Trouble Shooting

8/16/2019 C7.
1 DE200E0/DE220E0 Generator Set GTY00001-UP(SEBP7395 - 11) - Documentation
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Product: GENER ATO R SET

Mode l: C 7.1DE200E GENER ATO R SET GTY
C onfiguration: C 7.1 DE200E0/DE220E0 Ge ne rator Se t GTY00001-UP
Testing and Adjusting

C7.1 Generator Set Engines
Media Number -M0071960-00 Publication Date -01/04/2016 Date Updated -27/04/2016
i05182663
Troubleshooting
SMCS - 1000-035
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.
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.

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8/16/2019 C7.1 DE200E0/DE220E0 Generator Set GTY00001-UP(SEBP7395 - 11) - Documentation
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 tightened to
Sealed Correctly in the Cylinder Head
Fuel the correct torque in the threaded hole of the cylinder
Injection head.
A. Verify that the fuel injection nozzle is sealed
Nozzle
correctly in the cylinder head.
Verify that the problem is resolved.
Result: The fuel injection nozzle is sealed correctly in

the cylinder head.
Proceed to Test Step 2.
Result: There is debris on the mounting surface of the

cylinder head or extra gaskets were left in the cylinder
2. Check for Debris on the Mating Surface
head for the fuel injection nozzle.
of the Cylinder Head with the Gaskets or
the Insert
Remove any extra gaskets or debris.
A. Check for debris on the mating surface of
the cylinder head. Debris
Result: There is no debris on the mounting surface of
B. Make sure that extra gaskets were removed
the cylinder head or extra gaskets left in the cylinder
from the threaded recess in the cylinder head
for the fuel injection nozzle.
3. Check the Connections of the High Fuel Result: A high-pressure fuel line is leaking.
Pressure Fuel Line leak
Repair or replace the high-pressure fuel line that is
A. Check for a damaged or leaking high- leaking.
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 replacement
A. Verify that all fuel injection nozzles are the Nozzle part.
correct replacement parts for the engine.
The Engine Exhaust has too Much Black Smoke
Probable Cause
Table 2
Result: There is debris on the mounting surface of the

cylinder head or extra gaskets were left in the cylinder
1. Check for Debris on the Mating Surface
of the Cylinder Head with the Gaskets or the
Insert
Remove any extra gaskets or debris.
A. Check for debris on the mating surface of the
cylinder head. Debris
Result: There is no debris on the mounting surface of
the cylinder head or extra gaskets left in the cylinder
from the threaded recess in the cylinder head for
the fuel injection nozzle.
2. Check for Correct Operation of the Fuel Fuel Result: The fuel nozzle is not operating properly.
Nozzle Nozzle
Replace the fuel nozzle.
A. Make sure that the components of the fuel
injection nozzle are tightened to the correct Verify that the problem is resolved.
torques.
Result: The fuel nozzle is operating properly.
B. Make sure that the gaskets and the insert are
positioned correctly. Proceed to Test Step 3.
C. Test the fuel injection nozzle on a nozzle tester

in order to measure the pressure setting.

3. Check that the Correct Fuel Nozzles are
Installed Install the correct fuel nozzles.
Fuel Refer to the Parts Manual for the correct replacement
A. Verify that all fuel injection nozzles are the Nozzle part.
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 correctly

in the cylinder head.
Injection head.
Nozzle

the cylinder head.
2. Check for Debris on the Mating Surface Debris Result: There is debris on the mounting surface of the
of the Cylinder Head with the Gaskets or cylinder head or extra gaskets were left in the cylinder
the Insert head for the fuel injection nozzle.
A. Check for debris on the mating surface of Remove any extra gaskets or debris.
the cylinder head.

from the threaded recess in the cylinder head Result: There is no debris on the mounting surface of
for the fuel injection nozzle. the cylinder head or extra gaskets left in the cylinder
Result: A high-pressure fuel line is leaking.

3. Check the Connections of the High
leaking.
Pressure Fuel Line
Fuel
A. Check for a damaged or leaking high- leak
pressure fuel line.
4. Check for Correct Operation of the Fuel

Nozzle
Result: The fuel nozzle is not operating properly.
injection nozzle are tightened to the correct
torques.
Fuel Verify that the problem is resolved.
Nozzle
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.
5. Check that the Correct Fuel Nozzles are Fuel Result: The correct fuel nozzles are not installed.
Installed Nozzle
Install the correct fuel nozzles.
A. Verify that that all fuel injection nozzles have
the correct code for the engine. Refer to the Parts Manual for the correct replacement
part.
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 that is
Fuel
leaking.
A. Check for a damaged or leaking low- Leak
pressure fuel line.
The Engine is Misfiring, Running Rough, or Running Poorly
Probable Cause
Table 4
Result: The fuel injection nozzle does not seal

Injection head.
Nozzle

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

3. Check the Connections of the High leaking.
Pressure Fuel Line
Fuel leak Verify that the problem is resolved.
A. Check for a leaking high-pressure fuel line.
4. Check for Correct Operation of the

Fuel Nozzle
Result: The fuel nozzle is not operating properly.
injection nozzle are tightened to the correct
torques.
Fuel Verify that the problem is resolved.
Nozzle
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.
Install the correct fuel nozzles.

5. Check that the Correct Fuel Nozzles
Refer to the Parts Manual for the correct replacement
are Installed
part.
Fuel
A. Verify that all fuel injection nozzles have the Nozzle
correct code for the engine.
Result: The correct fuel nozzles are installed.
6. Check for a Restriction in the High- High- Result: A high-pressure fuel line is restricted or
pressure Fuel Line pressure damaged.
fuel line
A. Check for a damaged or restricted high- restriction Repair or replace the high-pressure fuel line that is
pressure fuel line. restricted or damaged.
Result: A high-pressure fuel line is not restricted or

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

7. Check for the Correct Seat Washer thick.
2.0 mm
(0.08 inch)
A. Verify that the seat washer is 2.0 mm Replace the seat washer with the correct seat washer.
seat
(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
1. Check for Fuel Leaks through the Threaded Fuel Result: There are fuel leaks.through the threaded
Connection of the Body and the Nozzle Nut leaks connection of the body and the nozzle nut.
A. Check for fuel leaks.through the threaded Make sure that the threads are clean. Tighten the
connection of the body and the nozzle nut. body to the correct torque.
Result: There are no fuel leaks.through the

threaded connection of the body and the nozzle
nut.
Result: The valve has debris or is damaged.

2. Check for Debris or Damage on the Orifices
Clean the surface of the orifices with solvent.
Damage
Replace the fuel injection nozzles if corrosion
A.Visually inspect the components of the valve for or
exists.
carbon pitting, for scoring, or for other damage. Debris
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.
2. Verify the Operation of the Fuel Fuel Result: The fuel injection nozzle is stuck. Debris or
Injection Nozzle injection damage exists on the fuel injection nozzle.
nozzle
A.Verify that the fuel injection nozzle is The fuel injection nozzle must be cleaned or replaced.
not stuck.
Result: The fuel injection nozzle is not stuck.
Result: The orifices are blocked or restricted.
3. Check for a Blockage or The fuel injection nozzle must be cleaned or replaced.
Restriction in the Orifices
Orifice Verify that the problem is resolved.
A.Inspect the orifices for carbon blockage
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 Clean the passage in order to remove any carbon buildup
Fuel return
or other debris.
passage
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 Filter or replaced.
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.
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Result: There is damage or a

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

2. Check for a Restriction in the Tube between
replace the component.
the Air Filter and the Turbocharger
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
Result: There is a leak or a restriction

to the tube between the intake manifold
and the turbocharger.
3. Check for an Air Leak or Restriction in the Find the leak or restriction and repair
Tube between the Intake Manifold and the or replace the component.
Turbocharger
Air leak or
restriction
A. Check for a leak or a restriction in the tube
between the intake manifold and the turbocharger. Result: There is not a leak or a
restriction to the tube between the
intake manifold and the turbocharger.
4. Check for Restriction in the Exhaust System Restriction/damage Result: There is damage or a
restriction in the exhaust system
A. Check for damage or a restriction in the exhaust components.
system components.
The component must be repaired or
replaced.

components.
Result: The turbocharger is loose or

the clamps and bolts on the
turbocharger are loose.
Correctly position the turbocharger and

5. Check for Proper Installation of the
tighten the clamps and bolts.
Turbocharger
Turbocharger Verify that the problem is resolved.
A. Verify that turbocharger is not loose or the clamps
and bolts on the turbocharger are not loose.
Result: The turbocharger is not loose
or the clamps and bolts on the
turbocharger are not loose.
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, loose bolts, Intake manifold Verify that the problem is resolved.
or a distorted flange.
Result: The intake manifold does not
have cracks, loose bolts, or a distorted
flange.
Result: The exhaust manifold has

7. Inspect the Exhaust Manifold Exhaust manifold cracks, loose bolts, or a distorted
flange.
A. Inspect the exhaust manifold for cracks, loose
bolts, or a distorted flange. The exhaust manifold must be repaired
or replaced.
Result: The exhaust manifold does not

flange.
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 or a Restriction/damage
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
Debris
A. Inspect the compressor housing for debris.
Result: The compressor housing does
not contain debris.
Result: The turbocharger rotor has

11. Inspect the Turbocharger Rotor Carbon build-up carbon build-up.
A. Inspect the turbocharger rotor for carbon build- Remove the carbon.
up. Verify that the problem is resolved.
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
Fuel injection Verify that the problem is resolved.
A. Verify proper operation of the fuel injection pump. 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 wear or Damage/wear
damage.
Result: The fuel injection nozzles do
not have wear or damage.
Result: The intake and exhaust valves

14. Inspect the Intake and Exhaust Valves Intake/exhaust are burned.
valves
A. Inspect the intake and exhaust valves. Replace the inlet valves and the exhaust
valves. Determine the cause of the
damage to the valves.
Result: The intake and exhaust valves

are not burned.
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

has restrictions.
The air filter element must be cleaned or

1. Check for Restrictions in the Air Filter replaced.
Element
Result: The air filter element is not dirty
or does not have restrictions.
Result: There is damage or a restriction

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

2. Check for a Restriction in the Tube
the component.
between the Air Filter and the Turbocharger
restriction to the tube between the air filter
3. Check for Proper Installation of the Turbocharger Result: The turbocharger is loose or the
Turbocharger clamps and bolts on the turbocharger are
loose.
A. Verify that turbocharger is not loose or the
clamps and bolts on the turbocharger are not Correctly position the turbocharger and
loose. tighten the clamps and bolts.
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 or

replaced.
4. Inspect the Intake Manifold
A. Inspect the intake manifold for cracks, loose Intake manifold
bolts, or a distorted flange.
Result: The intake manifold does not
flange.
Result: The engine oil pipe has

restrictions.
The drain pipe must be repaired or

5. Inspect the Engine Oil Drain Pipe replaced.
A. Inspect the engine oil drain pipe for Restrictions Verify that the problem is resolved.
restrictions.
Result: The engine oil pipe does not have
restrictions.
6. Inspect the Turbocharger Seals Leaks Result: The turbocharger has combustion
gas or air leaks.
A. Inspect the turbocharger for combustion gas or
air leaks. Replace the turbocharger.
Result: The turbocharger does not have

combustion gas or air leaks.
Result: The turbocharger bearings are not

OK.

Turbocharger
OK.
Result: The compressor housing contains

debris.

Debris
Result: The compressor housing does not
contain debris.
Result: The turbocharger rotor has

carbon build-up.
9. Inspect the Turbocharger Rotor
Remove the carbon.
A. Inspect the turbocharger rotor for carbon Carbon build-up
build-up.
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.
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
A. Check the crankcase breather for restrictions.
resolved.

does not have restrictions.
3. Check for a Restriction in the Tube between the Restriction/damage Result: There is damage or a
Air Filter and the Turbocharger restriction to the tube between
the air filter and the turbocharger.
A. Check for damage or a restriction in the tube between
the air filter and the turbocharger. Find the restriction and repair or

resolved.
Result: There is not damage or

a restriction to the tube between
Result: The turbocharger is

loose or the clamps and bolts on
the turbocharger are loose.
Correctly position the

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

the turbocharger are not loose.
Result: The intake manifold has

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

5. Inspect the Intake Manifold
A. Inspect the intake manifold for cracks, loose bolts, or a Intake manifold
resolved.
distorted flange.
Result: The intake manifold
does not have cracks, loose
6. Inspect the Engine Oil Drain Pipe Restrictions Result: The engine oil pipe has
restrictions.
A. Inspect the engine oil drain pipe for restrictions. The drain pipe must be repaired
or replaced.

resolved.
Result: The engine oil pipe does

not have restrictions.
Result: The turbocharger has


7. Inspect the Turbocharger Seals
resolved.
A. Inspect the turbocharger for combustion gas or air Leaks
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.
bearings are OK.

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

resolved.

does not contain debris.
Result: The turbocharger rotor

has carbon build-up.
Remove the carbon.
10. Inspect the Turbocharger Rotor Verify that the problem is

resolved.
Carbon build-up
A. Inspect the turbocharger rotor for carbon build-up.
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-corrosion Anti-corrosion
resolved.
fluid. This condition only exists on a new engine which has fluid
not been operated.
not have excessive anti-corrosion
fluid.
Result: The high idle operates

12. Verify the High Idle Speed High idle for an excessive time.
A. Verify the high idle speed of the engine. The fuel injection pump must be

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 Restriction The bearing housing must be
repaired or the turbocharger
A. Inspect the turbocharger for a restriction in the bearing Restriction must be replaced.
housing.
resolved.
The engine uses an excessive amount of engine oil.
Probable Cause
Table 10

has restrictions.

Element
Result: The air filter element is not dirty
or does not have restrictions.
Restrictions
2. Check for Restrictions in the Crankcase Result: The crankcase breather has
Breather restrictions.
A. Check the crankcase breather for restrictions. The crankcase breather (if equipped), or
the tubing must be cleaned or replaced.
Result: The crankcase breather does not

have restrictions.
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 the Turbocharger 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 turbocharger
are not loose.
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 oil is being Engine oil Verify that the problem is resolved.
used.
Result: The correct type of engine oil is
being used.
restrictions.
A. Inspect the engine oil drain pipe for restrictions.
replaced.

restrictions.

restrictions.

replaced.
6. Inspect the Engine Oil Drain Pipe
Restrictions Verify that the problem is resolved.
restrictions.
Result: The turbine housing is damaged

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

the turbocharger must be replaced.
restriction.
Result: The turbine housing is not
damaged or does not have a restriction.

not OK.

Turbocharger
OK.

9. Inspect the Piston Rings Piston rings
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.
The fuel injection pump must be repaired

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

12. Inspect the Turbocharger for a Restriction
The bearing housing must be repaired or
A. Inspect the turbocharger for a restriction in the Restriction the turbocharger must be replaced.
bearing housing.
Excessive engine oil exists at the end of the turbine.
Probable Cause
Table 11

has restrictions.

1. Check for Restrictions in the Crankcase Breather
Restrictions Verify that the problem is
resolved.


components.
The component must be

2. Check for a Restriction in the Exhaust System
A. Check for damage or a restriction in the exhaust system Restriction/damage
resolved.
components.
Result: There is not damage or
a restriction in the exhaust
system components.
3. Check for Proper Installation of the Turbocharger Turbocharger Result: The turbocharger is
A. Verify that turbocharger is not loose or the clamps and the turbocharger are loose.
bolts on the turbocharger are not loose.
clamps and bolts.

resolved.


restrictions.
The drain pipe must be repaired

or replaced.
Restrictions
A. Inspect the engine oil drain pipe for restrictions. resolved.
Result: The engine oil pipe


The turbine housing must be

must be replaced.
Restriction/damage resolved.
A. Inspect the turbine housing for damage or a restriction.
not damaged or does not have a
restriction.

6. Inspect the Turbocharger Bearings Turbocharger bearings are not OK.
Bearings
A. Inspect the turbocharger bearings. Replace the turbocharger.

resolved.
bearings are OK.

has carbon build-up.
Remove the carbon.
7. Inspect the Turbocharger Rotor Verify that the problem is

resolved.
Carbon build-up
A. Inspect the turbocharger rotor for carbon 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.

Clean the turbocharger in order

to remove the anti-corrosion
fluid.
resolved.
not been operated.
not have excessive anti-
corrosion fluid.
Result: The high idle operates

10. Verify the High Idle Speed High idle for an excessive time.

resolved.


11. Inspect the Turbocharger for a Restriction The bearing housing must be
A. Inspect the turbocharger for a restriction in the bearing Restriction must be replaced.
housing.
resolved.
Excessive engine oil exists at the compressor end of the turbocharger.
Probable Cause
Table 12

dirty or has restrictions.

Air filter element
not dirty or does not have
restrictions.
Restrictions
2. Check for Restrictions in the Crankcase Breather Result: The crankcase breather
has restrictions.


air filter and the turbocharger.

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

intake manifold and the
turbocharger.
Result: The turbocharger is loose


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


leaks. Result: The turbocharger does
not have combustion gas or air
leaks.

bearings are not OK.

Turbocharger
bearings are OK.


does not contain debris.
Result: The piston rings have

wear.

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

Clean the turbocharger in order to

remove the anti-corrosion fluid.
not been operated.
not have excessive anti-corrosion
fluid.
Result: The high idle operates for

11. Verify the High Idle Speed High idle an excessive time.

The bearing housing must be
repaired or the turbocharger must
A. Inspect the turbocharger for a restriction in the bearing Restriction
be replaced.
housing.
Engine oil exists in the exhaust manifold.
Probable Cause
Table 13
Result: The crankcase breather has

restrictions.
The crankcase breather (if equipped), or the

1. Check for Restrictions in the
tubing must be cleaned or replaced.
Crankcase Breather
Restrictions
A. Check the crankcase breather for
restrictions.
have restrictions.
2. Check for Restriction in the Exhaust Restriction/damage Result: There is damage or a restriction in the
System exhaust system components.
A. Check for damage or a restriction in the The component must be repaired or replaced.
exhaust system components.
Result: There is not damage or a restriction in

the exhaust system components.
Result: The engine oil pipe has restrictions.
The drain pipe must be repaired or replaced.

A. Inspect the engine oil drain pipe for Restrictions
restrictions. Result: The engine oil pipe does not have
restrictions.
Result: The turbine housing is damaged or

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

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

OK.

Result: The turbocharger bearings are OK.

6. Inspect the Compressor for Debris Debris debris.

contain debris.
Result: The turbocharger rotor has carbon

build-up.
Remove the carbon.

build-up. Result: The turbocharger rotor does not have
carbon build-up.

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

excessive time.
The fuel injection pump must be repaired or

replaced.
High idle
Result: The high idle does not operate for an
excessive time.
Result: The turbocharger has a restriction in

10. Inspect the Turbocharger for a Restriction the bearing housing.
Restriction
The bearing housing must be repaired or the
A. Inspect the turbocharger for a restriction in turbocharger must be replaced.
the bearing housing.
Lack of lubrication to the turbocharger
Probable Cause
Table 14
Result: The turbocharger is loose or the clamps

and bolts on the turbocharger are loose.
Correctly position the turbocharger and tighten the

clamps and bolts.
Turbocharger
A. Verify that turbocharger is not loose or the Turbocharger
Result: The turbocharger is not loose or the
loose.
loose.
2. Check for Turbocharger for Proper

Lubrication
Result: The components listed are not operating
The flow of engine oil is delayed to the
properly.
turbocharger when the engine is started.
Insufficient oil flows to the turbocharger when
The component must be repaired or replaced.
the engine is running.
A. Check the following components for correct
lubrication
operation:
Result: The components listed are operating
properly.
· Engine oil pump
· Engine oil bypass valve
· Engine oil filter
· Viscosity of the engine oil
· Restrictions in oil lines
3. Inspect the Engine Oil Engine Oil Result: The engine oil is dirty.
A. Inspect the engine oil. Drain the engine oil. Install the correct type of
engine oil. Replace the engine oil filter.
Result: The engine oil is not dirty.
Result: The incorrect type of engine oil is being

used.
Drain the engine oil. Install the correct quantity and

4. Check the Engine Oil type of engine oil.
A. Verify that the correct type of engine oil is Engine oil Verify that the problem is resolved.
being used.
Result: The correct type of engine oil is being
used.
Result: The oil supply line is restricted.
The oil supply line must be repaired or replaced.

5. Check the Engine Oil Supply Line
A. Inspect the oil supply line from the engine oil Restrictions
pan for a restriction.
Result: The oil supply line is not restricted.
Engine RPM
6. Verify the Engine RPM Result: The engine rpm increases too rapidly
when the engine is started.
A. Verify the engine RPM during start-up.
Check the fuel injection pump for correct
operation and settings.
Result: The engine rpm does not increase too

rapidly when the engine is started.
Result: The high idle operates for an excessive

time.

replaced.
High idle
excessive time.
The supply line must be repaired or replaced.

Leaks
Result: The oil supply line does not have leaks.

Piston rings
Result: The piston rings do not have wear.
Result: The high idle operates for an excessive

10. Verify the High Idle Speed High idle time.
A. Verify the high idle speed of the engine. The fuel injection pump must be repaired or
replaced.

excessive time.
Result: The turbocharger has a restriction in the

bearing housing.

11. Inspect the Turbocharger for a turbocharger must be replaced.
Restriction
Restriction
A. Inspect the turbocharger for a restriction in
the bearing housing. Result: The turbocharger has a restriction in the
bearing housing.
Result: The engine oil filter has a restriction.
Clean the engine oil filter base and the housing for
the engine oil filter. Check the operation of the
engine oil bypass valve in the engine oil filter base.
Replace the engine oil filter.
12. Inspect the Engine Oil Filter
Oil Filter Verify that the problem is resolved.
A. Inspect the engine oil filter for a restriction.
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.
Result: The components listed are not operating
A. Check the following components for correct
properly.
operation or damage:
Engine
operation The component must be repaired or replaced.
· Compressor impeller of the turbocharger
· Cooling system
· Fuel injection pump
· Air/fuel ratio control
· Valve lash
· Fuel injection nozzles
The inside of the intake manifold is wet.

Probable Cause
Table 15

has restrictions.
The air filter element must be cleaned

1. Check for Restrictions in the Air Filter or replaced.
Element
Result: The air filter element is not
dirty or does not have restrictions.

restrictions.
The crankcase breather (if equipped),

or the tubing must be cleaned or
2. Check for Restrictions in the Crankcase
replaced.
Breather
Restrictions
Result: The crankcase breather does
not have restrictions.
3. Check for Proper Installation of the Air Filter Air filter Result: The air filter element is not
Element sealed properly.
A. Verify that the air filter element is 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.


4. Check for a Restriction in the Tube between
the Air Filter and the Turbocharger
Result: There is a leak or a restriction

to the tube between the intake manifold
5. Check for an Air Leak or Restriction in the Find the leak or restriction and repair
Tube between the Intake Manifold and the or replace the component.
Turbocharger
Air leak or
restriction
A. Check for a leak or a restriction in the tube
between the intake manifold and the turbocharger. Result: There is not a leak or a
intake manifold and the turbocharger.
6. Check for Restriction in the Exhaust System Restriction/damage Result: There is damage or a
A. Check for damage or a restriction in the exhaust components.
system components.
replaced.

components.
Result: The turbocharger is loose or

the clamps and bolts on the
Correctly position the turbocharger and

Turbocharger
A. Verify that turbocharger is not loose or the clamps
and bolts on the turbocharger are not loose.
Result: The turbocharger is not loose
turbocharger are not loose.
Result: The exhaust manifold has

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

or replaced.
8. Inspect the Exhaust Manifold
A. Inspect the exhaust manifold for cracks, loose Exhaust manifold
Result: The exhaust manifold does not
flange.
restrictions.
replaced.
Result: The engine oil pipe does not

have restrictions.

The turbine housing must be repaired

restriction. Result: The turbine housing is not
damaged or does not have a
restriction.


leaks.
Result: The turbocharger does not
have combustion gas or air leaks.

not OK.

Turbocharger
OK.



Result: The compressor housing does

not contain debris.
14. 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.

The bearing housing must be repaired

A. Inspect the turbocharger for a restriction in the Restriction
bearing housing. Result: The turbocharger does not
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 compressor is cracked.
A. Inspect the back plate of the compressor. The back plate of the compressor must
be repaired or the turbocharger must
be replaced.
Damaged compressor impeller of the turbocharger
Probable Cause
Table 16
Result: The air filter element is not sealed

properly.
Inspect the air filter element and the air

1. Check for Proper Installation of the Air supply line to the turbocharger for correct
Filter Element installation.
Air filter
A. Verify that the air filter element is sealed Verify that the problem is resolved.
properly.
properly.
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 Find the restriction and repair or replace the
between the Air Filter and the component.
Turbocharger
between the air filter and the turbocharger. Result: There is not damage or a restriction
turbocharger.
loose.

loose.

Lubrication
Result: The components listed are not
The flow of engine oil is delayed to the operating properly.
Insufficient oil flows to the turbocharger when The component must be repaired or
the engine is running. replaced.
Turbocharger
A. Check the following components for correct Verify that the problem is resolved.
lubrication
operation:
· Engine oil pump properly.
· Engine oil filter Proceed to Test Step 5.
Result: The incorrect oil is being used.
Drain the engine oil. Replace the engine oil

5. Check the Engine Oil filter. Install the correct type of engine oil.
being used.
Result: The correct oil is being used.
6. Check the Engine Oil Supply Line Restrictions Result: The oil supply line is restricted.
A. Inspect the oil supply line from the engine oil The oil supply line must be repaired or
pan for a restriction. replaced.

OK.


debris.

Debris
contain debris.
Engine RPM
9. Verify the Engine RPM Result: The engine rpm increases too
Result: The engine rpm does not increase

too rapidly when the engine is started.

excessive time.

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

replaced.
Leaks
leaks.


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

13. Inspect the Engine Oil Filter Oil Filter
Clean the engine oil filter base and the
A. Inspect the engine oil filter for a restriction. 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.

restriction.

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


1. Check for Restriction in the Exhaust
replaced.
System
A. Check for damage or a restriction in the
Result: There is not damage or a restriction
in the exhaust system components.
loose.

loose.

Lubrication
Turbocharger
lubrication
operation:
Result: The engine oil is dirty.
Drain the engine oil. Install the correct type

of engine oil. Replace the engine oil filter.
4. Inspect the Engine Oil
Engine Oil Verify that the problem is resolved.
A. Inspect the engine oil.
5. Check the Engine Oil Engine oil Result: The incorrect oil is being used.
A. Verify that the correct type of engine oil is Drain the engine oil. Replace the engine oil
being used. filter. Install the correct type of engine oil.
The oil supply line must be repaired or

6. Check the Engine Oil Supply Line replaced.
A. Inspect the oil supply line from the engine oil Restrictions Verify that the problem is resolved.

has a restriction.

restriction.

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

build-up.
Remove the carbon.

build-up. Result: The turbocharger rotor does not
have carbon build-up.
Result: The engine rpm increases too


10. Verify the Engine RPM
Engine RPM

excessive time.

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

12. Inspect the Fuel Injection Pump for Fuel pump operating correctly.
Proper Operation
A. Test the fuel injection pump for proper replaced.
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 damage
to the valves.
13. Inspect the Intake and Exhaust 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.

replaced.
Leaks
leaks.

15. Inspect the Turbocharger for a Restriction the bearing housing.
Restriction
A. Inspect the turbocharger for a restriction in turbocharger must be replaced.


housing for the engine oil filter. Check the
16. Inspect the Engine Oil Filter oil filter.
Oil Filter
A. Inspect the engine oil filter for a restriction. Verify that the problem is resolved.

restriction.

Engine operation
· Cooling system
· Valve lash
The rotating assembly of the turbocharger does not rotate freely.
Probable Cause
Table 18
1. Check for Proper Installation of the Air Air filter Result: The air filter element is not sealed
Filter Element properly.
A. Verify that the air filter element is sealed Inspect the air filter element and the air
supply line to the turbocharger for correct
properly. installation.

properly.

turbocharger.
Turbocharger
turbocharger.


replaced.
System
loose.
loose.

loose.

Lubrication
Turbocharger
lubrication
operation:

being used.

being used.
being used.
7. Check the Engine Oil Supply Line Restrictions Result: The oil supply line is restricted.
A. Inspect the oil supply line from the engine oil The oil supply line must be repaired or
replaced.



has a restriction.

restriction.

OK.



contain debris.

build-up.
Remove the carbon.



Engine RPM

14. Verify the High Idle Speed High idle excessive time.
A. Verify the high idle speed of the engine. Check the fuel injection pump for correct

an excessive time.

replaced.
Leaks
leaks.


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

Oil Filter

restriction.

Engine operation Result: The components listed are not
The engine may have stopped too soon from a operating properly.

A. Check the following components for correct replaced.
· Cooling system
· Valve lash
Worn bearings, bearing bores, and journals
Probable Cause
Table 19

turbocharger.
Turbocharger
turbocharger.
2. Check for Restriction in the Exhaust Restriction/damage Result: There is damage or a restriction in
System the exhaust system components.
A. Check for damage or a restriction in the The component must be repaired or

exhaust system components. replaced.

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 the Turbocharger Verify that the problem is resolved.
loose. Result: The turbocharger is not loose or the
loose.

Lubrication
Turbocharger
lubrication
operation:
5. Check the Engine Oil Engine oil Result: The incorrect type of engine oil is
being used.
A. Verify that the correct type of engine oil is
being used. Drain the engine oil. Install the correct
quantity and type of engine oil.
being used.




Engine RPM


A. Verify the high idle speed of the engine. operation and settings.

an excessive time.

replaced.
Leaks
leaks.

Oil Filter

restriction.

· Cooling system

· Valve lash
The turbocharger makes excessive noise.
Probable Cause
Table 20
Result: The air filter element is dirty or has

restrictions.

Element
Result: The air filter element is not dirty or
Result: The air filter element is not sealed

properly.
Inspect the air filter element and the air

2. Check for Proper Installation of the Air supply line to the turbocharger for correct
Filter Element installation.
Air filter
A. Verify that the air filter element is sealed Verify that the problem is resolved.
properly.
properly.
3. Check for a Restriction in the Tube Restriction/damage Result: There is damage or a restriction to
between the Air Filter and the the tube between the air filter and the
Turbocharger turbocharger.
A. Check for damage or a restriction in the tube Find the restriction and repair or replace the
between the air filter and the turbocharger. 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
Find the leak or restriction and repair or
the Tube between the Intake Manifold and
the Turbocharger
Air leak or
A. Check for a leak or a restriction in the tube restriction
between the intake manifold and the
Result: There is not a leak or a restriction to
turbocharger.
the tube between the intake manifold and the
turbocharger.


replaced.
System
loose.


loose.
Result: The intake manifold has cracks,

The intake manifold must be repaired or

7. Inspect the Intake Manifold replaced.
A. Inspect the intake manifold for cracks, loose Intake manifold Verify that the problem is resolved.
Result: The intake manifold does not have
cracks, loose bolts, or a distorted 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 cracks, Exhaust manifold
Result: The exhaust manifold does not have
cracks, loose bolts, or a distorted flange.
9. Check for Turbocharger for Proper Turbocharger Result: The components listed are not
Lubrication lubrication operating properly.
The flow of engine oil is delayed to the The component must be repaired or
turbocharger when the engine is started. replaced.
the engine is running. Verify that the problem is resolved.
A. Check the following components for correct Result: The components listed are operating
operation: properly.
· Engine oil pump Proceed to Test Step 10.

Result: The incorrect oil is being used.
Drain the engine oil. Replace the engine oil

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


OK.



contain debris.

build-up.
Remove the carbon.



Engine RPM

A. Verify the high idle speed of the engine. Check the fuel injection pump for correct

an excessive time.

replaced.
Leaks
leaks.


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

Oil Filter

restriction.


· Cooling system
· Valve lash
Sludge or carbon deposits in the bearing housing
Probable Cause
Table 21

restrictions.
The crankcase breather (if equipped), or the

1. Check for Restrictions in the Crankcase
tubing must be cleaned or replaced.
Breather
Restrictions Verify that the problem is resolved.
A. Check the crankcase breather for
restrictions.
have restrictions.
2. Check for Turbocharger for Proper Turbocharger Result: The components listed are not
Lubrication lubrication operating properly.
The flow of engine oil is delayed to the The component must be repaired or
turbocharger when the engine is started. replaced.
the engine is running. Verify that the problem is resolved.
A. Check the following components for correct Result: The components listed are operating
operation: properly.
· Engine oil pump Proceed to Test Step 3.


being used.

being used.
being used.



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



Engine RPM

replaced.
Leaks
leaks.

9. Inspect the Engine Oil Filter Oil Filter
A. Inspect the engine oil filter for a restriction. housing for the engine oil filter. Check the
oil filter.

restriction.

Engine operation
· Cooling system
· Valve lash
Troubleshooting the Engine

When you are troubleshooting the engine, refer to the Specifications Module and the Systems Operation, Testing and
Adjusting Module for additional information.
The engine will not start.
Probable Cause
Table 22
1. Interview the Operator Starting Result: The engine

procedures starting procedure
A. Ensure the engine starting procedure was followed. was incorrectly
followed.
Ensure that the engine

starting procedure is
correctly followed.
Verify that the

problem is resolved.
Result: The engine

starting procedure
was correctly
followed.
Proceed to Test Step

2.
Result: The manual

valve in the fuel line is
closed.
Open the valve.
2. Check the Fuel Shutoff Valve Verify that the

Fuel valve
A. Make sure the fuel shutoff valve is Open.
Result: The manual
valve in the fuel line is
open.

3.
Result: The fuel level

is low in the fuel tank.
Fill the fuel tank with

fuel. Remove the air
from the fuel system.
3. Check the Fuel Level
Verify that the
Fuel level problem is resolved.
A. Check the fuel level.
Result: The fuel level
is not low in the fuel
tank.

4.
4. Check the Fuel Quality Contamination Result: The fuel
contains water, dirt,

A. Check the fuel for contamination. ice, or wax.
Replace the fuel

filters. Replace the
fuel in the fuel tank
with clean fuel.
Verify that the

Result: The fuel does

not contain water,
dirt, ice, or wax.

5.
Result: Engine
cranking speed is too
slow.
Make the necessary

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

6.
6. Check the Engine Glow Plugs Engine Glow Result: The glow
Plugs plugs for the fuel
A. Inspect the cable connections and the electrical connections of the glow injection pump do not
plugs and the electrical components of the starting aid circuit. Test the glow operate correctly.
plugs for correct operation.
Make the necessary
repairs.
Verify that the

Result: The glow

plugs for the fuel
injection pump
operate correctly.

7.
Result: The fuel

shutoff solenoid is not
operating correctly.
Replace a fuel shutoff

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

shutoff solenoid is

8.
8. Check the Operation of the Fuel Transfer Pump Fuel transfer Result: The
pump operation of the fuel
A. Check the fuel pressure when the engine is cranking. Refer to the transfer pump is not
Specifications Module, "Fuel Transfer Pump" topic for additional correct.
information.
Remove the fuel
transfer pump if the
fuel pressure is too
low. The fuel transfer
pump must be
Verify that the

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

9.
Result: The fuel filter

or the fuel lines are
restricted.
Replace the suspect

component.
9. Check the Fuel Filter
Verify that the
Fuel filter/fuel
A. Check the fuel filter and fuel lines for restrictions. problem is resolved.
lines
Drain any water from the fuel filter.
Result: The fuel filter
or the fuel lines are
not restricted.

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

A. Inspect the governor and the fuel injection linkage for damage or the fuel linkage governor or the fuel
injection linkage for incorrect assembly in the timing gear case. injection linkage.
Make the necessary

repairs.
Verify that the

Result: There is not

a problem with the
governor or the fuel
injection linkage.

12.
12. Inspect the Fuel Injection Nozzles Fuel Injection Result: A fuel
Nozzles injection nozzle is not
A. Run the engine at the rpm that gives maximum misfiring or rough running. operating correctly.
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
loosened. If loosening the fuel line nut does not affect the operation of the fuel injection nozzle.
engine, the fuel injection nozzle is probably suspect. Test the fuel injection Make sure that all of
nozzle for that cylinder. the fuel injection
nozzles are the
B. Make sure that the fuel injection nozzles are properly sealed in the correct type for the
threaded ports. Make sure that the fuel injection nozzles are correctly engine. Test the
aligned in the threaded ports. Make sure that the fuel injection nozzles are pressure setting of the
tightened to the correct torque. Ensure that the gaskets and the seat fuel injection nozzles.
washers are installed on the fuel injection nozzles correctly. Make sure that Refer to the
the bottom of the threaded ports are clean and free of debris. Make sure Specifications
that the bottom of the threaded ports do not contain extra gaskets. Module, "Fuel
Injection Nozzles"
topic for additional
information.
Verify that the

Result: The fuel

injection nozzles are
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
following conditions: have low
compression.
· Piston rings are worn or broken.
· The piston height is incorrect. Cylinder Make the necessary
· The piston is damaged. compression repairs.
· The fuel injection nozzles are not seated correctly.
· The valve lash requires adjustment. Verify that the
· The fuel injection pump timing is incorrect. problem is resolved.
· The engine timing is incorrect.
· When an inlet valve or an exhaust valve is fully seated, gases leak past the
valve head.
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.

Replace the fuel filter. Drain any water from
1. Inspect the Fuel System
the fuel filter.
Fuel
A. Check the fuel filter or the fuel lines for restrictions.
System Verify that the problem is resolved.
Excess water can build up in the fuel filter.
Result: The fuel filter or the fuel lines are
not restricted.
2. Check the Operation of the Fuel Transfer Pump Fuel Result: The operation of the fuel transfer
transfer pump is not correct.
A. Check the fuel pressure when the engine is cranking. pump
Refer to the Specifications Module, "Fuel Transfer Pump" Remove the fuel transfer pump if the fuel
topic for additional information. pressure is too low. The fuel transfer pump
must be repaired or replaced.
Result: The operation of the fuel transfer

pump is correct.
Result: The air inlet or the exhaust system is

restricted.
Remove any restrictions.

3. Inspect the Air Inlet and Exhaust System Air inlet
and Verify that the problem is resolved.
A. Check the air inlet and exhaust system for restrictions.. exhaust
system 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
Air in the Find the air leak in the fuel system. Repair
fuel the fuel system.
A. Inspect the fuel system for air leaks in the system.
system
The engine misfires or the engine runs rough.
Probable Cause
Table 24
1. Measure the Fuel Pressure Fuel Pressure Result: The fuel

pressure is low.
A. Make sure that sufficient fuel is in the fuel tank. Remove any air in the fuel
system. Make the necessary
repairs.
B. Look for leaks or suspect bends in the fuel line between the fuel tank and
the fuel transfer pump. Verify that the
C. Check the outlet pressure of the fuel transfer pump.
Result: The fuel
pressure is not low.

2.
Result: Air is in the

fuel system.
Find the air leak in

the fuel system.
Repair the fuel
system.
2. Check for Air in the Fuel System
Air in the fuel
Verify that the
A. Inspect the fuel system for air leaks in the system. system
Result: Air is not in

the fuel system.

3.
Result: The valve

lash is not correct.
Adjust the valve lash.
3. Check the Valve Lash Verify that the

Valve lash
A. Check the engine valve lash.
Result: The valve
lash is correct.

4.
4. Check the Timing for the Fuel Injection Pump Fuel injection Result: The
pump timing operation of the fuel
A. Check the timing of the fuel injection pump. Adjust the timing or replace injection pump is not
the fuel injection pump. Refer to the Specifications Module, "Fuel Injection correct.
Pump" topic for additional information.
The fuel injection
B. Check the operation of the fuel rack linkage. pump must be
C. Make sure that the high-pressure fuel lines are connected to the fuel
injection nozzles in the correct order. Verify that the
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 Result: The
damaged fuel lines or fittings must be repaired or replaced. operation of the fuel
injection pump is
correct.

5.
5. Inspect the Fuel Injection Nozzles Fuel Injection Result: A fuel

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

Result: The fuel

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
A. Check the engine mounts for proper installation. suspect components.
B. Check the engine mounts for correct positioning. Verify that the
Engine mounts
C. Check the bolts of the engine mounts for correct tightening.
Result: The engine
These conditions will cause a vibration. mounts are correctly
tightened and the
engine mounts are
mounted correctly.

7.
Result: The fuel

contains water, dirt,
ice, or wax.
Replace the fuel

filters. Replace the
fuel in the fuel tank
with clean fuel.
7. Check the Fuel Quality
Verify that the
Contamination
A. Check the fuel for contamination. problem is resolved.
Result: The fuel

does not contain
water, dirt, ice, or
wax.

8.
8. Check the Cylinder Compression Cylinder Result: The

compression cylinders have low
A. Starting the engine may be difficult in warm weather. The engine may not compression.
start in cold weather. Low compression is most frequently caused by the
following conditions: Make the necessary
repairs.
· The piston height is incorrect. Verify that the
· The piston is damaged. problem is resolved.
· The valve lash requires adjustment.
· The fuel injection pump timing is incorrect.
· When an inlet valve or an exhaust valve is fully seated, gases leak past the
valve head.
The engine runs evenly, but the engine loses power.
Probable Cause
Table 25
1. Check the Engine for Low Compression

Result: The cylinders have
A. Starting the engine may be difficult in warm weather. The engine low compression.
may not start in cold weather. Low compression is most frequently
caused by the following conditions: Repair or replace the engine
component causing low
· Cylinder walls are worn or damaged. compression.
Low
· The piston height is incorrect. Verify that the problem is
compression
· The piston height is incorrect. resolved.
· The valve lash requires adjustment. Result: The cylinders do not
· The fuel injection pump timing is incorrect. have low compression.
· When an inlet valve or an exhaust valve is fully seated, gases leak Proceed to Test Step 2.
past the valve head.
2. Check the Timing for the Fuel Injection Pump Fuel injection Result: The operation of the
pump timing fuel injection pump is not
A. Check the timing of the fuel injection pump. Adjust the timing or correct.
replace the fuel injection pump. Refer to the Specifications Module,

"Fuel Injection Pump" topic for additional information. The fuel injection pump must
be repaired or replaced.
B. Check the operation of the fuel rack linkage.
C. Make sure that the high-pressure fuel lines are connected to the resolved.
fuel injection nozzles in the correct order.
Result: The operation of the
D. Make sure that the mounting bolts of the fuel injection pump are fuel injection pump is correct.
restrictions. The damaged fuel lines or fittings must be repaired or Proceed to Test Step 3.
replaced.
Result: The valve lash is not

correct.

3. Check the Valve Lash
Valve lash resolved.
Result: The valve lash is
correct.
Result: The air filter element

is dirty or has restrictions.

Air filter
resolved.
A. Check the condition of the air filter element. element
Result: The air filter element
is not dirty or does not have
restrictions.
5. Check for Air in the Fuel System Air in the fuel Result: Air is in the fuel
system system.
A. Inspect the fuel system for air leaks in the system.

Find the air leak in the fuel
system. Repair the fuel
system.

resolved.
Result: Air is not in the fuel

system.
Result: The fuel transfer

pump is not operating
correctly.
6. Check the Fuel Transfer Pump for Proper Operation
The fuel transfer pump must
be repaired or replaced.
A. Check the fuel pressure when the engine is cranking. Refer to the
Fuel Install the fuel transfer pump
Specifications Module, "Fuel Transfer Pump" topic for additional
pressure with the lobe of the camshaft
information.
on minimum lift. Tighten the
Remove the fuel transfer pump if the fuel pressure is too low.
mounting bolts evenly.

resolved.
The engine lacks power.
Probable Cause
Table 26
1. Test the Quality of the Fuel Fuel Result: The fuel quality
quality does not meet the engine
A. Test the quality level of the fuel, make sure the fuel quality meets the specifications.
engine specifications.
Remove the fuel from the
fuel tank. Install a new fuel
filter. Put a good grade of
clean fuel in the fuel tank.

resolved.
Result: The fuel quality

meets the engine
specifications.
Result: The fuel pressure

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

with the governor or the
fuel injection linkage.
Make the necessary

repairs.
3. Inspect the Fuel Injection Linkage and the Governor
Governor
and fuel Verify that the problem is
A. Inspect the governor and the fuel injection linkage for damage or the fuel
injection resolved.
injection linkage for incorrect assembly in the timing gear case.
linkage
Result: There is not a
problem with the governor
or the fuel injection linkage.
4. Measure the Valve Lash Valve Result: The valve lash

lash exceeds the specification.
A. Measure the valve lash.
Adjust the valve lash. Refer
to the Specifications
Module, "Engine Design"

topic for the valve lash
setting.

resolved.

within the specification.
5. Inspect the Operation of the Fuel Injection Pump Result: The operation of
the fuel injection pump is
A. Check the timing of the fuel injection pump. Adjust the timing or replace not correct.
the fuel injection pump. Refer to the Specifications Module, "Fuel Injection
Pump" topic for additional information. The fuel injection pump must be Make the necessary
repaired or replaced. repairs.
Fuel
B. Make sure that the linkage of the fuel rack operates correctly. Verify that the problem is
Injection
resolved.
Pump
C. Make sure that the high pressure fuel lines are connected to the fuel
injection nozzles in the correct order. Result: The operation of
the fuel injection pump is
D. Make sure that the mounting bolts of the fuel injection pump are correct.
restrictions. The damaged fuel lines or fittings must be repaired or replaced. Proceed to Test Step 6.
6. Inspect the Fuel Injection Nozzles Fuel Result: A fuel injection

Injection nozzle is not operating
A. Run the engine at the rpm that gives maximum misfiring or rough running. Nozzles correctly.
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 operation of the injection nozzle.
engine, the fuel injection nozzle is probably suspect. Test the fuel injection Make sure that all of the
nozzle for that cylinder. fuel injection nozzles are the
correct type for the engine.
B. Make sure that the fuel injection nozzles are properly sealed in the Test the pressure setting of
threaded ports. Make sure that the fuel injection nozzles are correctly the fuel injection nozzles.
aligned in the threaded ports. Make sure that the fuel injection nozzles are Refer to the Specifications
tightened to the correct torque. Ensure that the gaskets and the seat Module, "Fuel Injection
washers are installed on the fuel injection nozzles correctly. Make sure that Nozzles" topic for
the bottom of the threaded ports are clean and free of debris. Make sure additional information.
that the bottom of the threaded ports do not contain extra gaskets.
resolved.
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 the
information.
pulley is not damaged.
Result: The engine mounts are loose, worn, or suspect.

2. Inspect the Engine Mounts
Tighten all mounting bolts. Inspect the engine mounts for
Engine
A. Inspect the engine mounts for loose bolts or wear or for damage. Use new parts for replacement.
mounts
damage.
The engine has excessive combustion noise.
Probable Cause
Table 28
1. Test the Quality of the Fuel Fuel Result: The fuel quality
quality does not meet the engine
A. Test the quality level of the fuel, make sure the fuel quality meets the specifications.
engine specifications.
Remove the fuel from the
fuel tank. Install a new fuel

filter. Put a good grade of
clean fuel in the fuel tank.

resolved.
Result: The fuel quality

meets the engine
specifications.
Result: A fuel injection

nozzle is not operating
correctly.
Replace the suspect fuel

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

height is incorrect.
A. Measure the engine piston height.
To obtain the correct
piston height, the piston,
the piston pin, the bearings,
or the connecting rod

should be replaced.

resolved.
The engine has excessive valve compartment noise.
Probable Cause
Table 29
Troubleshooting Test
Values Results
Steps
Result: Valve springs or locks are broken.
Install new parts. Broken locks can cause the valve to slide into the
1. Inspect the Valve
cylinder. Major damage to the engine can occur.
Springs and Locks
Valve springs
A. Inspect the valve springs and locks
and locks for damage.
Result: Valve springs or locks are not broken.
Result: The bolts and nuts, which hold the rocker arm assembly, are
loose.
Tighten the bolts or nuts. Refer to the Specifications Module,

2. Inspect the Rocker
"Rocker Shaft" topic for additional information.
Arms
Rocker arm
A. Inspect the rocker arm assemblies
assemblies for damage.
Result: The bolts and nuts, which hold the rocker arm assembly, are
not loose.
3. Measure the Valve Valve lash Result: The valve lash exceeds the specification.
Lash
Adjust the valve lash. Refer to the Specifications Module, "Engine
Design" topic for the valve lash setting.
A. Measure the valve lash.

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 and

1. Inspect the Engine Oil Cooler Core
Assembly, "Engine Oil Cooler - Remove" and
Disassembly and Assembly, "Engine Oil Cooler -
A. Drain the coolant from the engine and the
Install". Fit new seals between the oil cooler and the oil
radiator. Drain the lubricating engine oil from the
cooler cover.
engine oil cooler. Refer to the Operation and Engine
Refill the crankcase with clean engine oil to the correct
Maintenance Manual for more information. Oil
level. Refer to the Operation and Maintenance Manual
Cooler
for more information.
B. Inspect the engine oil cooler core for leaks. Core
Refer to Systems Operation, Testing and
Adjusting, "Cooling System - Inspect" for the
correct procedure.
Result: The engine oil cooler does not have leaks.
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 have faults
B. Inspect the cylinder head gasket for faults and
or signs of leakage.
any signs of leakage.
3. Inspect the Cylinder Head Cylinder Result: The cylinder head is not flat or has cracks.
head
A. Check the cylinder head for cracks. Repair the cylinder head and/or replace the cylinder
head.
B. Check the cylinder head for flatness. Refer to
Systems Operation, Testing and Adjusting, Verify that the problem is resolved.
"Cylinder Head - Inspect" for the correct
procedure. Result: The cylinder head is flat and does not have
cracks.
Result: The cylinder block has faults or signs of

leakage.
4. Inspect the Cylinder Block Replace the cylinder block. If signs of leakage are
found, determine the cause of the leakage. Refer to
Cylinder
A. Inspect the top face of the cylinder block for Systems Operation, Testing and Adjusting, "Cylinder
block
faults and signs of leakage. Block - Inspect" for the correct procedure.
After the Repair
A. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
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
1. Inspect the Main Bearings Main Result: The main

Bearings bearings are damaged.
A. Inspect the main bearings and the bearing surfaces of the crankshaft.
Replace damaged parts.
Verify that the problem

is resolved.
Result: The main

bearings are not
damaged.
Result: The crankshaft

is damaged.
Replace the crankshaft.

Clean the engine
thoroughly.
2. Inspect the Crankshaft
Crankshaft Verify that the problem
A. Inspect the crankshaft for damage..
is resolved.
Result: The crankshaft

is not damaged.
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
Height is 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 Fuel Result: A fuel injection

Injection nozzle is not operating
A. Run the engine at the rpm that gives maximum misfiring or rough running. Nozzles correctly.
nut at a time. Then, tighten that nut before the next fuel line nut is loosened. If Replace the suspect fuel
loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle.
injection nozzle is probably suspect. Test the fuel injection nozzle for that Make sure that all of the
cylinder. fuel injection nozzles are
the correct type for the
B. Make sure that the fuel injection nozzles are properly sealed in the engine. Test the
threaded ports. Make sure that the fuel injection nozzles are correctly aligned pressure setting of the
in the threaded ports. Make sure that the fuel injection nozzles are tightened fuel injection nozzles.
to the correct torque. Ensure that the gaskets and the seat washers are Refer to the
installed on the fuel injection nozzles correctly. Make sure that the bottom of Specifications Module,
the threaded ports are clean and free of debris. Make sure that the bottom "Fuel Injection Nozzles"
of the threaded ports do not contain extra gaskets. topic for additional
information.
C. Ensure the projection of the fuel injection nozzles are positioned correctly
in the precombustion chamber. Verify that the problem
is resolved.
The rocker arm has insufficient movement and the valve lash exceeds the specification.
Probable Cause
Table 32
Result: Lubrication of
internal engine components
is inadequate.
Make the necessary repairs.

1. Check the Lubrication of Internal Components
A. Check lubrication of the valves. There must be a strong flow of oil at
Lubrication resolved.
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.
2. Check the Rocker Arms for Wear or Damage Damage or Result: Rocker arm parts
wear are worn.
A.Visually inspect the rocker arms for wear or damage.
If there is too much wear,
install new parts or rocker
arms. Adjust the valve lash.

resolved.
Result: Rocker arm parts

are not worn.
Result: The end of the

valve stem is worn.
Install new valves. Adjust

the valve lash.
3. Inspect the Valve Stems
Damage or Verify that the problem is
A. Inspect the valve stems for wear. wear resolved.
Result:The end of the valve

stem is not worn.

not correct.

4. Check the Valve Lash
Valve lash resolved.
correct.
5. Inspect the Engine Pushrods Damage or Result: The pushrods are

wear worn.
A. Visually inspect the pushrods for wear or damage.
install new pushrods. Adjust
the valve lash.

resolved.
Result: The pushrods are

not worn.
Result: The valve lifters are

worn.

install new valve lifters.
6. Inspect the Valve Lifters
Damage or
A. Visually inspect the valve lifters for wear or damage. wear
resolved.
Result: The valve lifters are

not worn.
Result: The components

are worn.
7. Inspect the Camshaft
Replace suspect parts.
A. Measure the valve lash. Adjust 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
D. Check for wear on the valve lifters. are not worn.
8. Inspect the Rocker Arm Assembly Damage or Result: The bolts and the
wear nuts that hold the rocker
A. Visually inspect the rocker arms for wear, damage or loose bolts.. arm assembly are loose.
Tighten the bolts and the

nuts.

resolved.
A cylinder head valve is loose.
Probable Cause
Table 33
Values Results
Steps
Result: The valve keeper for the valve is broken.
Replace the valve keeper. Broken keepers can cause the valve to slide into
1. Inspect the Valve
the cylinder. Major engine damage can result.
Keepers
Valve
A. Inspect the engine valve keepers
keepers for damage.
Result: The valve keeper for the valve is not broken.
2. Inspect the Valve Result: The valve springs are broken or damaged.
Springs
Valve Install new valve springs.
A. Inspect the valve springs springs
for damage.. Verify that the problem is resolved.
Oil condenses at the exhaust.
Probable Cause
Table 34
1. Inspect the Valve Valve Result: The valve compartment contains too much oil.
Compartment compartment
Look at both ends of the rocker arm shaft. Be sure that a plug is
A. Inspect the valve installed in each end.
compartment for excessive oil.. Verify that the problem is resolved.
Result: The valve compartment does not contain too much oil.
Result: The valve guides are worn.
Install new valve guides. Recondition the cylinder head.

2. Inspect the Valve Guides
A. Measure the timing of the Timing
fuel injection pump.
Result: The valve guides are not worn..
Result: The piston rings are worn.

3. Inspect the Engine Piston
Rings Replace worn parts.
The piston rings are worn. Refer to the Specifications Module,
Piston rings
A. Inspect the engine piston "Pistons and Rings" topic for additional 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 worn.

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

oil filter. Put clean oil in the engine.
Oil Verify that the problem is resolved.
Result: Dirt is not in the engine oil.
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 Result: Fuel is in the engine oil.
oil pressure. Inspect the engine for the following leaks:
Fuel Replace the damaged component.
· Fuel leaks into the crankcase from the fuel transfer pump. leak
· Fuel leaks past the valve in a fuel injection nozzle. Verify that the problem is resolved.
· 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
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Result: The cylinder head gasket is damaged.
Install a new cylinder head gasket.

1. Inspect the Cylinder Head Gasket
A. Inspect the cylinder head gasket for Head gasket
damage.
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 head
A. Inspect the cylinder head for damage.
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 Low Result: The cylinders
compression have low
A. Starting the engine may be difficult in warm weather. The engine may not compression.
start in cold weather. Low compression is most frequently caused by the
following conditions: Repair or replace the
engine component
· Cylinder walls are worn or damaged. causing low

· Piston rings are worn or broken. compression.
· The piston height is incorrect.
· The piston height is incorrect. Verify that the problem
· The fuel injection nozzles are not seated correctly. is resolved.
· The valve lash requires adjustment.
· The fuel injection pump timing is incorrect. Result: The cylinders
· The engine timing is incorrect. do not have low
· When an inlet valve or an exhaust valve is fully seated, gases leak past the compression.
valve head.
2.
Result: A fuel
injection nozzle is not
Replace the suspect

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

3.
3. Inspect the Operation of the Fuel Injection Pump Fuel Result: The operation
of the fuel injection
A. Check the timing of the fuel injection pump. Adjust the timing or replace Injection pump is not correct.
the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump
Pump" topic for additional information. The fuel injection pump must be Make the necessary
repaired or replaced. repairs.
B. Make sure that the linkage of the fuel rack operates correctly. Verify that the problem
is resolved.
C. Make sure that the high pressure fuel lines are connected to the fuel
injection nozzles in the correct order. Result: The operation
of the fuel injection
D. Make sure that the mounting bolts of the fuel injection pump are tightened pump is correct.
to the correct torque. Inspect the fuel lines for leaks or for restrictions. The
damaged fuel lines or fittings must be repaired or replaced. Proceed to Test Step
4.
Result: There is a
restriction in the air
inlet system.
4. Inspect the Air Inlet System
The air cleaner must
Restriction be cleaned or
A. Check the air cleaner for restrictions.
replaced.

is resolved.
The engine exhaust has too much white smoke or too much blue smoke.
Probable Cause
Table 39
1. Check the Oil Level Oil level Result: The engine contains too much engine
oil.
A. Check the engine oil level.
Drain the excess engine oil from the engine oil
pan.
Result: The engine does not contain too much

engine oil.
Result: The timing of fuel injection pump is

incorrect.
Adjust the timing. Refer to the Specifications

Module, "Fuel Injection Pump" topic for
2. Inspect the Fuel Injection Pump Timing
additional information.
A. Check the fuel injection pump for the correct Timing
timing.
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.
Replace worn parts.

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

Temperature suspect.
A. If the engine consistently runs below the normal
operating temperature, inspect the water Replace the water temperature regulator.
temperature regulator.
Result: The water temperature regulator is not

suspect.
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 assembly, and
Restrictions
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.

1. Check the Oil Level
Oil level
A. Check the engine oil level.
Result: The engine oil level is not low.
2. Inspect the Engine Oil Filter Oil filter Result: The engine oil filter is
restricted.
A. Inspect the engine oil filter for restrictions.
Install a new engine oil filter. Replace
the oil in the engine with clean engine
oil. Check the operation of the engine
oil bypass valve for the engine oil filter.
Result: The engine oil filter is not

restricted.
3. Inspect the Engine Oil for Fuel Result: Fuel is in the engine oil.
A. Fuel leaks will cause high fuel consumption and low Replace the damaged component.
engine oil pressure. Inspect the engine for the following leaks:
Fuel leak
· Fuel leaks into the crankcase from the fuel transfer pump.
· Fuel leaks past the valve in a fuel injection nozzle. Result: Fuel is not in the engine oil.
· The pressure setting of the fuel injection nozzles is too high.
· The drive is broken on the fuel injection pump. Proceed to Test Step 4.
Result: The clearance is not within

specifications.
Make the necessary repairs.

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

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

proper lubrication.
6. Inspect the Oil Pump Suction Tube Suction Result: The suction tube is loose or
tube damaged.
A. Inspect the oil pump suction tube for damage or a loose
connection. The suction tube must be repaired or
replaced.
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
bypass
A. Inspect oil pump bypass valve for proper operation. Verify that the problem is resolved.
valve
Result: The engine oil bypass valve
operates correctly.
Result: The engine oil pump does not

operate correctly.
8. Inspect the Engine Oil Pump
The components must be repaired or
A. Inspect the engine oil pump for proper operation. replaced.
B. Check the distance of the face of the cover of the oil Oil pump Verify that the problem is resolved.
pump above the face of the idler gear. Refer to the
Specifications Module, "Engine Oil Pump" topic. Check the Result: The engine oil pump operates
wear of the lobe on the oil pump. correctly.
9. Inspect the Crankshaft Clearance Result: The clearance is not within

specifications.
A. Measure the clearance between the crankshaft and the

crankshaft bearings. Replace the crankshaft or the
crankshaft bearings. Refer to the
Specifications Module, "Crankshaft"
topic for additional information.
Result: The clearance is within

specifications.
Result: The clearance is not within

specifications.
10. Inspect the Camshaft
Replace the camshaft or the camshaft
A. Measure the clearance between the camshaft and the Clearance
bearings.
camshaft bearings.
The engine oil pressure is too high.
Probable Cause
Table 41
Result: The engine oil bypass valve does not

1. Inspect the Engine Oil Bypass Valve open.
Bypass
A. Inspect the engine oil bypass valve for proper The bypass valve must be cleaned or replaced.
valve
operation.
The engine uses too much engine oil.
Probable Cause
Table 42
Values Results
Steps
Result: The engine contains too much engine oil.
Drain the excess engine oil from the engine oil pan.
1. Check the Oil Level
A. Check the engine oil
level
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
leaks
leaks.
Result: The engine oil lines do not have leaks.
3. Inspect the Engine Replace the valve guides.

Valve 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 Rings Replace worn parts.
Piston The piston rings are worn. Refer to the Specifications Module, "Pistons and
A. Inspect the engine piston rings Rings" topic for additional information.
rings for wear.
The engine overheats.
Probable Cause
Table 43
Result: The air flow through the radiator is

restricted.
Clean the exterior of the radiator in order to

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

properly.
Replace the faulty pressure cap.

3. Inspect the Coolant Pressure Cap
Coolant
Pressure
A. Test the operation of the pressure cap.
Cap
Result: The coolant pressure cap is working
properly.
4. Inspect the Cooling System Cooling Result: Gases from combustion are in the
System coolant.
A. Inspect the cooling system for gases from
combustion. Find the source of the entry of the gases from
combustion into the coolant system. Repair the
source of the problem.
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. Verify that the problem is resolved.
Regulator
Refer to the Systems Operation, Testing and
Adjusting Module or the Specifications Module for Result: The water temperature regulator is not
additional information. suspect.
Result: The water pump is suspect.
The water pump must be repaired or replaced.

6. Inspect the Water Pump
Water Verify that the problem is resolved.
A. Test the water pump for proper operation.. pump
Result: The water pump is not suspect.
7. Operating Conditions Load Result: The engine is operating with too much
load.
A. Check the load the engine is operating under.
Reduce the load.
Result: The engine is not operating with too
much load.

incorrect.
8. Inspect the Fuel Injection Pump Timing
Adjust the timing. Refer to the Specifications
A. Check the fuel injection pump for the correct Timing Module, "Fuel Injection Pump" topic for
timing. 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 Remove the restriction.

Exhaust System
Restriction
A. Inspect the air inlet and exhaust
system, look for a restriction. Result: There is not a restriction in the air inlet or exhaust system.
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
Specifications Module, "Fuel Injection Pump" topic for additional
Timing
A. Measure the timing of the fuel 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
1. Measure the Charge of the cable clamps and to battery posts. Tighten the cable clamps on the
the Battery battery posts.
Battery
voltage
A. Measure the battery voltage. Verify that the problem is resolved.
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.
Result: The ignition switch, the start relay, or the starting motor
solenoid are not operating properly.
3. Inspect the Ignition Switch,
the Start Relay, and the
Replace or repair the components that are not operating properly.
Starting Motor Solenoid
Starter Verify that the problem is resolved.
A. Inspect the ignition switch,
circuit
the start relay, and the starting
Result: The ignition switch, the start relay, or the starting motor
motor solenoid for proper
solenoid are operating properly.
operation.
4. Inspect the Starting Motor Voltage Result: An excessive voltage drop exists in the cables or across the
Circuit drop terminals in the circuits for the starting motor.
A. Inspect the starting motor Replace the damaged parts.
circuit for a voltage drop.

B. Inspect the battery cables
and battery terminals for loose
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.
Replace the overrunning clutch.

1. Inspect the Pinion Drive
Pinion Verify that the problem is resolved.
A. Inspect the overrunning clutch for the pinion
drive
drive.
Result: The overrunning clutch for the pinion
drive does not slip.
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.
3. Inspect the Shift Lever Shift lever Result: The shift lever or the linkage is damaged.
A. Inspect the shift lever and linkage for damage. Replace the shift lever or the linkage.
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 not

4. Inspect the Starting Motor Solenoid operating properly.
Starter
A. Inspect the starting motor solenoid for proper Verify that the problem is resolved.
solenoid
operation.
Result: The starting motor solenoid is operating
properly.
Result: The armature or idler gear of the starting

5. Inspect the Armature or Idler Gear of the
motor is damaged.
Starting Motor
Starting
Replace the starting motor.
A. Inspect the armature or idler gear of the starting motor
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
1. Measure the Charge of the Battery Result: The battery has a low charge.
Battery voltage
Charge the battery. Replace a faulty battery. Clean all cable terminals
A. Measure the battery voltage. and battery posts. Apply the 1U-8267 Battery Saver and Cleaner on
the cable clamps and to battery posts. Tighten the cable clamps on the
battery posts.

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
relay
proper operation.
Result: The start relay is operation properly.
Result: An excessive voltage drop exists in the cables or across the

3. Inspect the Starting Motor
terminals in the circuits for the starting motor.
Circuit
Replace the damaged parts.
A. Inspect the starting motor
circuit for a voltage drop.
Voltage Verify that the problem is resolved.
drop
B. Inspect the battery cables and
Result: An excessive voltage drop does not exist in the cables or
battery terminals for loose
across the terminals in the circuits for the starting motor.
connections, corrosion, or other
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
1. Inspect the Ignition Switch, the Start Relay, Starter Result: The ignition switch, the start relay, or the
and the Starting Motor Solenoid circuit starting motor solenoid are not operating properly.
A. Inspect the ignition switch, the start relay, and the Replace or repair the components that are not
starting motor solenoid for proper operation. operating properly.
The pinion gear does not disengage after the engine starts to run.
Probable Cause
Table 49
Result: The return spring of the pinion solenoid is

damaged.
1. Inspect the Return Spring of the Pinion Replace the return spring of the pinion solenoid.
Solenoid
Return Verify that the problem is resolved.
A. Inspect the return spring of the pinion solenoid Spring
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
A. Inspect the shift lever and linkage for damage. lever
Result: The shift lever or the linkage is not
damaged.
3. Inspect the Ignition Switch, the Start Relay, Starter Result: The ignition switch, the start relay, or the
and the Starting Motor Solenoid circuit starting motor solenoid are not operating properly.
A. Inspect the ignition switch, the start relay, and the Replace or repair the components that are not
operating properly.
starting motor solenoid for proper operation.

The alternator does not charge the battery or the alternator charge rate is slow or
irregular.
Probable Cause
Table 50
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. 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. Replace a

2. Inspect the Alternator
damaged pulley.
Drive Pulley
Drive
A. Inspect the pulley for wear pulley
or for damage.
Result: The drive pulley for the alternator is not loose or worn.
3. Inspect the Electrical Electrical Result: The electrical cables and connections in the charging and
Connections connections starting circuits are loose or damaged.
A. Inspect the electrical cables Inspect all cables and connections. All connections must be clean
and connections in the charging and tight. Apply the 1U-8267 Battery Saver and Cleaner on the
and starting circuits. cable terminals and the connections. Replace suspect parts.
Result: The electrical cables and connections in the charging and
starting circuits are not loose or damaged.
4. 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 properly.
Alternator
· Regulator or the field winding
of the rotor
· Brushes
· Rectifier
The alternator charges the battery to a voltage that is too high.
Probable Cause
Table 51
1. Check the Alternator for Proper

Operation Result: One of the components is not operating
properly.
A. Test the following alternator components:
Alternator Replace the component that is not operating properly.
· Regulator or the field winding of the rotor
· Brushes Verify that the problem is resolved.
· Rectifier
The alternator is noisy.
Probable Cause
Table 52
1. Inspect the Alternator Drive Belt Drive belt Result: The drive belt for the alternator is loose.
A. Verify that the tension is correct on the The drive belt must be adjusted or replaced.
drive belt.
B. Inspect the drive belt for wear and for
damage. Result: The drive belt for the alternator is not loose.
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 Pulley Replace a damaged pulley.
Drive
A. Inspect the pulley for wear or for Verify that the problem is resolved.
pulley
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 pulley
alignment
and drive belt.
Result: The drive belt and the drive pulley are in
alignment.
Result: The bearings of the alternator are worn or

4. Check the Alternator for Proper damaged.
Operation
Alternator Replace the alternator.
A. Inspect the alternator bearings.
C opyright 1993 - 2019 C ate rpillar Inc.

Fri Aug 16 2019 07:05:15 GMT+0400 (Gulf Standard Tim e )
All R ights R e se rve d.
Private Ne twork For SIS Lice nse e s.

Trouble Shooting

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8/16/2019 C7.

1 DE200E0/DE220E0 Generator Set GTY00001-UP(SEBP7395 - 11) - Documentation

Product: GENER ATO R SET

Testing and Adjusting

Troubleshooting The Fuel Injection Nozzles On The Engine

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 correctly

Result: The fuel injection nozzle is sealed correctly in

Proceed to Test Step 2.

Result: There is debris on the mounting surface of the

Result: A high-pressure fuel line is not leaking.

Proceed to Test Step 4.

Result: The correct fuel nozzles are not installed.

The Engine Exhaust has too Much Black Smoke

Result: There is debris on the mounting surface of the

positioned correctly. Proceed to Test Step 3.

C. Test the fuel injection nozzle on a nozzle tester

Result: The correct fuel nozzles are not installed.

Result: The fuel injection nozzle does not seal correctly

Result: The fuel injection nozzle is sealed correctly in

Proceed to Test Step 2.

the cylinder head.

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line that is

Proceed to Test Step 4.

4. Check for Correct Operation of the Fuel

Verify that the problem is resolved.

Result: The correct fuel nozzles are installed.

Proceed to Test Step 6.

Result: A low-pressure fuel line is leaking.

The Engine is Misfiring, Running Rough, or Running Poorly

Result: The fuel injection nozzle does not seal

Result: The fuel injection nozzle is sealed correctly in

Proceed to Test Step 2.

Proceed to Test Step 3.

Result: A high-pressure fuel line is leaking.

Repair or replace the high-pressure fuel line that is

Proceed to Test Step 4.

4. Check for Correct Operation of the

Result: The correct fuel nozzles are not installed.

Install the correct fuel nozzles.

Proceed to Test Step 6.

Verify that the problem is resolved.

Result: A high-pressure fuel line is not restricted or

Proceed to Test Step 7.

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

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester

Verify that the problem is resolved.

Result: There are no fuel leaks.through the

Proceed to Test Step 2.

Result: The valve has debris or is damaged.

Result: The opening pressure is not correct.

Proceed to Test Step 2.

Result: The fuel injection nozzle is not stuck.

Proceed to Test Step 3.

Result: The orifices are blocked or restricted.

Proceed to Test Step 4.

Result: The fuel return passage is blocked or restricted.

Troubleshooting the Turbocharger

Result: The air filter element is dirty or

The air filter element must be cleaned