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Find the restriction and repair or


replace the component.

Verify that the problem is resolved.


A. Check for damage or a restriction in the
tube between the air filter and the
Result: There is not damage or a
turbocharger.
restriction to the tube between the air
filter and the turbocharger.

Proceed to Test Step 3.

Result: There is a leak or a restriction


to the tube between the intake
manifold and the turbocharger.
3. Check for an Air Leak or Restriction
Find the leak or restriction and repair
in the Tube between the Intake Manifold
or replace the component.
and the Turbocharger
Air leak or
Verify that the problem is resolved.
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.

Proceed to Test Step 4.

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.
A. Check for damage or a restriction in the
exhaust system components.
Result: There is not damage or a
restriction in the exhaust system
components.

Proceed to Test Step 5.

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Result: The turbocharger is loose or


the clamps and bolts on the
turbocharger are loose.

5. Check for Proper Installation of the 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.

Proceed to Test Step 6.

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.

Proceed to Test Step 7.

Result: The exhaust manifold has


cracks, loose bolts, or a distorted
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.
loose bolts, or a distorted flange.
Result: The exhaust manifold does
not have cracks, loose bolts, or a
distorted flange.

Proceed to Test Step 8.

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Result: The turbine housing is


damaged or has a restriction.

The turbine housing must be repaired


or the turbocharger must be replaced.
8. Inspect the Turbocharger
Verify that the problem is resolved.
A. Inspect the turbine housing for damage Restriction/damage
or a restriction. Result: The turbine housing is not
damaged or does not have a
restriction.

Proceed to Test Step 9.

Result: The turbocharger bearings are


not OK.

Replace the turbocharger.


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

Proceed to Test Step 10.

Result: The compressor housing


contains debris.

Clean the compressor housing.


10. Inspect the Compressor for Debris
Verify that the problem is resolved.
A. Inspect the compressor housing for Debris
debris. Result: The compressor housing does
not contain debris.

Proceed to Test Step 11.

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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Verify that the problem is resolved.

Result: The turbocharger rotor does


not have carbon build-up.

Proceed to Test Step 12.

Result: The fuel injection pump is not


operating properly.

The fuel injection pump must be


repaired or replaced.
12. Inspect the Fuel Injection Pump
Verify that the problem is resolved.
A. Verify proper operation of the fuel Fuel injection pump
injection pump.
Result: The fuel injection pump is
operating properly.

Proceed to Test Step 13.

Result: The fuel injection nozzles


have wear or damage.

The fuel injection nozzles must be


repaired or replaced.
13. Inspect the Fuel Injection Nozzles
Verify that the problem is resolved.
A. Inspect the fuel injection nozzles for Damage/wear
wear or damage.
Result: The fuel injection nozzles do
not have wear or damage.

Proceed to Test Step 14.

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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Proceed to Test Step 15.

Result: The piston rings have wear.


15. Inspect the Piston Rings
Replace the piston rings.
Piston rings
A. Inspect the piston rings for wear.
Verify that the problem is resolved.

The engine exhaust has excessive black smoke.

Probable Cause

Table 8
Troubleshooting Test Steps Values Results

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.

Proceed to Test Step 2.

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.

Restriction/damage Verify that the problem is resolved.


A. Check for damage or a restriction in
the tube between the air filter and the
turbocharger. Result: There is not damage or a
restriction to the tube between the air
filter and the turbocharger.

Proceed to Test Step 3.

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Result: The turbocharger is loose or


the clamps and bolts on the
turbocharger are loose.

3. Check for Proper Installation of the Correctly position the turbocharger and
Turbocharger 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.

Proceed to Test Step 4.

Result: The intake manifold has


cracks, loose bolts, or a distorted
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.
loose bolts, or a distorted flange.
Result: The intake manifold does not
have cracks, loose bolts, or a distorted
flange.

Proceed to Test Step 5.

Result: The engine oil pipe has


restrictions.

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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Proceed to Test Step 6.

Result: The turbocharger has


combustion gas or air leaks.

Replace the turbocharger.


6. Inspect the Turbocharger Seals
Verify that the problem is resolved.
A. Inspect the turbocharger for Leaks
combustion gas or air leaks.
Result: The turbocharger does not have
combustion gas or air leaks.

Proceed to Test Step 7.

Result: The turbocharger bearings are


not OK.

Replace the turbocharger.


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

Proceed to Test Step 8.

Result: The compressor housing


contains debris.

Clean the compressor housing.


8. Inspect the Compressor for Debris
Verify that the problem is resolved.
A. Inspect the compressor housing for Debris
debris. Result: The compressor housing does
not contain debris.

Proceed to Test Step 9.

Result: The turbocharger rotor has


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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Verify that the problem is resolved.

The engine exhaust has excessive blue smoke.

Probable Cause

Table 9
Troubleshooting Test Steps Values Results

Result: The air filter element is


dirty or has restrictions.

The air filter element must be


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

Proceed to Test Step 2.

Result: The crankcase breather


has restrictions.

The crankcase breather (if


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

Proceed to Test Step 3.

3. Check for a Restriction in the Tube Result: There is damage or a


between the Air Filter and the Turbocharger Restriction/damage restriction to the tube between the

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air filter and the turbocharger.

Find the restriction and repair or


replace the component.

Verify that the problem is


A. Check for damage or a restriction in the resolved.
tube between the air filter and the turbocharger.
Result: There is not damage or a
restriction to the tube between the
air filter and the turbocharger.

Proceed to Test Step 4.

Result: The turbocharger is loose


or the clamps and bolts on the
turbocharger are 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.

Proceed to Test Step 5.

Result: The intake manifold has


cracks, loose bolts, or a distorted
flange.

5. Inspect the Intake Manifold The intake manifold must be


repaired or replaced.
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


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

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Proceed to Test Step 6.

Result: The engine oil pipe has


restrictions.

The drain pipe must be repaired or


replaced.
6. Inspect the Engine Oil Drain Pipe
Verify that the problem is
A. Inspect the engine oil drain pipe for Restrictions
resolved.
restrictions.
Result: The engine oil pipe does
not have restrictions.

Proceed to Test Step 7.

Result: The turbocharger has


combustion gas or air leaks.

Replace the turbocharger.


7. Inspect the Turbocharger Seals
Verify that the problem is
A. Inspect the turbocharger for combustion gas Leaks resolved.
or air leaks.
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.

8. Inspect the Turbocharger Bearings Verify that the problem is


Turbocharger resolved.
A. Inspect the turbocharger bearings. Bearings
Result: The turbocharger bearings
are OK.

Proceed to Test Step 9.

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Result: The compressor housing


contains debris.

Clean the compressor housing.

9. Inspect the Compressor for Debris Verify that the problem is


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

Proceed to Test Step 10.

Result: The turbocharger rotor has


carbon build-up.

Remove the carbon.


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

Proceed to Test Step 11.

Result: The turbocharger has


excessive anti-corrosion fluid.

Clean the turbocharger in order to


remove the anti-corrosion fluid.
11. Inspect the Turbocharger for Fluid
Verify that the problem is
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.

Proceed to Test Step 12.

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

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repaired or replaced.

Verify that the problem is


resolved.

Result: The high idle does not


operate for an excessive time.

Proceed to Test Step 13.

Result: The turbocharger has a


restriction in the bearing housing.
13. Inspect the Turbocharger for a
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.
Verify that the problem is
resolved.

The engine uses an excessive amount of engine oil.

Probable Cause

Table 10
Troubleshooting Test Steps Values Results

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.

Proceed to Test Step 2.

2. Check for Restrictions in the Restrictions Result: The crankcase breather has
Crankcase Breather restrictions.

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