti-corrosion fluid.

an excessive time.

High idle
A. Verify the high idle speed of the engine.

Restriction The bearing housing must be
Restriction
A. Inspect the turbocharger for a restriction in be replaced.
Engine oil exists in the exhaust manifold.
Probable Cause
Table 13

restrictions.
1. Check for Restrictions in the
Crankcase Breather The crankcase breather (if equipped), or
Restrictions the tubing must be cleaned or replaced.
restrictions. Verify that the problem is resolved.
Result: The crankcase breather does not
34 of 124 10/4/2017, 10:18 AM

have restrictions.

in the exhaust system components.

2. Check for Restriction in the replaced.
Exhaust System
Restriction/damage
the exhaust system components. Result: There is not damage or a
components.

restrictions.

restrictions.
have restrictions.
Result: The turbine housing is damaged

or has a restriction.
The turbine housing must be repaired or

4. Inspect the Turbocharger the turbocharger must be replaced.
A. Inspect the turbine housing for Restriction/damage Verify that the problem is resolved.
damage or a restriction.
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not OK.

Turbocharger
OK.

contains debris.

not contain debris.

carbon build-up.
Remove the carbon.

A. Inspect the turbocharger rotor for Carbon build-up
carbon build-up. Result: The turbocharger rotor does not
have carbon build-up.
8. Inspect the Piston Rings Replace the piston rings.
Piston rings Verify that the problem is resolved.

Result: The piston rings do not have
36 of 124 10/4/2017, 10:18 AM

wear.

excessive time.
The fuel injection pump must be repaired

or replaced.
engine.
Result: The high idle does not operate
for an excessive time.

Restriction
The bearing housing must be repaired or
Restriction the turbocharger must be replaced.
Lack of lubrication to the turbocharger
Probable Cause
Table 14
Result: The turbocharger is loose or the

clamps and bolts on the turbocharger are
1. Check for Proper Installation of the loose.
Turbocharger
Correctly position the turbocharger and
A. Verify that turbocharger is not loose or Turbocharger tighten the clamps and bolts.
are not loose. Verify that the problem is resolved.
Result: The turbocharger is not loose or the

clamps and bolts on the turbocharger are not
37 of 124 10/4/2017, 10:18 AM

loose.
2. Check for Turbocharger for Proper

Lubrication
Result: The components listed are not
The flow of engine oil is delayed to the operating properly.
turbocharger when the engine is started.
Insufficient oil flows to the turbocharger The component must be repaired or
when the engine is running. replaced.
Turbocharger
A. Check the following components for Verify that the problem is resolved.
lubrication
correct operation:
Result: The components listed are operating
Engine oil pump properly.
Engine oil bypass valve
Engine oil filter Proceed to Test Step 3.
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
Engine Oil Verify that the problem is resolved.
A. Inspect the engine oil.
Result: The engine oil is not dirty.
Result: The incorrect type of engine oil is

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

5. Check the Engine Oil Supply Line replaced.
A. Inspect the oil supply line from the Restrictions Verify that the problem is resolved.
engine oil pan for a restriction.
Result: The oil supply line is not restricted.
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.
Result: The engine rpm does not increase
too rapidly when the engine is started.

excessive time.
The fuel injection pump must be repaired or

replaced.
engine.
Result: The high idle does not operate for
an excessive time.

8. Inspect the Oil Supply Line Leaks
39 of 124 10/4/2017, 10:18 AM


replaced.

Result: The oil supply line does not have
leaks.

9. Inspect the Piston Rings
Piston rings
Result: The piston rings do not have wear.

excessive time.
The fuel injection pump must be repaired or

replaced.
engine.
an excessive time.
Result: The turbocharger has a restriction in

The bearing housing must be repaired or the

11. Inspect the Turbocharger for a turbocharger must be replaced.
Restriction
Restriction Verify that the problem is resolved.
restriction in the bearing housing. Result: The turbocharger has a restriction in
40 of 124 10/4/2017, 10:18 AM

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
12. Inspect the Engine Oil Filter the engine oil filter base. Replace the engine
oil filter.
A. Inspect the engine oil filter for a Oil Filter
restriction. Verify that the problem is resolved.
Result: The engine oil filter does not have a

restriction.
13. Correct Engine Operation
The engine may have stopped too soon

from a high load condition.
A. Check the following components for operating properly.
correct operation or damage:
Engine
operation
Compressor impeller of the turbocharger replaced.
Cooling system
Fuel injection pump Verify that the problem is resolved.
Air/fuel ratio control
Valve lash
Fuel injection nozzles
The inside of the intake manifold is wet.
Probable Cause
Table 15
1. Check for Restrictions in the Air Result: The air filter element is dirty
Filter Element or has restrictions.
Air filter element
A. Check the condition of the air filter The air filter element must be cleaned
41 of 124 10/4/2017, 10:18 AM

or replaced.

element.

restrictions.
The crankcase breather (if equipped),

2. Check for Restrictions in the or the tubing must be cleaned or
Crankcase Breather replaced.
Restrictions
restrictions.
Result: The crankcase breather does

sealed properly.
Inspect the air filter element and the

3. Check for Proper Installation of the air supply line to the turbocharger for
Air Filter Element correct installation.
Air filter
A. Verify that the air filter element is Verify that the problem is resolved.
sealed properly.
Result: The air filter element is sealed
properly.

between the Air Filter and the restriction to the tube between the air
Turbocharger Restriction/damage filter and the turbocharger.
A. Check for damage or a restriction in the Find the restriction and repair or
42 of 124 10/4/2017, 10:18 AM


turbocharger.
Result: There is a leak or a restriction

to the tube between the intake
manifold and the turbocharger.
5. Check for an Air Leak or Restriction
Find the leak or restriction and repair
in the Tube between the Intake Manifold
or replace the component.
and the Turbocharger
Air leak or
A. Check for a leak or a restriction in the restriction
tube between the intake manifold and the
turbocharger.
intake manifold and the turbocharger.

components.

6. Check for Restriction in the Exhaust
replaced.
System
components.
7. Check for Proper Installation of the Result: The turbocharger is loose or

Turbocharger Turbocharger the clamps and bolts on the
43 of 124 10/4/2017, 10:18 AM

Correctly position the turbocharger

and tighten the clamps and bolts.
A. Verify that turbocharger is not loose or Verify that the problem is resolved.
Result: The exhaust manifold has

flange.
The exhaust manifold must be

8. Inspect the Exhaust Manifold
A. Inspect the exhaust manifold for cracks, Exhaust manifold
Result: The exhaust manifold does
distorted flange.

restrictions.

restrictions.
have restrictions.

10. Inspect the Turbocharger damaged or has a restriction.
Restriction/damage
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A. Inspect the turbine housing for damage
or a restriction. Result: The turbine housing is not
restriction.


A. Inspect the turbocharger for combustion Leaks
gas or air leaks.

not OK.

Turbocharger
OK.

contains debris.
13. Inspect the Compressor for Debris Clean the compressor housing.
A. Inspect the compressor housing for Debris Verify that the problem is resolved.
debris.
Result: The compressor housing does
not contain debris.
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Piston rings
A. Inspect the piston rings for wear. Result: The piston rings do not have
wear.

The bearing housing must be repaired

Restriction
Restriction
A. Inspect the turbocharger for a restriction
in the bearing housing.
have a restriction in the bearing
housing.
Result: The air inlet heater has fuel

leaks.
Repair the leaks.

16. Inspect the Air Inlet Heater
Leaks
A. Test the air inlet heater for leakage.
Result: The air inlet heater does not
have fuel leaks.
Result: The back plate of the

17. Inspect the Compressor compressor is cracked.
Compressor
A. Inspect the back plate of the The back plate of the compressor must
46 of 124 10/4/2017, 10:18 AM

be repaired or the turbocharger must

be replaced.
compressor.
Damaged compressor impeller of the turbocharger
Probable Cause
Table 16

sealed properly.
Inspect the air filter element and the air

1. Check for Proper Installation of supply line to the turbocharger for correct
the Air Filter Element installation.
Air filter
sealed properly.
properly.

turbocharger.
Find the restriction and repair or replace
the component.
Turbocharger
turbocharger.
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loose.
3. Check for Proper Installation of Correctly position the turbocharger and

the Turbocharger tighten the clamps and bolts.
A. Verify that turbocharger is not loose Turbocharger Verify that the problem is resolved.
turbocharger are not loose. Result: The turbocharger is not loose or
are not loose.
4. Check for Turbocharger for

Proper Lubrication
Turbocharger
lubrication
correct operation:
Result: The components listed are
Engine oil pump operating properly.
Result: The incorrect oil is being used.
Drain the engine oil. Replace the engine

5. Check the Engine Oil oil filter. Install the correct type of engine
oil.
oil is being used. Verify that the problem is resolved.
Result: The correct oil is being used.
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replaced.
6. Check the Engine Oil Supply Line
A. Inspect the oil supply line from the Restrictions
Result: The oil supply line is not
restricted.
Result: The turbocharger bearings are not

OK.

Turbocharger
OK.
Result: The compressor housing contains

debris.

debris. Result: The compressor housing does not
contain debris.
9. Verify the Engine RPM Result: The engine rpm increases too
Engine RPM
A. Verify the engine RPM during start-
up. Check the fuel injection pump for correct
49 of 124 10/4/2017, 10:18 AM



excessive time.

engine.
an excessive time.

replaced.
Leaks
leaks.
Result: The turbocharger has a restriction


12. Inspect the Turbocharger for a the turbocharger must be replaced.
Restriction
Restriction Verify that the problem is resolved.
restriction in the bearing housing. Result: The turbocharger does not have a
50 of 124 10/4/2017, 10:18 AM


restriction.

housing for the engine oil filter. Check
the operation of the engine oil bypass
13. Inspect the Engine Oil Filter valve in the engine oil filter base. Replace
the engine oil filter.
Result: The engine oil filter does not

have a restriction.

A. Check the following components for
operating properly.
Compressor impeller of the Engine operation
replaced.
turbocharger
Cooling system
Fuel injection pump
Valve lash
Damage to the turbine
Probable Cause
Table 17
1. Check for Restriction in the Result: There is damage or a restriction

Exhaust System Restriction/damage in the exhaust system components.
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replaced.

components.

loose.

are not loose.

Proper Lubrication
Turbocharger
lubrication
correct operation:
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type of engine oil. Replace the engine oil
4. Inspect the Engine Oil filter.
Engine Oil
A. Inspect the engine oil. Verify that the problem is resolved.

oil filter. Install the correct type of engine
5. Check the Engine Oil
oil.
oil is being used.

replaced.
restricted.

7. Inspect the Turbocharger or has a restriction.
A. Inspect the turbine housing for Restriction/damage The turbine housing must be repaired or
damage or a restriction. the turbocharger must be replaced.
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OK.

Turbocharger
OK.

carbon build-up.
Remove the carbon.



10. Verify the Engine RPM operation and settings.
Engine RPM
A. Verify the engine RPM during start- Verify that the problem is resolved.
up.
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excessive time.

engine.
an excessive time.
Result: The fuel injection pump is not

operating correctly.
The fuel injection pump must be repaired

12. Inspect the Fuel Injection Pump or replaced.
for Proper Operation
Fuel pump
A. Test the fuel injection pump for
proper operation. Result: The fuel injection pump is
operating correctly.
Result: The inlet valves and the exhaust

valves are burned.
Replace the inlet valves and the exhaust

valves. Determine the cause of the
13. Inspect the Intake and Exhaust
damage to the valves.
Valves
Burned valves Verify that the problem is resolved.
A. Inspect the intake and exhaust
valves.
Result: The inlet valves and the exhaust
valves are not burned.

Leaks replaced.
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leaks.


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

restriction.


have a restriction.

The engine may have stopped too soon operating properly.
A. Check the following components for Engine operation
replaced.
Compressor impeller of the
56 of 124 10/4/2017, 10:18 AM

turbocharger
Cooling system
Fuel injection pump
Valve lash
The rotating assembly of the turbocharger does not rotate freely.
Probable Cause
Table 18

sealed properly.

Air filter
sealed properly.
properly.

turbocharger.
the component.
Turbocharger
turbocharger.
57 of 124 10/4/2017, 10:18 AM



Exhaust System
Restriction/damage
components.

loose.

are not loose.

Proper Lubrication
operating properly.
The flow of engine oil is delayed to the
replaced.
Insufficient oil flows to the turbocharger
when the engine is running. Turbocharger
lubrication
correct operation:
operating properly.
Engine oil pump
Engine oil filter
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being used.

oil is being used.
being used.

replaced.
restricted.

Engine Oil
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the turbocharger must be replaced.
A. Inspect the turbine housing for Restriction/damage

OK.

Bearings Verify that the problem is resolved.
Turbocharger
Bearings
A. Inspect the turbocharger bearings. Result: The turbocharger bearings are
OK.

debris.

debris. Result: The compressor housing does not
contain debris.

carbon build-up.
Remove the carbon.
carbon build-up. Verify that the problem is resolved.
Result: The turbocharger rotor does not
60 of 124 10/4/2017, 10:18 AM



Engine RPM
up.

excessive time.

engine.
an excessive time.

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

restriction.


have a restriction.

operating properly.
replaced.
turbocharger
Cooling system
Fuel injection pump
Valve lash
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Worn bearings, bearing bores, and journals
Probable Cause
Table 19

turbocharger.
the component.
Turbocharger
turbocharger.


Exhaust System
Restriction/damage
components.
3. Check for Proper Installation of Result: The turbocharger is loose or the

the Turbocharger clamps and bolts on the turbocharger are
loose.
A. Verify that turbocharger is not loose Turbocharger
or the clamps and bolts on the Correctly position the turbocharger and
turbocharger are not loose. tighten the clamps and bolts.
63 of 124 10/4/2017, 10:18 AM

Result: The turbocharger is not loose or

are not loose.

Proper Lubrication
Turbocharger
lubrication
correct operation:

being used.

oil is being used.
being used.
6. Check the Engine Oil Supply Line Result: The oil supply line is restricted.
A. Inspect the oil supply line from the Restrictions The oil supply line must be repaired or
engine oil pan for a restriction. replaced.
64 of 124 10/4/2017, 10:18 AM


restricted.

Engine Oil


Engine RPM
up.

excessive time.
9. Verify the High Idle Speed Check the fuel injection pump for correct
engine. Verify that the problem is resolved.

an excessive time.
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replaced.
Leaks
leaks.

restriction.


have a restriction.

A. Check the following components for operating properly.
Engine operation
Compressor impeller of the replaced.
turbocharger
Cooling system Verify that the problem is resolved.
Fuel injection pump
Valve lash
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The turbocharger makes excessive noise.
Probable Cause
Table 20
Result: The air filter element is dirty or

has restrictions.
The air filter element must be cleaned or

replaced.
Filter Element
element.
Result: The air filter element is not dirty
or does not have restrictions.

sealed properly.

Air filter
sealed properly.
properly.
3. Check for a Restriction in the Tube Result: There is damage or a restriction

between the Air Filter and the to the tube between the air filter and the
Turbocharger Restriction/damage turbocharger.
A. Check for damage or a restriction in Find the restriction and repair or replace
67 of 124 10/4/2017, 10:18 AM

the component.

turbocharger.
Result: There is a leak or a restriction to

the tube between the intake manifold and
the turbocharger.
4. Check for an Air Leak or
Restriction in the Tube between the Find the leak or restriction and repair or
Intake Manifold and the replace the component.
Turbocharger
Air leak or
restriction
A. Check for a leak or a restriction in
the tube between the intake manifold Result: There is not a leak or a restriction
and the turbocharger. to the tube between the intake manifold
and the turbocharger.


Exhaust System
Restriction/damage
components.
6. Check for Proper Installation of Result: The turbocharger is loose or the

the Turbocharger Turbocharger clamps and bolts on the turbocharger are
loose.
68 of 124 10/4/2017, 10:18 AM

Correctly position the turbocharger and

tighten the clamps and bolts.
A. Verify that turbocharger is not loose Verify that the problem is resolved.
are not loose.
Result: The intake manifold has cracks,

The intake manifold must be repaired or

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

The exhaust manifold must be repaired or

replaced.
8. Inspect the Exhaust Manifold
A. Inspect the exhaust manifold for Exhaust manifold
cracks, loose bolts, or a distorted flange. Result: The exhaust manifold does not
flange.
9. Check for Turbocharger for Result: The components listed are not
Proper Lubrication Turbocharger operating properly.
lubrication
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The flow of engine oil is delayed to the

correct operation:

oil filter. Install the correct type of engine
10. Check the Engine Oil
oil.
oil is being used.

replaced.
restricted.

12. Inspect the Turbocharger OK.
Bearings Turbocharger
Bearings Replace the turbocharger.
A. Inspect the turbocharger bearings.
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OK.

debris.

13. Inspect the Compressor for
Debris
Debris
A. Inspect the compressor housing for
Result: The compressor housing does not
debris.
contain debris.

carbon build-up.
Remove the carbon.



Engine RPM
up.
71 of 124 10/4/2017, 10:18 AM


excessive time.

engine.
an excessive time.

replaced.
Leaks
leaks.


Restriction
Restriction
restriction in the bearing housing. Result: The turbocharger does not have a

restriction.
19. Inspect the Engine Oil Filter
A. Inspect the engine oil filter for a Oil Filter housing for the engine oil filter. Check
restriction. the operation of the engine oil bypass
valve in the engine oil filter base. Replace
72 of 124 10/4/2017, 10:18 AM


have a restriction.

operating properly.
replaced.
turbocharger
Cooling system
Fuel injection pump
Valve lash
Sludge or carbon deposits in the bearing housing
Probable Cause
Table 21

restrictions.
1. Check for Restrictions in the The crankcase breather (if equipped), or

Crankcase Breather the tubing must be cleaned or replaced.
Restrictions
restrictions.
Result: The crankcase breather does not
have restrictions.
73 of 124 10/4/2017, 10:18 AM

2. Check for Turbocharger for Proper

Lubrication
Turbocharger
lubrication
correct operation:
Result: The incorrect type of engine oil

is being used.

oil is being used.
being used.

Engine Oil
74 of 124 10/4/2017, 10:18 AM


replaced.
restricted.


the turbocharger must be replaced.
A. Inspect the turbine housing for Restriction/damage


Engine RPM
up.

Leaks The supply line must be repaired or
75 of 124 10/4/2017, 10:18 AM

replaced.

leaks.

restriction.

9. Inspect the Engine Oil Filter valve in the engine oil filter base.
Replace the engine oil filter.

have a restriction.

operating properly.
replaced.
turbocharger
Cooling system
Fuel injection pump
Valve lash
Troubleshooting the Engine

When you are troubleshooting the engine, refer to the Specifications Module and the Systems Operation,
76 of 124 10/4/2017, 10:18 AM

Testing and Adjusting Module for additional information.
The engine will not start.
Probable Cause
Table 22
Result: The engine starting

procedure was incorrectly
followed.
Ensure that the engine starting

procedure is correctly
followed.
1. Interview the Operator
Starting
A. Ensure the engine starting procedure was followed. procedures
resolved.
Result: The engine starting

procedure was correctly
followed.
Result: The manual valve in

the fuel line is closed.
Open the valve.

2. Check the Fuel Shutoff Valve
Fuel valve resolved.
A. Make sure the fuel shutoff valve is Open.
Result: The manual valve in
the fuel line is open.
3. Check the Fuel Level Result: The fuel level is low

in the fuel tank.
Fuel level
A. Check the fuel level.
Fill the fuel tank with fuel.
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Remove the air from the fuel

system.

resolved.
Result: The fuel level is not

low in the fuel tank.
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
Contamination Verify that the problem is
A. Check the fuel for contamination.
resolved.
Result: The fuel does not

contain water, dirt, ice, or wax.
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: Crank Speed resolved.
1. The engine oil is too thick.
2. The connections of the battery cables to the starting Result: Engine cranking speed
motor are loose. is OK.
6. Check the Engine Glow Plugs Result: The glow plugs for the
Engine Glow fuel injection pump do not
A. Inspect the cable connections and the electrical Plugs operate correctly.
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connections of the glow plugs and the electrical resolved.
components of the starting aid circuit. Test the glow
plugs for correct operation. Result: The glow plugs for the
fuel injection pump operate
correctly.
Result: The fuel shutoff

solenoid is not operating
correctly.
Replace a fuel shutoff solenoid

7. Check the Fuel Shutoff Solenoid that is suspect.
A. Ensure that the fuel shutoff solenoid operates Solenoid Verify that the problem is
correctly. resolved.
Result: The fuel shutoff

solenoid is operating correctly.
Result: The operation of the

fuel transfer pump is not
correct.
Remove the fuel transfer pump

if the fuel pressure is too low.
8. Check the Operation of the Fuel Transfer Pump
The fuel transfer pump must
be repaired or replaced.
A. Check the fuel pressure when the engine is Fuel transfer
cranking. Refer to the Specifications Module, "Fuel pump
Transfer Pump" topic for additional information.
resolved.

fuel transfer pump is correct.
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Result: The fuel filter or the

fuel lines are restricted.
Replace the suspect

component.
9. Check the Fuel Filter
Fuel filter/fuel Verify that the problem is
A. Check the fuel filter and fuel lines for restrictions.
lines resolved.
Drain any water from the fuel filter.
Result: The fuel filter or the
fuel lines are not restricted.
10. Check the Timing for the Fuel Injection Pump
A. Check the timing of the fuel injection pump. Adjust Result: The operation of the
the timing or replace the fuel injection pump. Refer to fuel injection pump is not
the Specifications Module, "Fuel Injection Pump" correct.
topic for additional information.
The fuel injection pump must
B. Check the operation of the fuel rack linkage. be repaired or replaced.
Fuel injection
C. Make sure that the high-pressure fuel lines are Verify that the problem is
pump timing
connected to the fuel injection nozzles in the correct resolved.
order.
D. Make sure that the mounting bolts of the fuel fuel injection pump is correct.
injection pump are tightened to the correct torque.
Inspect the fuel lines for leaks or for restrictions. The Proceed to Test Step 11.
damaged fuel lines or fittings must be repaired or
replaced.
Result: There is a problem

with the governor or the fuel
11. Inspect the Fuel Injection Linkage and the
injection linkage.
Governor
Governor and
A. Inspect the governor and the fuel injection linkage fuel injection
for damage or the fuel injection linkage for incorrect linkage
assembly in the timing gear case.
resolved.
Result: There is not a problem
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injection linkage.
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 Replace the suspect fuel
on the injection line for each cylinder. Loosen one nut injection nozzle.
at a time. Then, tighten that nut before the next fuel Make sure that all of the fuel
line nut is loosened. If loosening the fuel line nut does injection nozzles are the
not affect the operation of the engine, the fuel injection correct type for the engine.
nozzle is probably suspect. Test the fuel injection Test the pressure setting of the
nozzle for that cylinder. fuel injection nozzles. Refer to
Fuel Injection the Specifications Module,
B. Make sure that the fuel injection nozzles are Nozzles "Fuel Injection Nozzles" topic
properly sealed in the threaded ports. Make sure that for additional information.
the fuel injection nozzles are correctly aligned in the
threaded ports. Make sure that the fuel injection Verify that the problem is
nozzles are tightened to the correct torque. Ensure that resolved.
the gaskets and the seat washers are installed on the
fuel injection nozzles correctly. Make sure that the Result: The fuel injection
bottom of the threaded ports are clean and free of nozzles are operating correctly.
debris. Make sure that the bottom of the threaded ports
do not contain extra gaskets. 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
Result: The cylinders have
following conditions:
low compression.
Piston rings are worn or broken.
Cylinder Make the necessary repairs.
The piston height is incorrect.
compression
The piston is damaged.
The fuel injection nozzles are not seated correctly.
resolved.
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.
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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
Result: The fuel filter or the fuel lines

are restricted.
Check the fuel lines and the fuel filter.

1. Inspect the Fuel System Replace the fuel filter. Drain any
water from the fuel filter.
A. Check the fuel filter or the fuel lines for
Fuel System
restrictions. Excess water can build up in the fuel Verify that the problem is resolved.
filter.
Result: The fuel filter or the fuel lines
are not restricted.
Result: The operation of the fuel

transfer pump is not correct.
Remove the fuel transfer pump if the

2. Check the Operation of the Fuel Transfer
fuel pressure is too low. The fuel
Pump
transfer pump must be repaired or
replaced.
A. Check the fuel pressure when the engine is Fuel transfer
cranking. Refer to the Specifications Module, pump
"Fuel Transfer Pump" topic for additional
information.
Result: The operation of the fuel
transfer pump is correct.
Result: The air inlet or the exhaust

3. Inspect the Air Inlet and Exhaust System system is restricted.
Air inlet and
A. Check the air inlet and exhaust system for exhaust Remove any restrictions.
restrictions.. system
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Result: The air inlet or the exhaust

system is not restricted.
Result: Air is in the fuel system.

4. Check for Air in the Fuel System
Find the air leak in the fuel system.
Air in the
A. Inspect the fuel system for air leaks in the Repair the fuel system.
fuel system
system.
The engine misfires or the engine runs rough.
Probable Cause
Table 24
Result: The fuel pressure is

low.
1. Measure the Fuel Pressure
A. Make sure that sufficient fuel is in the fuel tank.
Remove any air in the fuel system.
Fuel Pressure resolved.
B. Look for leaks or suspect bends in the fuel line
between the fuel tank and the fuel transfer pump.
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 Find the air leak in the fuel
Air in the fuel system. Repair the fuel system.
A. Inspect the fuel system for air leaks in the system. system
resolved.
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Result: Air is not in the fuel

system.
Result: The valve lash is not

correct.
Adjust the valve lash.

3. Check the Valve Lash
Valve lash resolved.
A. Check the engine valve lash.
Result: The valve lash is
correct.
the Specifications Module, "Fuel Injection Pump" topic correct.
for additional information.
Fuel injection
pump timing
order.
replaced.

A. Run the engine at the rpm that gives maximum Fuel Injection
misfiring or rough running. Then, loosen a fuel line nut Nozzles Replace the suspect fuel
on the injection line for each cylinder. Loosen one nut injection nozzle.
84 of 124 10/4/2017, 10:18 AM

at a time. Then, tighten that nut before the next fuel Make sure that all of the fuel
line nut is loosened. If loosening the fuel line nut does injection nozzles are the
not affect the operation of the engine, the fuel injection correct type for the engine.
nozzle is probably suspect. Test the fuel injection Test the pressure setting of the
nozzle for that cylinder. fuel injection nozzles. Refer to
the Specifications Module,
B. Make sure that the fuel injection nozzles are "Fuel Injection Nozzles" topic
properly sealed in the threaded ports. Make sure that for additional information.
the fuel injection nozzles are correctly aligned in the
threaded ports. Make sure that the fuel injection Verify that the problem is
nozzles are tightened to the correct torque. Ensure that resolved.
the gaskets and the seat washers are installed on the
fuel injection nozzles correctly. Make sure that the Result: The fuel injection
bottom of the threaded ports are clean and free of nozzles are operating correctly.
debris. Make sure that the bottom of the threaded ports
do not contain extra gaskets. 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
A. Check the engine mounts for proper installation.
components.
B. Check the engine mounts for correct positioning.
Engine mounts
resolved.
C. Check the bolts of the engine mounts for correct
tightening.
Result: The engine mounts are
correctly tightened and the
These conditions will cause a vibration.
engine mounts are mounted
correctly.
Result: The fuel contains

water, dirt, ice, or wax.
7. Check the Fuel Quality
Replace the fuel filters.
Contamination Replace the fuel in the fuel
A. Check the fuel for contamination.
tank with clean fuel.

resolved.
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Result: The fuel does not

contain water, dirt, ice, or wax.
8. Check the Cylinder Compression

weather. The engine may not start in cold weather. Low
compression is most frequently caused by the
Result: The cylinders have
following conditions:
low compression.
Piston rings are worn or broken.
Cylinder Make the necessary repairs.
compression
The piston is damaged.
resolved.
The engine runs evenly, but the engine loses power.
Probable Cause
Table 25
1. Check the Engine for Low Compression Result: The cylinders have low
compression.
weather. The engine may not start in cold weather. Repair or replace the engine
Low compression is most frequently caused by the component causing low
following conditions: compression.
Low
compression
Cylinder walls are worn or damaged. Verify that the problem is
Piston rings are worn or broken. resolved.
The piston height is incorrect. Result: The cylinders do not
The fuel injection nozzles are not seated correctly. have low compression.
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the Specifications Module, "Fuel Injection Pump" correct.
Fuel injection
pump timing
order.
replaced.

correct.

correct.

4. Check for Restrictions in the Air Filter Element dirty or has restrictions.
Air filter
A. Check the condition of the air filter element. element The air filter element must be
87 of 124 10/4/2017, 10:18 AM


resolved.

not dirty or does not have
restrictions.
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
Air in the fuel Verify that the problem is
A. Inspect the fuel system for air leaks in the system. system resolved.
Result: Air is not in the fuel

system.
Result: The fuel transfer pump

6. Check the Fuel Transfer Pump for Proper
Operation The fuel transfer pump must be
A. Check the fuel pressure when the engine is Install the fuel transfer pump
cranking. Refer to the Specifications Module, "Fuel Fuel pressure with the lobe of the camshaft on
Transfer Pump" topic for additional information. minimum lift. Tighten the
Remove the fuel transfer pump if the fuel pressure is mounting bolts evenly.
too low.
resolved.
The engine lacks power.
Probable Cause
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Table 26
Result: The fuel quality does

not meet the engine
specifications.
Remove the fuel from the fuel

tank. Install a new fuel filter. Put
1. Test the Quality of the Fuel a good grade of clean fuel in the
fuel tank.
Fuel
A. Test the quality level of the fuel, make sure the fuel
quality
quality meets the engine specifications. Verify that the problem is
resolved.
Result: The fuel quality meets

the engine specifications.
Result: The fuel pressure is low.

2. Measure the Fuel Pressure
A. Make sure that sufficient fuel is in the fuel tank.
Remove any air in the fuel system. Verify that the problem is
Fuel resolved.
B. Look for leaks or suspect bends in the fuel line between Pressure
the fuel tank and the fuel transfer pump. Result: The fuel pressure is not
low.
C. Check the outlet pressure of the fuel transfer pump.
Result: There is a problem with

the governor or the fuel injection
linkage.
3. Inspect the Fuel Injection Linkage and the Governor
Governor Make the necessary repairs.
A. Inspect the governor and the fuel injection linkage for and fuel
damage or the fuel injection linkage for incorrect injection Verify that the problem is
assembly in the timing gear case. linkage resolved.
Result: There is not a problem

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injection linkage.
Result: The valve lash exceeds

the specification.
Adjust the valve lash. Refer to

the Specifications Module,
"Engine Design" topic for the
4. Measure the Valve Lash valve lash setting.
Valve lash
A. Measure the valve lash. Verify that the problem is
resolved.
Result: The valve lash is within

the specification.
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
fuel injection pump is not
Specifications Module, "Fuel Injection Pump" topic for
correct.
additional information. The fuel injection pump must be
B. Make sure that the linkage of the fuel rack operates Fuel
correctly. Injection
resolved.
Pump
C. Make sure that the high pressure fuel lines are
connected to the fuel injection nozzles in the correct order.
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.
6. Inspect the Fuel Injection Nozzles Fuel Result: A fuel injection nozzle
Injection is not operating correctly.
A. Run the engine at the rpm that gives maximum Nozzles
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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 Replace the suspect fuel
loosened. If loosening the fuel line nut does not affect the injection nozzle.
operation of the engine, the fuel injection nozzle is Make sure that all of the fuel
probably suspect. Test the fuel injection nozzle for that injection nozzles are the correct
cylinder. type for the engine. Test the
pressure setting of the fuel
B. Make sure that the fuel injection nozzles are properly injection nozzles. Refer to the
sealed in the threaded ports. Make sure that the fuel Specifications Module, "Fuel
injection nozzles are correctly aligned in the threaded Injection Nozzles" topic for
ports. Make sure that the fuel injection nozzles are additional information.
tightened to the correct torque. Ensure that the gaskets and
the seat washers are installed on the fuel injection nozzles Verify that the problem is
correctly. Make sure that the bottom of the threaded ports resolved.
are clean and free of debris. Make sure that the bottom of
the threaded ports do not contain extra gaskets.
The engine has excessive vibration.
Probable Cause
Table 27
Result: The bolts for the pulleys are loose or the

pulley is damaged.
1. Inspect the Engine Pulleys
Tighten the bolts. If the pulley is worn or
damaged, use new parts for replacement.
A. Inspect the engine pulleys for damage or
loose bolts.
Pulleys Verify that the problem is resolved.
Refer to the Specifications Module,
"Crankshaft Pulley" topic for additional
Result: The bolts for the pulleys are not loose or
information.
the pulley is not damaged.
2. Inspect the Engine Mounts Result: The engine mounts are loose, worn, or
suspect.
Engine
A. Inspect the engine mounts for loose
mounts
bolts or damage. Tighten all mounting bolts. Inspect the engine
mounts for wear or for damage. Use new parts
91 of 124 10/4/2017, 10:18 AM

for replacement.
The engine has excessive combustion noise.
Probable Cause
Table 28
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
1. Test the Quality of the Fuel
fuel tank.
Fuel
A. Test the quality level of the fuel, make sure the fuel
quality Verify that the problem is
quality meets the engine specifications.
resolved.
Result: The fuel quality meets

the engine specifications.
2. 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 Replace the suspect fuel
injection line for each cylinder. Loosen one nut at a time. injection nozzle.
Then, tighten that nut before the next fuel line nut is Make sure that all of the fuel
loosened. If loosening the fuel line nut does not affect the injection nozzles are the correct
Fuel
operation of the engine, the fuel injection nozzle is type for the engine. Test the
Injection
probably suspect. Test the fuel injection nozzle for that pressure setting of the fuel
Nozzles
cylinder. injection nozzles. Refer to the
Specifications Module, "Fuel
B. Make sure that the fuel injection nozzles are properly Injection Nozzles" topic for
sealed in the threaded ports. Make sure that the fuel additional information.
injection nozzles are correctly aligned in the threaded ports.
Make sure that the fuel injection nozzles are tightened to Verify that the problem is
the correct torque. Ensure that the gaskets and the seat resolved.
92 of 124 10/4/2017, 10:18 AM

washers are installed on the fuel injection nozzles correctly.

Result: The fuel injection
Make sure that the bottom of the threaded ports are clean
nozzles are operating correctly.
and free of debris. Make sure that the bottom of the
threaded ports do not contain extra gaskets.
Result: The piston height is

incorrect.
To obtain the correct piston

3. Measure the Piston Height
height, the piston, the piston pin,
Piston
the bearings, or the connecting
A. Measure the engine piston height. height
rod should be replaced.

resolved.
The engine has excessive valve compartment noise.
Probable Cause
Table 29
Result: Valve springs or locks are broken.
Install new parts. Broken locks can cause the valve to

1. Inspect the Valve Springs slide into the cylinder. Major damage to the engine can
and Locks occur.
Valve springs
A. Inspect the valve springs and locks Verify that the problem is resolved.
and locks for damage.
Result: Valve springs or locks are not broken.
2. Inspect the Rocker Arms Result: The bolts and nuts, which hold the rocker arm
assembly, are loose.
Rocker arm
A. Inspect the rocker arm
assemblies Tighten the bolts or nuts. Refer to the Specifications
assemblies for damage.
Module, "Rocker Shaft" topic for additional
93 of 124 10/4/2017, 10:18 AM

information.
Result: The bolts and nuts, which hold the rocker arm
assembly, are not loose.
Result: The valve lash exceeds the specification.
3. Measure the Valve Lash Adjust the valve lash. Refer to the Specifications
Module, "Engine Design" topic for the valve lash
Valve lash
A. Measure the valve lash. setting.
Engine oil is in the cooling system.
Probable Cause
Table 30
Result: The engine oil cooler has leaks.
Replace the oil cooler. Refer to Disassembly

1. Inspect the Engine Oil Cooler Core
and Assembly, "Engine Oil Cooler - Remove"
and Disassembly and Assembly, "Engine Oil
A. Drain the coolant from the engine and the
Cooler - Install". Fit new seals between the oil
radiator. Drain the lubricating engine oil
cooler and the oil cooler cover.
from the engine oil cooler. Refer to the
Refill the crankcase with clean engine oil to
Operation and Maintenance Manual for more Engine Oil
the correct level. Refer to the Operation and
information. Cooler
Maintenance Manual for more information.
Core
B. Inspect the engine oil cooler core for
leaks. Refer to Systems Operation, Testing
and Adjusting, "Cooling System - Inspect"
Result: The engine oil cooler does not have
for the correct procedure.
leaks.
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Result: The cylinder head gasket has faults or

signs of leakage.
2. Inspect the Cylinder Head Gasket
Replace the cylinder head gasket.
A. Remove the cylinder head. Refer to
Disassembly and Assembly, "Cylinder Head
Head Verify that the problem is resolved.
- Remove" for the correct procedure.
gasket
Result: The cylinder head gasket does not
B. Inspect the cylinder head gasket for faults
have faults or signs of leakage.
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
A. Check the cylinder head for cracks. cylinder head.
Cylinder
B. Check the cylinder head for flatness. Verify that the problem is resolved.
head
Refer to Systems Operation, Testing and
Adjusting, "Cylinder Head - Inspect" for the Result: The cylinder head is flat and does not
correct procedure. have cracks.
Result: The cylinder block has faults or signs

of leakage.
Replace the cylinder block. If signs of leakage

4. Inspect the Cylinder Block
are found, determine the cause of the leakage.
Cylinder Refer to Systems Operation, Testing and
A. Inspect the top face of the cylinder block
block Adjusting, "Cylinder Block - Inspect" for the
for faults and signs of leakage.
correct procedure.
After the Repair
A. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
95 of 124 10/4/2017, 10:18 AM

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
Result: The main bearings are

damaged.
Replace damaged parts.

1. Inspect the Main Bearings
Main
A. Inspect the main bearings and the bearing surfaces of resolved.
Bearings
the crankshaft.
Result: The main bearings are
not damaged.
Result: The crankshaft is

damaged.
Replace the crankshaft. Clean

the engine thoroughly.
2. Inspect the Crankshaft
Crankshaft
A. Inspect the crankshaft for damage.. resolved.
Result: The crankshaft is not

damaged.
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Result: The piston height is not

correct.
Replace the damaged

3. Inspect the Piston Height
component.
A. Check the piston height.
Piston Verify that the problem is
Height resolved.
B. Inspect the piston, the connecting rod, and the
crankshaft for wear. Check for correct installation.
Result: The piston height is
correct.
4. Inspect the Fuel Injection Nozzles

misfiring or rough running. Then, loosen a fuel line nut on
the injection line for each cylinder. Loosen one nut at a Result: A fuel injection nozzle
time. Then, tighten that nut before the next fuel line nut is is not operating correctly.
loosened. If loosening the fuel line nut does not affect the
operation of the engine, the fuel injection nozzle is Replace the suspect fuel
probably suspect. Test the fuel injection nozzle for that injection nozzle.
cylinder. Make sure that all of the fuel
injection nozzles are the correct
B. Make sure that the fuel injection nozzles are properly Fuel type for the engine. Test the
sealed in the threaded ports. Make sure that the fuel Injection pressure setting of the fuel
injection nozzles are correctly aligned in the threaded Nozzles injection nozzles. Refer to the
ports. Make sure that the fuel injection nozzles are Specifications Module, "Fuel
tightened to the correct torque. Ensure that the gaskets Injection Nozzles" topic for
and the seat washers are installed on the fuel injection additional information.
nozzles correctly. Make sure that the bottom of the
threaded ports are clean and free of debris. Make sure that Verify that the problem is
the bottom of the threaded ports do not contain extra resolved.
gaskets.
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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Table 32
Result: Lubrication of internal

engine components is
inadequate.

1. Check the Lubrication of Internal Components
A. Check lubrication of the valves. There must be a strong
Lubrication resolved.
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.
Result: Lubrication of internal
engine components is
adequate.
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
Damage or
A.Visually inspect the rocker arms for wear or damage. wear
resolved.
Result: Rocker arm parts are

not worn.
Result: The end of the valve

stem is worn.
3. Inspect the Valve Stems Install new valves. Adjust the

Damage or valve lash.
A. Inspect the valve stems for wear. wear
resolved.
Result:The end of the valve
98 of 124 10/4/2017, 10:18 AM

stem is not worn.

correct.

correct.
Result: The pushrods are

worn.
If there is too much wear,

install new pushrods. Adjust
the valve lash.
5. Inspect the Engine Pushrods
Damage or
A. Visually inspect the pushrods for wear or damage. wear
resolved.
Result: The pushrods are not

worn.
Result: The valve lifters are

worn.
6. Inspect the Valve Lifters If there is too much wear,

Damage or install new valve lifters.
A. Visually inspect the valve lifters for wear or damage. wear Adjust the valve lash.

resolved.
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Result: The valve lifters are

not worn.
Result: The components are

worn.
7. Inspect the Camshaft
Replace suspect parts. Adjust
A. Measure the valve lash. the valve lash.
B. Check for free movement of the valves. Damage or Verify that the problem is
wear resolved.
C. Check for bent valve stems.
Result: The components are
D. Check for wear on the valve lifters. not worn.
Result: The bolts and the nuts

that hold the rocker arm
8. Inspect the Rocker Arm Assembly assembly are loose.
Damage or
A. Visually inspect the rocker arms for wear, damage or Tighten the bolts and the nuts.
wear
loose bolts..
resolved.
A cylinder head valve is loose.
Probable Cause
Table 33
Result: The valve keeper for the valve is broken.

1. Inspect the Valve Keepers
Valve Replace the valve keeper. Broken keepers can cause the
A. Inspect the engine valve valve to slide into the cylinder. Major engine damage can
keepers
keepers for damage. result.
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Result: The valve keeper for the valve is not broken.
Result: The valve springs are broken or damaged.

2. Inspect the Valve Springs
Valve Install new valve springs.
A. Inspect the valve springs for
springs
damage..
Oil condenses at the exhaust.
Probable Cause
Table 34
Result: The valve compartment contains too much oil.
Look at both ends of the rocker arm shaft. Be sure that

1. Inspect the Valve a plug is installed in each end.
Compartment
Valve Verify that the problem is resolved.
A. Inspect the valve compartment
compartment for excessive oil.. Result: The valve compartment does not contain too
much oil.
Result: The valve guides are worn.
Install new valve guides. Recondition the cylinder

2. Inspect the Valve Guides head.
A. Measure the timing of the Timing Verify that the problem is resolved.
fuel injection pump.
Result: The valve guides are not worn..
101 of 124 10/4/2017, 10:18 AM

Result: The piston rings are worn.

3. Inspect the Engine Piston
Replace worn parts.
Rings
The piston rings are worn. Refer to the Specifications
Piston rings Module, "Pistons and Rings" topic for additional
A. Inspect the engine piston
information.
rings for wear.
The valve lash is less than the required specification.
Probable Cause
Table 35
Result: The valve seat or the face of the valve is

1. Inspect the Engine Valves worn.
A. Inspect the engine valve seats and Valves Adjust the valve lash.
valves.
Engine components have early wear.
Probable Cause
Table 36
Result: Dirt is in the engine oil.
Remove the dirty engine oil. Install

1. Inspect the Engine Oil a new oil filter. Put clean oil in the
Oil engine.
A. Inspect the engine oil.
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
A. Inspect all gaskets and connections. system
Result: Leaks do not exist in the air
inlet system.
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
Result: Fuel is in the engine oil.
following leaks:
Replace the damaged component.
Fuel leaks into the crankcase from the fuel transfer Fuel leak
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.
Coolant is in the engine oil.
Probable Cause
Table 37
1. Inspect the Cylinder Head Gasket Result: The cylinder head gasket is damaged.
A. Inspect the cylinder head gasket for Head gasket Install a new cylinder head gasket.
damage.
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Result: The cylinder head gasket is not

damaged.
Result: The cylinder head is cracked or

damaged.
Install a new cylinder head.

2. Inspect the Cylinder Head
Cylinder Verify that the problem is resolved.
A. Inspect the cylinder head for damage. head
Result: The cylinder head is not cracked or
damaged.
Result: The cylinder block is cracked or

damaged.
3. Inspect the Cylinder Block
Cylinder
Install a new cylinder block.
A. Inspect the cylinder block for damage. block
The engine exhaust has too much black smoke or too much gray smoke.
Probable Cause
Table 38
1. Check the Engine for Low Compression Result: The cylinders have low
compression.
A. Starting the engine may be difficult in warm weather.
The engine may not start in cold weather. Low Repair or replace the engine
compression is most frequently caused by the following Low component causing low
conditions: compression compression.
Cylinder walls are worn or damaged. Verify that the problem is

Piston rings are worn or broken. resolved.
104 of 124 10/4/2017, 10:18 AM


Result: The cylinders do not
have low compression.
When an inlet valve or an exhaust valve is fully seated,
gases leak past the valve head.

misfiring or rough running. Then, loosen a fuel line nut Replace the suspect fuel
on the injection line for each cylinder. Loosen one nut at injection nozzle.
a time. Then, tighten that nut before the next fuel line nut Make sure that all of the fuel
is loosened. If loosening the fuel line nut does not affect injection nozzles are the correct
the operation of the engine, the fuel injection nozzle is type for the engine. Test the
probably suspect. Test the fuel injection nozzle for that pressure setting of the fuel
cylinder. injection nozzles. Refer to the
Fuel Injection Specifications Module, "Fuel
B. Make sure that the fuel injection nozzles are properly Nozzles Injection Nozzles" topic for
sealed in the threaded ports. Make sure that the fuel additional information.
injection nozzles are correctly aligned in the threaded
ports. Make sure that the fuel injection nozzles are Verify that the problem is
tightened to the correct torque. Ensure that the gaskets resolved.
and the seat washers are installed on the fuel injection
nozzles correctly. Make sure that the bottom of the Result: The fuel injection
threaded ports are clean and free of debris. Make sure nozzles are operating correctly.
that the bottom of the threaded ports do not contain extra
gaskets. Proceed to Test Step 3.
3. Inspect the Operation of the Fuel Injection Pump Result: The operation of the
fuel injection pump is not
A. Check the timing of the fuel injection pump. Adjust correct.
the timing or replace the fuel injection pump. Refer to
the Specifications Module, "Fuel Injection Pump" topic Make the necessary repairs.
for additional information. The fuel injection pump must
Fuel Injection
be repaired or replaced. Verify that the problem is
Pump
resolved.
B. Make sure that the linkage of the fuel rack operates
correctly. Result: The operation of the
fuel injection pump is correct.
C. Make sure that the high pressure fuel lines are
connected to the fuel injection nozzles in the correct Proceed to Test Step 4.
105 of 124 10/4/2017, 10:18 AM

order.
D. Make sure that the mounting bolts of the fuel

Inspect the fuel lines for leaks or for restrictions. The
replaced.
Result: There is a restriction in

the air inlet system.
4. Inspect the Air Inlet System
The air cleaner must be cleaned
Restriction or replaced.
A. Check the air cleaner for restrictions.
resolved.
The engine exhaust has too much white smoke or too much blue smoke.
Probable Cause
Table 39
Result: The engine contains too much

engine oil.
Drain the excess engine oil from the

engine oil pan.
1. Check the Oil Level
Oil level Verify that the problem is resolved.
A. Check the engine oil level.
Result: The engine does not contain too
much engine oil.
2. Inspect the Fuel Injection Pump Result: The timing of fuel injection pump
Timing is incorrect.
Timing
A. Check the fuel injection pump for the Adjust the timing. Refer to the
106 of 124 10/4/2017, 10:18 AM

Specifications Module, "Fuel Injection

Pump" topic for additional information.

correct timing.
Result: The timing of fuel injection pump
is correct.
Replace the valve guides.

3. Inspect the Engine Valve Guides
Valve guides
A. Inspect the engine valve guides for wear.
Result: The valve guides are not worn.
Result: The piston rings are worn.
Replace worn parts.

The piston rings are worn. Refer to the
Specifications Module, "Pistons and
4. Inspect the Engine Piston Rings
Rings" topic for additional information.
Piston rings
A. Inspect the engine piston rings for wear.
Result: The piston rings are not worn.
Result: The water temperature regulator

is suspect.
5. Operating Conditions
Replace the water temperature regulator.
A. If the engine consistently runs below the Operating
normal operating temperature, inspect the Temperature Verify that the problem is resolved.
water temperature regulator.
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
Clean the vent hole, the breather
Restrictions
assembly, and the breather hose.
A.Visually inspect the components.
The engine has low oil pressure.
Probable Cause
Table 40
Result: The engine oil level is low.
Fill the engine oil to the correct level.

Oil level
Result: The engine oil level is not low.
Result: The engine oil filter is

restricted.
Install a new engine oil filter. Replace

the oil in the engine with clean engine
2. Inspect the Engine Oil Filter oil. Check the operation of the engine
Oil filter oil bypass valve for the engine oil
A. Inspect the engine oil filter for restrictions. filter.
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 Result: Fuel is in the engine oil.
and low engine oil pressure. Inspect the engine
for the following leaks: Replace the damaged component.
Fuel leaks into the crankcase from the fuel Verify that the problem is resolved.
Fuel leak
transfer pump.
Fuel leaks past the valve in a fuel injection Result: Fuel is not in the engine oil.
nozzle.
The pressure setting of the fuel injection nozzles Proceed to Test Step 4.
is too high.
The drive is broken on the fuel injection pump.
Result: The clearance is not within

specifications.

4. Inspect the Clearance of the Rocker Arm
A. Measure the clearance.between the bore of the Clearance
rocker arm and the rocker shaft.
Result: The clearance is within
specifications.
Result: The rocker assembly does not

have proper lubrication.
Replace parts which are worn. Refer to

5. Inspect the Rocker Assembly the Specifications Module, "Rocker
Shaft" topic for additional information.
A. Inspect the rocker assembly for proper Lubrication
lubrication. Verify that the problem is resolved.
Result: The rocker assembly has

proper lubrication.
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Result: The suction tube is loose or

damaged.
The suction tube must be repaired or

6. Inspect the Oil Pump Suction Tube replaced.
A. Inspect the oil pump suction tube for damage Suction tube Verify that the problem is resolved.
or a loose connection.
Result: The suction tube is not loose
or damaged.
Result: The engine oil bypass valve

does not operate correctly.
Clean the bypass valve. Replace the

bypass valve if the spring is broken or
7. Inspect the Oil Pump Bypass Valve
the plunger is damaged.
Oil pump
A. Inspect oil pump bypass valve for proper
bypass valve Verify that the problem is resolved.
operation.
Result: The engine oil bypass valve
operates correctly.
Result: The engine oil pump does not

8. Inspect the Engine Oil Pump operate correctly.
A. Inspect the engine oil pump for proper The components must be repaired or
operation. replaced.
B. Check the distance of the face of the cover of Oil pump Verify that the problem is resolved.
the oil pump above the face of the idler gear.
Refer to the Specifications Module, "Engine Oil Result: The engine oil pump operates
Pump" topic. Check the wear of the lobe on the correctly.
oil pump.
110 of 124 10/4/2017, 10:18 AM


specifications.
Replace the crankshaft or the

crankshaft bearings. Refer to the
9. Inspect the Crankshaft Specifications Module, "Crankshaft"
A. Measure the clearance between the crankshaft Clearance
and the crankshaft bearings. Verify that the problem is resolved.
Result: The clearance is within

specifications.

specifications.
10. Inspect the Camshaft
Replace the camshaft or the camshaft
A. Measure the clearance between the camshaft Clearance
bearings.
and the camshaft bearings.
The engine oil pressure is too high.
Probable Cause
Table 41
Result: The engine oil bypass valve does

not open.
1. Inspect the Engine Oil Bypass Valve
Bypass The bypass valve must be cleaned or
A. Inspect the engine oil bypass valve for proper
valve replaced.
operation.
The engine uses too much engine oil.
111 of 124 10/4/2017, 10:18 AM

Probable Cause
Table 42
Result: The engine contains too much engine oil.
Drain the excess engine oil from the engine oil pan.
Oil level
Result: The engine does not contain too much engine oil.
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 Oil leaks
leaks.
Result: The engine oil lines do not have leaks.
3. Inspect the Engine Valve Replace the valve guides.

Guides
Valve Verify that the problem is resolved.
A. Inspect the engine valve guides
guides for wear. Result: The valve guides are not worn.
4. Inspect the Engine Piston Result: The piston rings are worn.
Rings
Piston Replace worn parts.
A. Inspect the engine piston rings The piston rings are worn. Refer to the Specifications Module,
rings for wear. "Pistons and Rings" topic for additional information.
112 of 124 10/4/2017, 10:18 AM

The engine overheats.
Probable Cause
Table 43
Result: The air flow through the radiator

is restricted.
Clean the exterior of the radiator in order

1. Inspect the Cooling System to remove all restrictions.
A. Check the air flow through the radiator for Restriction Verify that the problem is resolved.
a restriction.
Result: The air flow through the radiator
is not restricted.
Result: The coolant level in the engine is

low.
Add coolant into the radiator to the correct

level.
2. Check the Coolant Level
Coolant Verify that the problem is resolved.
A. Check the coolant level.
Result: The coolant level in the engine is
not low.
Result: The coolant pressure cap is not

3. Inspect the Coolant Pressure Cap working properly.
Coolant
A. Test the operation of the pressure cap. Pressure Cap Replace the faulty pressure cap.
113 of 124 10/4/2017, 10:18 AM

Result: The coolant pressure cap is

working properly.
Result: Gases from combustion are in the

coolant.
Find the source of the entry of the gases

from combustion into the coolant system.
4. Inspect the Cooling System
Repair the source of the problem.
Cooling
A. Inspect the cooling system for gases from
System Verify that the problem is resolved.
combustion.
Result: Gases from combustion are not in
the coolant.
Result: The water temperature regulator is

suspect.
5. Inspect the Water Temperarure
Regulator Replace the faulty water temperature
regulator.
A. Test the water temperature regulator for
correct operation. Regulator Verify that the problem is resolved.
Refer to the Systems Operation, Testing and
Adjusting Module or the Specifications Result: The water temperature regulator is
Module for additional information. not suspect.
Result: The water pump is suspect.
The water pump must be repaired or

6. Inspect the Water Pump replaced.
Water pump
A. Test the water pump for proper operation.. Verify that the problem is resolved.
Result: The water pump is not suspect.
114 of 124 10/4/2017, 10:18 AM

Result: The engine is operating with too

much load.
Reduce the load.

7. Operating Conditions
A. Check the load the engine is operating Load
under.
Result: The engine is not operating with
too much load.
Result: The timing of fuel injection pump

is incorrect.
8. Inspect the Fuel Injection Pump Timing
Adjust the timing. Refer to the
A. Check the fuel injection pump for the Timing Specifications Module, "Fuel Injection
correct timing. Pump" topic for additional information.
The exhaust temperature is too high.
Probable Cause
Table 44
Result: There is a restriction in the air inlet or exhaust

system.
1. Inspect the Air Inlet and
Exhaust System Remove the restriction.
A. Inspect the air inlet and Restriction Verify that the problem is resolved.
exhaust system, look for a
restriction. Result: There is not a restriction in the air inlet or
exhaust system.
115 of 124 10/4/2017, 10:18 AM

Result: The timing of the fuel injection pump is

incorrect.
2. Measure the Fuel Injection
Pump Timing
Adjust the timing of the fuel injection pump. Refer to the
Timing Specifications Module, "Fuel Injection Pump" topic for
A. Measure the timing of the fuel
additional information.
injection pump.
The starting motor does not turn or the starting motor turns too slowly.
Probable Cause
Table 45
Result: The battery has a low charge.
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
1. Measure the Charge of the
battery posts. Tighten the cable clamps on the battery
Battery
Battery posts.
voltage
A. Measure the battery voltage.
Result: The battery does not have a low charge.
Result: A short circuit was found.
2. Inspect the Starting Motor Repair the short circuit.

Starting
A. Inspect the brushes for the Verify that the problem is resolved.
motor
starting motor. Inspect the brushes
brushes
for a short circuit. Result: A short circuit was not found.
116 of 124 10/4/2017, 10:18 AM

Result: The ignition switch, the start relay, or the

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

Circuit
Result: An excessive voltage drop exists in the cables or
A. Inspect the starting motor across the terminals in the circuits for the starting motor.
circuit for a voltage drop.
Voltage
Replace the damaged parts.
drop
B. Inspect the battery cables and
battery terminals for loose Verify that the problem is resolved.
connections, corrosion, or other
damage.
The starting motor turns, but the pinion gear does not engage the flywheel ring gear.
Probable Cause
Table 46
Result: The overrunning clutch for the

pinion drive slips.
1. Inspect the Pinion Drive Replace the overrunning clutch.
A. Inspect the overrunning clutch for the Pinion drive Verify that the problem is resolved.
pinion drive.
Result: The overrunning clutch for the
pinion drive does not slip.
117 of 124 10/4/2017, 10:18 AM

Result: The ring gear of the flywheel is

damaged.
Replace the flywheel.

2. Inspect the Flywheel Ring Gear
Flywheel
A. Inspect the flywheel ring gear for damage..
Result: The ring gear of the flywheel is
not damaged.
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 Shift lever
damage.
Result: The shift lever or the linkage is not
damaged.
Result: The starting motor solenoid is not

operating properly.
Replace or repair the components that are

4. Inspect the Starting Motor Solenoid not operating properly.
Starter
A. Inspect the starting motor solenoid for Verify that the problem is resolved.
solenoid
proper operation.
Result: The starting motor solenoid is
operating properly.
5. Inspect the Armature or Idler Gear of Starting Result: The armature or idler gear of the
the Starting Motor motor starting motor is damaged.
118 of 124 10/4/2017, 10:18 AM

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
Table 47
Result: The battery has a low charge.
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
1. Measure the Charge of the
battery posts. Tighten the cable clamps on the battery
Battery
Battery posts.
voltage
A. Measure the battery voltage.
Result: The battery does not have a low charge.
Result: The start relay is not operation properly.
Replace the start relay.

2. Inspect the Start Relay
Start Verify that the problem is resolved.
A. Check the start relay for proper
relay
operation.
Result: The start relay is operation properly.
3. Inspect the Starting Motor Result: An excessive voltage drop exists in the cables or
Circuit Voltage across the terminals in the circuits for the starting motor.
drop
A. Inspect the starting motor circuit Replace the damaged parts.
119 of 124 10/4/2017, 10:18 AM

for a voltage drop. Verify that the problem is resolved.
B. Inspect the battery cables and Result: An excessive voltage drop does not exist in the
battery terminals for loose cables or across the terminals in the circuits for the
connections, corrosion, or other starting motor.
damage.
Result: The overrunning clutch for the pinion drive slips.

4. Inspect the Pinion Drive
Pinion Replace the overrunning clutch.
A. Inspect the overrunning clutch
drive
for the pinion drive.
The starting motor continues to run after the ignition switch is released.
Probable Cause
Table 48
Result: The ignition switch, the start relay,

1. Inspect the Ignition Switch, the Start or the starting motor solenoid are not
Relay, and the Starting Motor Solenoid operating properly.
Starter
A. Inspect the ignition switch, the start relay, Replace or repair the components that are not
circuit
and the starting motor solenoid for proper operating properly.
operation.
The pinion gear does not disengage after the engine starts to run.
Probable Cause
Table 49
1. Inspect the Return Spring of the Pinion Return Result: The return spring of the pinion
Solenoid Spring solenoid is damaged.
120 of 124 10/4/2017, 10:18 AM

Replace the return spring of the pinion

solenoid.

A. Inspect the return spring of the pinion
solenoid for damage.
Result: The return spring of the pinion
solenoid is not damaged.
Result: The shift lever or the linkage is

damaged.
Replace the shift lever or the linkage.

2. Inspect the Shift Lever
Shift Verify that the problem is resolved.
A. Inspect the shift lever and linkage for
lever
damage.
Result: The shift lever or the linkage is not
damaged.
Result: The ignition switch, the start relay,

3. Inspect the Ignition Switch, the Start or the starting motor solenoid are not
Relay, and the Starting Motor Solenoid operating properly.
Starter
A. Inspect the ignition switch, the start relay, Replace or repair the components that are not
circuit
and the starting motor solenoid for proper operating properly.
operation.
The alternator does not charge the battery or the alternator charge rate is slow or
irregular.
Probable Cause
Table 50
1. Inspect the Alternator Drive Drive belt Result: The drive belt for the alternator is loose.
121 of 124 10/4/2017, 10:18 AM

Belt
The drive belt must be adjusted or replaced.
A. Verify that the tension is
correct on the drive belt.
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.

2. Inspect the Alternator Drive
Replace a damaged pulley.
Pulley
Drive pulley Verify that the problem is resolved.
A. Inspect the pulley for wear or
for damage.
Result: The drive pulley for the alternator is not loose
or worn.
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
3. Inspect the Electrical
Saver and Cleaner on the cable terminals and the
Connections
connections. Replace suspect parts.
Electrical
A. Inspect the electrical cables
connections Verify that the problem is resolved.
and connections in the charging
and starting circuits.
Result: The electrical cables and connections in the
charging and starting circuits are not loose or
damaged.
4. Check the Alternator for Result: One of the components is not operating
Proper Operation properly.
Alternator
A. Test the following alternator Replace the component that is not operating properly.
122 of 124 10/4/2017, 10:18 AM

components:
Regulator or the field winding

of the rotor Verify that the problem is resolved.
Brushes
Rectifier
The alternator charges the battery to a voltage that is too high.
Probable Cause
Table 51
1. Check the Alternator for Proper

Operation
Result: One of the components is not operating
properly.
A. Test the following alternator
components:
Replace the component that is not operating
Alternator
properly.
Regulator or the field winding of the
rotor
Brushes
Rectifier
The alternator is noisy.
Probable Cause
Table 52
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. Verify that the problem is resolved.
Drive belt
B. Inspect the drive belt for wear and for Result: The drive belt for the alternator is not
damage. loose.
123 of 124 10/4/2017, 10:18 AM

Result: The drive pulley for the alternator is

loose or worn.
Tighten the nuts of the pulley to the correct

2. Inspect the Alternator Drive Pulley torque. Replace a damaged pulley.
A. Inspect the pulley for wear or for Drive pulley Verify that the problem is resolved.
damage.
Result: The drive pulley for the alternator is not
loose or worn.
Result: The drive belt and the drive pulley are

not in alignment.
Adjust the alignment.

3. Inspect the Belt Alignment
Belt Verify that the problem is resolved.
A. Inspect the alignment of the drive
alignment
pulley and drive belt.
Result: The drive belt and the drive pulley are in
alignment.
Result: The bearings of the alternator are worn

4. Check the Alternator for Proper or damaged.
Operation
Alternator Replace the alternator.
A. Inspect the alternator bearings.
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124 of 124 10/4/2017, 10:18 AM

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Troubleshooting The Fuel Injection Nozzles On The Engine

1 of 124 10/4/2017, 10:18 AM

Refer to Specifications, "Fuel Injection Nozzles" for additional information.

The Engine is Difficult to Start or the Engine Runs Rough

Result: The fuel injection nozzle does not seal

Make sure that the gaskets, the insert, and the

Result: The fuel injection nozzle is sealed

Proceed to Test Step 2.

Result: There is debris on the mounting

2 of 124 10/4/2017, 10:18 AM

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line

Proceed to Test Step 4.

Result: The correct fuel nozzles are not

The Engine Exhaust has too Much Black Smoke

3 of 124 10/4/2017, 10:18 AM

Proceed to Test Step 2.

2. Check for Correct Operation of the Fuel

C. Test the fuel injection nozzle on a nozzle Proceed to Test Step 3.

Result: The correct fuel nozzles are not

Result: The fuel injection nozzle does not seal

4 of 124 10/4/2017, 10:18 AM

hole of the cylinder head.

Verify that the problem is resolved.

Result: The fuel injection nozzle is sealed

Proceed to Test Step 2.

Result: There is debris on the mounting

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line

Proceed to Test Step 4.

5 of 124 10/4/2017, 10:18 AM

Result: The correct fuel nozzles are not

Install the correct fuel nozzles.

Result: The correct fuel nozzles are installed.

Proceed to Test Step 6.

Result: A low-pressure fuel line is leaking.

The Engine is Misfiring, Running Rough, or Running Poorly

6 of 124 10/4/2017, 10:18 AM

the mating surface of the cylinder head are

Make sure that the fuel injection nozzle is

Result: The fuel injection nozzle is sealed

Proceed to Test Step 2.

Result: There is debris on the mounting

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line

Proceed to Test Step 4.

7 of 124 10/4/2017, 10:18 AM

4. Check for Correct Operation of the

Result: The correct fuel nozzles are not

Install the correct fuel nozzles.

Proceed to Test Step 6.

Result: A high-pressure fuel line is

Repair or replace the high-pressure fuel line

Proceed to Test Step 7.

8 of 124 10/4/2017, 10:18 AM

Result: The seat washer is not 2.0 mm

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester

Result: There are fuel leaks.through the