320D2 Troubleshooting9

(1)

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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.

(2)

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

1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head

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

Fuel Injection Nozzle

Result: The fuel injection nozzle does not seal

correctly in the cylinder head.

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

Verify that the problem is resolved.

Result: The fuel injection nozzle is sealed

correctly in the cylinder head. Proceed to Test Step 2.

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

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

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

Debris

Result: There is debris on the mounting

surface of the cylinder head or extra gaskets were left in the cylinder head for the fuel injection nozzle.

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

Result: There is no debris on the mounting

surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection nozzle.

(3)

Proceed to Test Step 3.

3. Check the Connections of the High Pressure Fuel Line

A. Check for a damaged or leaking high-pressure fuel line.

Fuel leak

Result: A high-pressure fuel line is leaking.

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

Result: A high-pressure fuel line is not

leaking.

4. Check that the Correct Fuel Nozzles are Installed

A. Verify that all fuel injection nozzles are the correct replacement parts for the engine.

Fuel Nozzle

Result: The correct fuel nozzles are not

installed.

Install the correct fuel nozzles.

Refer to the Parts Manual for the correct replacement part.

The Engine Exhaust has too Much Black Smoke

Probable Cause

Table 2

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

Debris

Result: There is debris on the mounting surface

of the cylinder head or extra gaskets were left in the cylinder head for the fuel injection nozzle. Remove any extra gaskets or debris.

surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection

(4)

nozzle.

2. Check for Correct Operation of the Fuel Nozzle

A. Make sure that the components of the fuel injection nozzle are tightened to the correct torques.

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

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

Fuel Nozzle

Result: The fuel nozzle is not operating

properly.

Replace the fuel nozzle.

Result: The fuel nozzle is operating properly.

3. Check that the Correct Fuel Nozzles are Installed

A. Verify that all fuel injection nozzles are the correct replacement parts for the engine.

Fuel Nozzle

installed.

The Engine has Lost Power and the Engine Uses too Much Fuel

Probable Cause

Table 3

1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head

Result: The fuel injection nozzle does not seal

correctly in the cylinder head.

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

(5)

hole of the cylinder head.

Debris

surface of the cylinder head or extra gaskets left in the cylinder head for the fuel injection nozzle.

A. Check for a damaged or leaking high-pressure fuel line.

Fuel leak

leaking.

4. Check for Correct Operation of the Fuel Nozzle

A. Make sure that the components of the fuel injection nozzle are tightened to the

Fuel Nozzle

properly.

(6)

correct torques.

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

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

Result: The fuel nozzle is operating properly.

A. Verify that that all fuel injection nozzles have the correct code for the engine.

Fuel Nozzle

installed.

Result: The correct fuel nozzles are installed.

6. Check the Connections of the Low Pressure Fuel Line

A. Check for a damaged or leaking low-pressure fuel line.

Fuel Leak

Result: A low-pressure fuel line is leaking.

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

The Engine is Misfiring, Running Rough, or Running Poorly

Probable Cause

Table 4

1. Check that the Fuel Injection Nozzle is Sealed Correctly in the Cylinder Head

Result: The fuel injection nozzle does not

seal correctly in the cylinder head.

(7)

the mating surface of the cylinder head are clean.

Make sure that the fuel injection nozzle is tightened to the correct torque in the threaded hole of the cylinder head. Verify that the problem is resolved.

Debris

surface of the cylinder head or extra gaskets left in the cylinder head for the fuel

injection nozzle. Proceed to Test Step 3.

A. Check for a leaking high-pressure fuel line.

Fuel leak

leaking.

(8)

4. Check for Correct Operation of the Fuel Nozzle

A. Make sure that the components of the fuel injection nozzle are tightened to the correct torques.

B. Make sure that the gaskets and the insert are positioned correctly. C. Test the fuel injection nozzle on a nozzle tester in order to measure the pressure setting.

Fuel Nozzle

properly.

Replace the fuel nozzle.

Result: The fuel nozzle is operating

properly.

A. Verify that all fuel injection nozzles have the correct code for the engine.

Fuel Nozzle

installed.

Result: The correct fuel nozzles are

installed.

6. Check for a Restriction in the High-pressure Fuel Line

A. Check for a damaged or restricted high-pressure fuel line.

High-pressure fuel line restriction

Result: A high-pressure fuel line is

restricted or damaged.

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

restricted or damaged. Proceed to Test Step 7.

(9)

7. Check for the Correct Seat Washer

A. Verify that the seat washer is 2.0 mm (0.08 inch) thick.

2.0 mm

(0.08 inch) seat washer

Result: The seat washer is not 2.0 mm

(0.08 inch) thick.

Replace the seat washer with the correct seat 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

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

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

Fuel leaks

Result: There are fuel leaks.through the

threaded connection of the body and the nozzle nut.

Make sure that the threads are clean. Tighten the body to the correct torque. Verify that the problem is resolved.

Result: There are no fuel leaks.through the

threaded connection of the body and the nozzle nut.

(10)

Orifices

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

Debris

Clean the surface of the orifices with

solvent. Replace the fuel injection nozzles if corrosion exists.

The fuel injection nozzle does not inject fuel in the correct quantity or in the correct

pattern.

Probable Cause

Table 6

1. Check the Setting for the Opening Pressure

A. Test the setting of the opening pressure.

Opening pressure

Result: The opening pressure is not correct.

Adjust the setting to the correct pressure. Verify that the problem is resolved.

Result: The opening pressure is correct.

2. Verify the Operation of the Fuel Injection Nozzle

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

Fuel injection nozzle

Result: The fuel injection nozzle is stuck. Debris

or damage exists on the fuel injection nozzle. The fuel injection nozzle must be cleaned or replaced.

Result: The fuel injection nozzle is not stuck.

3. Check for a Blockage or Restriction in the Orifices

A.Inspect the orifices for carbon

Orifice blockage

Result: The orifices are blocked or restricted.

The fuel injection nozzle must be cleaned or replaced.

(11)

buildup.

Result: The orifices are not blocked or restricted.

4. Check for a Blockage or Restriction in the Fuel Return

A.Inspect the fuel return passage.

Fuel return passage

Result: The fuel return passage is blocked or

restricted.

Clean the passage in order to remove any carbon buildup or other debris.

Troubleshooting the Turbocharger

The engine lacks power.

Probable Cause

Table 7

1. Check for Restrictions in the Air Filter Element

A. Check the condition of the air filter element.

Air filter element

Result: The air filter element is dirty

or has restrictions.

The air filter element must be cleaned or replaced.

Result: The air filter element is not

dirty or does not have restrictions. Proceed to Test Step 2.

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

Turbocharger Restriction/damage

Result: There is damage or a

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

(12)

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

turbocharger.

Find the restriction and repair or replace the component.

Result: There is not damage or a

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

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

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.

Result: There is not a leak or a

restriction to the tube between the intake manifold and the turbocharger. Proceed to Test Step 4.

4. Check for Restriction in the Exhaust System

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

Restriction/damage

restriction in the exhaust system components.

The component must be repaired or replaced.

(13)

5. Check for Proper Installation of the Turbocharger

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

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. Proceed to Test Step 6.

6. Inspect the Intake Manifold

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

Intake manifold

Result: The intake manifold has

cracks, loose bolts, or a distorted flange.

The intake manifold must be repaired or replaced.

Result: The intake manifold does not

have cracks, loose bolts, or a distorted flange.

7. Inspect the Exhaust Manifold

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

Exhaust manifold

Result: The exhaust manifold has

The exhaust manifold must be repaired or replaced.

Result: The exhaust manifold does

not have cracks, loose bolts, or a distorted flange.

(14)

8. 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. Verify that the problem is resolved.

Result: The turbine housing is not

damaged or does not have a restriction.

9. Inspect the Turbocharger Bearings

A. Inspect the turbocharger bearings.

Turbocharger Bearings

Result: The turbocharger bearings are

not OK.

Replace the turbocharger.

OK.

10. 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. Proceed to Test Step 11.

11. 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.

(15)

Result: The turbocharger rotor does

not have carbon build-up. Proceed to Test Step 12.

12. Inspect the Fuel Injection Pump

A. Verify proper operation of the fuel injection pump.

Fuel injection pump

Result: The fuel injection pump is not

operating properly.

The fuel injection pump must be repaired or replaced.

Result: The fuel injection pump is

operating properly. Proceed to Test Step 13.

13. Inspect the Fuel Injection Nozzles

A. Inspect the fuel injection nozzles for wear or damage.

Damage/wear

Result: The fuel injection nozzles

have wear or damage.

The fuel injection nozzles must be repaired or replaced.

Result: The fuel injection nozzles do

not have wear or damage. Proceed to Test Step 14.

14. Inspect the Intake and Exhaust Valves

A. Inspect the intake and exhaust valves.

Intake/exhaust valves

Result: The intake and exhaust valves

are burned.

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

Result: The intake and exhaust valves

(16)

15. Inspect the Piston Rings

A. Inspect the piston rings for wear. Piston rings

Result: The piston rings have wear.

Replace the piston rings.

The engine exhaust has excessive black smoke.

Probable Cause

Table 8

Air filter element

Result: The air filter element is dirty or

has restrictions.

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.

(17)

Turbocharger

Correctly position the turbocharger and tighten the clamps and bolts.

Intake manifold

Result: The intake manifold does not

have cracks, loose bolts, or a distorted flange.

5. 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.

Result: The engine oil pipe does not

(18)

6. 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.

Result: The turbocharger does not have

combustion gas or air leaks. Proceed to Test Step 7.

not OK.

OK.

Debris

contains debris.

Carbon build-up

(19)

The engine exhaust has excessive blue smoke.

Probable Cause

Table 9

1. Check for Restrictions in the Air Filter Element

Air filter element

Result: The air filter element is

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

not dirty or does not have restrictions.

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.

does not have restrictions. Proceed to Test Step 3.

3. Check for a Restriction in the Tube

between the Air Filter and the Turbocharger Restriction/damage

(20)

air filter and the turbocharger. Find the restriction and repair or replace the component.

restriction to the tube between the air filter and the turbocharger. Proceed to Test Step 4.

Turbocharger

Result: The turbocharger is loose

or the clamps and bolts on the turbocharger are loose.

Result: The turbocharger is not

loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 5.

Intake manifold

Result: The intake manifold does

(21)

Restrictions

restrictions.

Result: The engine oil pipe does

not have restrictions. Proceed to Test Step 7.

Leaks

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 8.

Result: The turbocharger bearings

are not OK.

Replace the turbocharger. Verify that the problem is resolved.

are OK.

(22)

A. Inspect the compressor housing for debris. Debris

contains debris.

does not contain debris. Proceed to Test Step 10.

Carbon build-up

carbon build-up. Remove the carbon. Verify that the problem is resolved.

Result: The turbocharger rotor

does not have carbon build-up. Proceed to Test Step 11.

11. Inspect the Turbocharger for Fluid

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

Anti-corrosion fluid

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

have excessive anti-corrosion fluid.

12. 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.

(23)

repaired or replaced. Verify that the problem is resolved.

Result: The high idle does not

operate for an excessive time. Proceed to Test Step 13.

13. 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.

The engine uses an excessive amount of engine oil.

Probable Cause

Table 10

Air filter element

2. Check for Restrictions in the Crankcase Breather

Restrictions Result: The crankcase breather has restrictions.

(24)

Result: The crankcase breather does

Turbocharger

4. Check the Engine Oil

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

Engine oil

Result: The incorrect type of engine

oil is being used.

Drain the engine oil. Install the correct quantity and type of engine oil.

Result: The correct type of engine oil

is being used.

(25)

have restrictions. Proceed to Test Step 6.

Restrictions

restrictions.

Restriction/damage

damaged or has a restriction.

damaged or does not have a restriction. Proceed to Test Step 8.

not OK.

(26)

OK.

Result: The piston rings do not have

wear.

10. 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.

Result: The oil supply line does not

have leaks.

High idle

Result: The high idle operates for an

excessive time.

Result: The high idle does not operate

for an excessive time. Proceed to Test Step 12.

12. Inspect the Turbocharger for a

Restriction Restriction

(27)

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

Excessive engine oil exists at the end of the turbine.

Probable Cause

Table 11

Restrictions

has restrictions.

2. Check for a Restriction in the Exhaust System

Restriction/damage

(28)

Turbocharger

loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 4.

Restrictions

restrictions.

Result: The engine oil pipe does

Restriction/damage

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

(29)

are not OK.

Replace the turbocharger. Verify that the problem is resolved.

are OK.

Carbon build-up

has carbon build-up. Remove the carbon. Verify that the problem is resolved.

does not have carbon build-up. Proceed to Test Step 8.

Result: The piston rings have

wear.

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

Result: The piston rings do not

have wear.

9. Inspect the Turbocharger for Fluid _{Anti-corrosion fluid}

(30)

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

have excessive anti-corrosion fluid.

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

an excessive time.

Restriction

Excessive engine oil exists at the compressor end of the turbocharger.

Probable Cause

Table 12

(31)

1. Check for Restrictions in the Air Filter Element

Air filter element

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

Restrictions

Result: The crankcase breather has

restrictions.

Turbocharger

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

turbocharger.

Restriction/damage

restriction to the tube between the air filter and the turbocharger. Find the restriction and repair or replace the component.

restriction to the tube between the air filter and the turbocharger. Proceed to Test Step 4.

(32)

4. 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.

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.

restriction to the tube between the intake manifold and the

turbocharger.

Fuel Nozzle

loose or the clamps and bolts on the turbocharger are not loose.

Leaks

(33)

are not OK.

are OK.

A. Inspect the compressor housing for debris. Debris

contains debris.

does not contain debris. Proceed to Test Step 9.

Result: The piston rings do not

have wear.

10. Inspect the Turbocharger for Fluid

Anti-corrosion fluid

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

(34)

have excessive anti-corrosion fluid. Proceed to Test Step 11.

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

an excessive time.

Restriction

Engine oil exists in the exhaust manifold.

Probable Cause

Table 13

Restrictions

restrictions.

The crankcase breather (if equipped), or the tubing must be cleaned or replaced. Verify that the problem is resolved.

(35)

2. Check for Restriction in the Exhaust System

Restriction/damage

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

Restrictions

restrictions.

Restriction/damage

Result: The turbine housing is damaged

or has a restriction.

damaged or does not have a restriction. Proceed to Test Step 5.

(36)

not OK.

OK.

Debris

contains debris.

Carbon build-up

Result: The turbocharger rotor does not

have carbon build-up. Proceed to Test Step 8.

(37)

wear.

High idle

excessive time.

Result: The high idle does not operate

for an excessive time. Proceed to Test Step 10.

Restriction

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

Lack of lubrication to the turbocharger

Probable Cause

Table 14

Turbocharger

Result: The turbocharger is loose or the

clamps and bolts on the turbocharger are loose.

Result: The turbocharger is not loose or the

(38)

loose.

2. 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

Result: The components listed are not

operating properly.

Result: The components listed are operating

properly.

3. 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.

Engine oil

Result: The incorrect type of engine oil is

being used.

Drain the engine oil. Install the correct quantity and type of engine oil.

Result: The correct type of engine oil is

(39)

5. 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.

Result: The oil supply line is not restricted.

6. 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.

Result: The engine rpm does not increase

too rapidly when the engine is started. Proceed to Test Step 7.

High idle

excessive time.

Result: The high idle does not operate for

an excessive time. Proceed to Test Step 8.

8. Inspect the Oil Supply Line _Leaks

(40)

A. Inspect the oil supply line for leaks.

The supply line must be repaired or replaced.

Result: The oil supply line does not have

leaks.

Result: The piston rings do not have wear.

High idle

excessive time.

Result: The high idle does not operate for

an excessive time. Proceed to Test Step 11.

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. Proceed to Test Step 12.

(41)

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

operating properly.

The inside of the intake manifold is wet.

Probable Cause

Table 15

A. Check the condition of the air filter

Air filter element

(42)

element.

or replaced.

Restrictions

restrictions.

Result: The crankcase breather does

3. Check for Proper Installation of the Air Filter Element

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

Air filter

sealed properly.

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

Result: The air filter element is sealed

properly.

Turbocharger

A. Check for damage or a restriction in the

Restriction/damage

(43)

tube between the air filter and the turbocharger.

replace the component.

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.

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.

restriction to the tube between the intake manifold and the turbocharger. Proceed to Test Step 6.

6. Check for Restriction in the Exhaust System

Restriction/damage

7. Check for Proper Installation of the

Turbocharger Turbocharger

(44)

turbocharger are loose.

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

The exhaust manifold must be repaired or replaced.

Result: The exhaust manifold does

Restrictions

restrictions.

have restrictions.

Restriction/damage

(45)

Leaks

not OK.

OK.

Debris

contains debris.

(46)

Result: The piston rings do not have

wear.

Restriction

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

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.

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.

(47)

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

sealed properly.

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

Result: The air filter element is sealed

properly.

Turbocharger

Restriction/damage

to the tube between the air filter and the turbocharger.

(48)

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.

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

operating properly.

Result: The components listed are

operating properly. Proceed to Test Step 5.

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.

Result: The correct oil is being used.

(49)

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.

Result: The oil supply line is not

restricted.

Result: The turbocharger bearings are not

OK.

Debris

Result: The compressor housing contains

debris.

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.