320D2 Troubleshooting6

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A. Inspect the oil supply line for leaks.

The supply line must be repaired or replaced.

Verify that the problem is resolved. Result: The oil supply line does not have leaks.

Proceed to Test Step 9.

9. Inspect the Piston Rings

A. Inspect the piston rings for wear. Piston rings

Result: The piston rings have wear. Replace the piston rings.

Verify that the problem is resolved.

Result: The piston rings do not have wear. Proceed to Test Step 10.

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

High idle

Result: The high idle operates for an excessive time.

The fuel injection pump must be repaired or replaced.

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

11. Inspect the Turbocharger for a Restriction

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

Restriction

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

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

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

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

Oil Filter

Result: The engine oil filter has a restriction.

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

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 correct operation or damage:

· Compressor impeller of the turbocharger · Cooling system

· Fuel injection pump · Air/fuel ratio control · Valve lash

· Fuel injection nozzles

Engine operation

Result: The components listed are not operating properly.

The component must be repaired or replaced.

The inside of the intake manifold is wet.

Probable Cause

Table 15

Troubleshooting Test Steps Values Results

1. Check for Restrictions in the Air Filter Element

A. Check the condition of the air filter

Air filter element

Result: The air filter element is dirty or has restrictions.

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element.

or replaced.

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

2. Check for Restrictions in the Crankcase Breather

A. Check the crankcase breather for restrictions.

Restrictions

Result: The crankcase breather has restrictions.

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

Verify that the problem is resolved. Result: The crankcase breather does not have restrictions.

3. Check for Proper Installation of the Air Filter Element

A. Verify that the air filter element is sealed properly.

Air filter

Result: The air filter element is not sealed properly.

Inspect the air filter element and the air supply line to the turbocharger for correct installation.

Verify that the problem is resolved. Result: The air filter element is sealed properly.

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

Turbocharger

A. Check for damage or a restriction in the

Restriction/damage

Result: There is damage or a

restriction to the tube between the air filter and the turbocharger.

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tube between the air filter and the turbocharger.

replace the component.

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

5. Check for an Air Leak or Restriction in the Tube between the Intake Manifold and the Turbocharger

A. Check for a leak or a restriction in the tube between the intake manifold and the turbocharger.

Air leak or restriction

Result: There is a leak or a restriction to the tube between the intake

manifold and the turbocharger. Find the leak or restriction and repair or replace the component.

Verify that the problem is resolved. Result: There is not a leak or a restriction to the tube between the intake manifold and the turbocharger. Proceed to Test Step 6.

6. Check for Restriction in the Exhaust System

A. Check for damage or a restriction in the exhaust system components.

Restriction/damage

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

Verify that the problem is resolved. Result: There is not damage or a restriction in the exhaust system components.

7. Check for Proper Installation of the

Turbocharger Turbocharger

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

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

turbocharger are loose.

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

turbocharger are not loose. Proceed to Test Step 8.

8. Inspect the Exhaust Manifold

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

Exhaust manifold

Result: The exhaust manifold has cracks, loose bolts, or a distorted flange.

The exhaust manifold must be repaired or replaced.

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

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

Restrictions

Result: The engine oil pipe has restrictions.

The drain pipe must be repaired or replaced.

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

10. Inspect the Turbocharger

Restriction/damage

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

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

The turbine housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction.

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

Leaks

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

Verify that the problem is resolved. Result: The turbocharger does not have combustion gas or air leaks. Proceed to Test Step 12.

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

Turbocharger Bearings

Result: The turbocharger bearings are not OK.

Replace the turbocharger.

Verify that the problem is resolved. Result: The turbocharger bearings are OK.

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

Debris

Result: The compressor housing contains debris.

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

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14. Inspect the Piston Rings

A. Inspect the piston rings for wear. Piston rings

Result: The piston rings have wear. Replace the piston rings.

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

Restriction

Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved. Result: The turbocharger does not have a restriction in the bearing housing.

16. Inspect the Air Inlet Heater

A. Test the air inlet heater for leakage. Leaks

Result: The air inlet heater has fuel leaks.

Repair the leaks.

Verify that the problem is resolved. Result: The air inlet heater does not have fuel leaks.

17. Inspect the Compressor

A. Inspect the back plate of the Compressor

Result: The back plate of the compressor is cracked.

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compressor.

be repaired or the turbocharger must be replaced.

Damaged compressor impeller of the turbocharger

Probable Cause

Table 16

1. Check for Proper Installation of the Air Filter Element

A. Verify that the air filter element is sealed properly.

Air filter

Result: The air filter element is not sealed properly.

Inspect the air filter element and the air supply line to the turbocharger for correct installation.

Verify that the problem is resolved. Result: The air filter element is sealed properly.

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

Turbocharger

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

Restriction/damage

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

Find the restriction and repair or replace the component.

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

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3. Check for Proper Installation of the Turbocharger

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

turbocharger are not loose.

Turbocharger

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

Correctly position the turbocharger and tighten the clamps and bolts.

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

4. Check for Turbocharger for Proper Lubrication

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

A. Check the following components for correct operation:

· Engine oil pump

· Engine oil bypass valve · Engine oil filter

· Viscosity of the engine oil · Restrictions in oil lines

Turbocharger lubrication

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

5. Check the Engine Oil

A. Verify that the correct type of engine oil is being used.

Engine oil

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

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

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

Restrictions

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

Verify that the problem is resolved. Result: The oil supply line is not restricted.

Result: The turbocharger bearings are not OK.

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

Debris

Result: The compressor housing contains debris.

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

9. Verify the Engine RPM

A. Verify the engine RPM during start-up.

Engine RPM

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

Check the fuel injection pump for correct operation and settings.

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Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 10.

High idle

11. Inspect the Oil Supply Line

A. Inspect the oil supply line for leaks. Leaks

Result: The oil supply line has leaks. The supply line must be repaired or replaced.

Restriction

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

The bearing housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved. Result: The turbocharger does not have a restriction in the bearing housing.

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Oil Filter

Verify that the problem is resolved. Result: The engine oil filter does not have a restriction.

· Compressor impeller of the turbocharger

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

· Fuel injection nozzles

Engine operation

Damage to the turbine

Probable Cause

Table 17

1. Check for Restriction in the

Exhaust System _{Restriction/damage}

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

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A. Check for damage or a restriction in the exhaust system components.

Verify that the problem is resolved. Result: There is not damage or a restriction in the exhaust system components.

2. Check for Proper Installation of the Turbocharger

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

turbocharger are not loose.

Turbocharger

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

Correctly position the turbocharger and tighten the clamps and bolts.

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

3. Check for Turbocharger for Proper Lubrication

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

A. Check the following components for correct operation:

· Engine oil pump

· Engine oil bypass valve · Engine oil filter

· Viscosity of the engine oil · Restrictions in oil lines

Turbocharger lubrication

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

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4. Inspect the Engine Oil

A. Inspect the engine oil. Engine Oil

Result: The engine oil is dirty.

Drain the engine oil. Install the correct type of engine oil. Replace the engine oil filter.

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

5. Check the Engine Oil

A. Verify that the correct type of engine oil is being used.

Engine oil

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

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

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

Restrictions

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

Verify that the problem is resolved. Result: The oil supply line is not restricted.

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

Restriction/damage

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

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

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

Result: The turbocharger bearings are not OK.

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

Carbon build-up

Result: The turbocharger rotor has carbon build-up.

Remove the carbon.

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

10. Verify the Engine RPM

A. Verify the engine RPM during start-up.

Engine RPM

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

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

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High idle

12. Inspect the Fuel Injection Pump for Proper Operation

A. Test the fuel injection pump for proper operation.

Fuel pump

Result: The fuel injection pump is not operating correctly.

The fuel injection pump must be repaired or replaced.

Verify that the problem is resolved. Result: The fuel injection pump is operating correctly.

13. Inspect the Intake and Exhaust Valves

A. Inspect the intake and exhaust valves.

Burned valves

Result: The inlet valves and the exhaust valves are burned.

Replace the inlet valves and the exhaust valves. Determine the cause of the damage to the valves.

Verify that the problem is resolved. Result: The inlet valves and the exhaust valves are not burned.

14. Inspect the Oil Supply Line

A. Inspect the oil supply line for leaks. Leaks

Result: The oil supply line has leaks. The supply line must be repaired or replaced.

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Restriction

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

The bearing housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved. Result: The turbocharger has a restriction in the bearing housing.

Oil Filter

Verify that the problem is resolved. Result: The engine oil filter does not have a restriction.

· Compressor impeller of the

Engine operation