Troubleshooting: Testing and Adjusting

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Testing and Adjusting

3054C Engines for Caterpillar Built Machines
Media Number -RENR2415-15 Publication Date -01/05/2015 Date Updated -16/01/2017
i05182663
Troubleshooting
SMCS - 1000
Introduction
Troubleshooting can be difficult. To make a repair to a problem, refer to the possible cause and
the corrective action. The most common problems are identified in this troubleshooting manual.
The symptoms, causes, and guidance for solving the problems are given.
The list of problems, causes, and corrections will only give an indication of the location of a
possible problem. There is also a list that shows some of the repairs that are required.
Sometimes additional repair work is required beyond the repair which is recommended.
Frequently, a problem does not exist in isolation. The problem can be a result of wear or of
damage to several parts which operate together as part of a system.
Service personnel may remember similar complaints which were corrected by a previous method
of troubleshooting. A similar complaint can have a different cause.
Get a good description of the problem from the operator and/or the person that owns the vehicle.
Knowing the details of the problem can save time. This will make the repair job faster and easier.
All possible problems and the probable causes cannot be listed. The technician must follow a
logical process of eliminating possible causes and of identifying the specific causes of the
problems.
Troubleshooting The Fuel Injection Nozzles On The Engine

Note: Be careful when you are handling the fuel injection nozzles in order to prevent damage to
the orifices, the threads, and other surfaces. When a fuel injection nozzle is installed, make sure
that all surfaces and threads are clean.
Only personnel that have the proper training should disassemble the fuel injection nozzles. Only
personnel that have the proper training should perform repairs to the fuel injection nozzle.
Replace the fuel injection nozzle if the fuel injection nozzle cannot be adjusted in order to operate
correctly.
Refer to Specifications, "Fuel Injection Nozzles" for additional information.
The Engine is Difficult to Start or the Engine Runs Rough
Probable Cause
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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 Sealed Correctly in the
Make sure that the fuel injection nozzle
Cylinder Head Fuel
is tightened to the correct torque in the
Injection
threaded hole of the cylinder head.
A. Verify that the fuel injection nozzle Nozzle
is sealed 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
2. Check for Debris on the Mating gaskets were left in the cylinder head
Surface of the Cylinder Head with for the fuel injection nozzle.
the Gaskets or the Insert
Remove any extra gaskets or debris.
A. Check for debris on the mating
surface of the cylinder head. Verify that the problem is resolved.
Debris
B. Make sure that extra gaskets were Result: There is no debris on the
removed from the threaded recess in mounting surface of the cylinder head
the cylinder head for the fuel injection or extra gaskets left in the cylinder head
nozzle. for the fuel injection nozzle.
3. Check the Connections of the High Fuel leak Result: A high-pressure fuel line is
Pressure Fuel Line leaking.
A. Check for a damaged or leaking Repair or replace the high-pressure fuel

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

leaking.
Result: The correct fuel nozzles are not

4. Check that the Correct Fuel installed.
Nozzles are Installed
Install the correct fuel nozzles.
Fuel
A. Verify that all fuel injection nozzles Refer to the Parts Manual for the correct
Nozzle
are the correct replacement parts for replacement part.
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
1. Check for Debris on the Mating gaskets were left in the cylinder head for
Surface of the Cylinder Head with the the fuel injection nozzle.
Gaskets or the Insert
surface of the cylinder head. Verify that the problem is resolved.
Debris
B. Make sure that extra gaskets were Result: There is no debris on the
removed from the threaded recess in the mounting surface of the cylinder head or
cylinder head for the fuel injection extra gaskets left in the cylinder head for
nozzle. the fuel injection nozzle.
2. Check for Correct Operation of the Fuel Result: The fuel nozzle is not operating
Fuel Nozzle Nozzle properly.
A. Make sure that the components of the Replace the fuel nozzle.
fuel injection nozzle are tightened to the
correct torques. Verify that the problem is resolved.
B. Make sure that the gaskets and the Result: The fuel nozzle is operating
insert are positioned correctly. properly.
C. Test the fuel injection nozzle on a Proceed to Test Step 3.

nozzle tester in order to measure the
pressure setting.
Result: The correct fuel nozzles are not

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

head are clean.
1. Check that the Fuel Injection
Make sure that the fuel injection nozzle
Cylinder Head Fuel
is tightened to the correct torque in the
Injection
threaded hole of the cylinder head.
A. Verify that the fuel injection nozzle Nozzle
is sealed correctly in the cylinder head.

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

or extra gaskets left in the cylinder head
for the fuel injection nozzle.
Result: A high-pressure fuel line is

leaking.
Repair or replace the high-pressure fuel

3. Check the Connections of the High
line that is leaking.
Pressure Fuel Line
Fuel leak Verify that the problem is resolved.
A. Check for a damaged or leaking
high-pressure fuel line.
Result: A high-pressure fuel line is not
leaking.
4. Check for Correct Operation of

the Fuel Nozzle Result: The fuel nozzle is not operating
properly.
A. Make sure that the components of
the fuel injection nozzle are tightened Replace the fuel nozzle.
to the correct torques.
Fuel Verify that the problem is resolved.
B. Make sure that the gaskets and the Nozzle
insert are positioned correctly. Result: The fuel nozzle is operating
properly.
C. Test the fuel injection nozzle on a
nozzle tester in order to measure the Proceed to Test Step 5.
pressure setting.
5. Check that the Correct Fuel Fuel Result: The correct fuel nozzles are not
Nozzles are Installed Nozzle installed.
A. Verify that that all fuel injection Install the correct fuel nozzles.
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

6.
leaking.
Pressure Fuel Line
Repair or replace the low-pressure fuel
A Fuel Leak
line that is leaking.
low-pressure fuel line.
The Engine is Misfiring, Running Rough, or Running Poorly
Probable Cause
Table 4
Result: The fuel injection nozzle

does not seal correctly in the cylinder
head.

1. Check that the Fuel Injection head are clean.
Cylinder Head Make sure that the fuel injection
Fuel Injection nozzle is tightened to the correct
A. Verify that the fuel injection Nozzle torque in the threaded hole of the
nozzle is sealed correctly in the cylinder head.
cylinder head.

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

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

leaking.
Repair or replace the high-pressure

3. Check the Connections of the
fuel line that is leaking.
High Pressure Fuel Line
Fuel leak Verify that the problem is resolved.
A. Check for a leaking high-pressure
fuel line.
not leaking.
4. Check for Correct Operation of

the Fuel Nozzle Result: The fuel nozzle is not
operating properly.
A. Make sure that the components of
the fuel injection nozzle are tightened Replace the fuel nozzle.
to the correct torques.
Fuel Nozzle
B. Make sure that the gaskets and the
insert are positioned correctly. Result: The fuel nozzle is operating
properly.
C. Test the fuel injection nozzle on a
nozzle tester in order to measure the Proceed to Test Step 5.
pressure setting.
5. Check that the Correct Fuel Fuel Nozzle Result: The correct fuel nozzles are
Nozzles are Installed not installed.
A. Verify that all fuel injection Install the correct fuel nozzles.
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.

restricted or damaged.
Repair or replace the high-pressure

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

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

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

2. Check for Debris or Damage on the damaged.
Orifices
Clean the surface of the orifices with
Damage or
A.Visually inspect the components of the solvent. Replace the fuel injection
Debris
valve for carbon pitting, for scoring, or nozzles if corrosion exists.
for other damage.
The fuel injection nozzle does not inject fuel in the correct quantity or in the
correct pattern.
Probable Cause
Table 6
Result: The opening pressure is not

correct.
1. Check the Setting for the
Adjust the setting to the correct pressure.
Opening Pressure
Opening
A. Test the setting of the opening pressure
pressure.
Result: The opening pressure is correct.
2. Verify the Operation of the Fuel injection Result: The fuel injection nozzle is stuck.
Fuel Injection Nozzle nozzle Debris or damage exists on the fuel
injection nozzle.
A.Verify that the fuel injection
nozzle is not stuck. The fuel injection nozzle must be cleaned
or replaced.
Result: The fuel injection nozzle is not

stuck.
Result: The orifices are blocked or

restricted.
The fuel injection nozzle must be cleaned

3. Check for a Blockage or
or replaced.
Restriction in the Orifices
Orifice
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
Fuel return Clean the passage in order to remove any
passage carbon buildup or other debris.
A.Inspect the fuel return passage.
Troubleshooting the Turbocharger

The engine lacks power.
Probable Cause
Table 7
1. Check for Restrictions in the Air Air filter element Result: The air filter element is
Filter Element dirty or has restrictions.
A. Check the condition of the air The air filter element must be
filter element. cleaned or replaced.
Verify that the problem is

resolved.
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.
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2. Find the restriction and repair or
Tube between the Air Filter and replace the component.
the Turbocharger
Restriction/damage
A. Check for damage or a restriction resolved.
in the tube between the air filter and
the turbocharger. Result: There is not damage or a
turbocharger.
Result: There is a leak or a

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

Exhaust System restriction in the exhaust system
components.
A. Check for damage or a restriction
in the exhaust system components. The component must be repaired
or replaced.

resolved.
Result: There is not damage or a

restriction in the exhaust system
components.
Result: The turbocharger is

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

5. Check for Proper Installation of turbocharger and tighten the
the Turbocharger clamps and bolts.
A. Verify that turbocharger is not Turbocharger Verify that the problem is

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

6. Inspect the Intake Manifold repaired or replaced.
A. Inspect the intake manifold for Verify that the problem is

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

7. Inspect the Exhaust Manifold Exhaust manifold has cracks, loose bolts, or a
distorted flange.
A. Inspect the exhaust manifold for
cracks, loose bolts, or a distorted The exhaust manifold must be
flange. repaired or replaced.

resolved.

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 Restriction/damage resolved.
damage or a restriction.
not damaged or does not have a
restriction.
Result: The turbocharger

bearings are not OK.
Replace the turbocharger.

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

10. Inspect the Compressor for Debris contains debris.
Debris
Clean the compressor housing.
A. Inspect the compressor housing
for debris. Verify that the problem is
resolved.

does not contain debris.
Result: The turbocharger rotor

has carbon build-up.
Remove the carbon.

Rotor Verify that the problem is
resolved.
Carbon build-up
A. Inspect the turbocharger rotor for
carbon build-up. 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 pump resolved.
A. Verify proper operation of the fuel
injection pump.
Result: The fuel injection pump
is operating properly.
Result: The fuel injection

nozzles have wear or damage.
The fuel injection nozzles must

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

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

resolved.
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.
resolved.
The engine exhaust has excessive black smoke.
Probable Cause
Table 8

dirty or has restrictions.
The air filter element must be

cleaned or replaced.
1. Check for Restrictions in the
Air Filter Element
Air filter element resolved.
A. Check the condition of the air
filter element.
restrictions.
2. Check for a Restriction in the Restriction/damage Result: There is damage or a

Tube between the Air Filter and restriction to the tube between the
the Turbocharger air filter and the turbocharger.
A. Check for damage or a restriction Find the restriction and repair or

in the tube between the air filter and replace the component.
the turbocharger.
resolved.

restriction to the tube between the
air filter and the turbocharger.
Result: The turbocharger is loose

or the clamps and bolts on the
turbocharger are loose.



flange.

4. Inspect the Intake Manifold repaired or replaced.
A. Inspect the intake manifold for Verify that the problem is

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

resolved.
Result: The engine oil pipe does

not have restrictions.
Result: The turbocharger has

combustion gas or air leaks.

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


Bearings
Bearings
bearings are OK.

contains debris.

8. Inspect the Compressor for
Debris Verify that the problem is
resolved.
Debris
for debris. Result: The compressor housing

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

carbon build-up.
resolved.
The engine exhaust has excessive blue smoke.
Probable Cause
Table 9
Result: The air filter element

is dirty or has restrictions.

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

breather has restrictions.
The crankcase breather (if

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

between the Air Filter and the restriction to the tube between
Turbocharger the air filter and the
turbocharger.
A. Check for damage or a restriction in
the tube between the air filter and the Find the restriction and repair
turbocharger. or replace the component.

resolved.
Result: There is not damage

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

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

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

has cracks, loose bolts, or a
distorted flange.

5. Inspect the Intake Manifold
A. Inspect the intake manifold for Intake manifold
resolved.
cracks, loose bolts, or a distorted flange.
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

resolved.
Result: The engine oil pipe

does not have restrictions.


resolved.
does not have combustion gas
or air leaks.

8. Inspect the Turbocharger Bearings Verify that the problem is

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

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

debris. housing.

resolved.

housing does not contain
debris.

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

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

excessive anti-corrosion fluid.
Clean the turbocharger in

order to remove the anti-
11. Inspect the Turbocharger for
corrosion fluid.
Fluid
A. Inspect the turbocharger for
Anti-corrosion fluid resolved.
excessive anti-corrosion fluid. This
condition only exists on a new engine
which has not been operated.
does not have excessive anti-
corrosion fluid.
Result: The high idle

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

resolved.
Result: The high idle does

not operate for an excessive
time.

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


Air Filter Element
filter element.
restrictions.
Restrictions
2. Check for Restrictions in the Result: The crankcase breather
Crankcase Breather has restrictions.
A. Check the crankcase breather for The crankcase breather (if

restrictions. equipped), or the tubing must be

resolved.
Result: The crankcase breather




Result: The incorrect type of

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

correct quantity and type of
4. Check the Engine Oil engine oil.
A. Verify that the correct type of Engine oil Verify that the problem is
engine oil is being used. resolved.
Result: The correct type of

5. Inspect the Engine Oil Drain Restrictions Result: The engine oil pipe has
Pipe restrictions.
A. Inspect the engine oil drain pipe The drain pipe must be repaired
for restrictions. or replaced.

resolved.

Result: The engine oil pipe has

restrictions.
The drain pipe must be repaired

6. Inspect the Engine Oil Drain or replaced.
Pipe
Restrictions
A. Inspect the engine oil drain pipe resolved.
for restrictions.


repaired or the turbocharger must
be replaced.
restriction.


Bearings
Bearings
bearings are OK.

9. Inspect the Piston Rings Piston rings wear.

resolved.
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
A. Inspect the oil supply line for Leaks resolved.
leaks.
Result: The oil supply line does
not have leaks.
Result: The high idle operates

for an excessive time.

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

The bearing housing must be
Restriction
Restriction be replaced.
A. Inspect the turbocharger for a
resolved.
Excessive engine oil exists at the end of the turbine.
+,-./
Probable
Table 11

breather has restrictions.

equipped), or the tubing must
1. Check for Restrictions in the be cleaned or replaced.
Crankcase Breather
Restrictions
A. Check the crankcase breather for resolved.
restrictions.
restrictions.

restriction in the exhaust
system components.
The component must be

2. Check for a Restriction in the repaired or replaced.
Exhaust System
Restriction/damage
A. Check for damage or a restriction in resolved.
the exhaust system components.
Result: There is not damage
or a restriction in the exhaust
system components.
3. Check for Proper Installation of the Turbocharger Result: The turbocharger is

Turbocharger loose or the clamps and bolts
A. Verify that turbocharger is not loose
or the clamps and bolts on the Correctly position the
turbocharger are not loose. turbocharger and tighten the
clamps and bolts.

resolved.

not loose.

has restrictions.
The drain pipe must be

4. Inspect the Engine Oil Drain Pipe
A. Inspect the engine oil drain pipe for Restrictions
resolved.
restrictions.
Result: The turbine housing

is damaged or has a
restriction.

must be replaced.
A. Inspect the turbine housing for Restriction/damage
resolved.
Result: The turbine housing
is 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.

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

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

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

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

excessive anti-corrosion
fluid.

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

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


resolved.
Result: The high idle does

not operate for an excessive
time.

housing.
Restriction
resolved.
Excessive engine oil exists at the compressor end of the turbocharger.
Probable Cause
Table 12

is dirty or has restrictions.

Filter Element
A. Check the condition of the air filter
element.
is not dirty or does not have
restrictions.
Restrictions
2. Check for Restrictions in the Result: The crankcase
Crankcase Breather breather has restrictions.
A. Check the crankcase breather for The crankcase breather (if

restrictions. equipped), or the tubing must
be cleaned or replaced.

resolved.

restrictions.

turbocharger.
3. Check for a Restriction in the Tube Find the restriction and repair
between the Air Filter and the or replace the component.
Turbocharger
Restriction/damage
A. Check for damage or a restriction in resolved.
the tube between the air filter and the
turbocharger. Result: There is not damage
or a restriction to the tube
between the air filter and the
turbocharger.
4. Check for an Air Leak or Air leak or Result: There is a leak or a

Restriction in the Tube between the restriction restriction to the tube between
Intake Manifold and the the intake manifold and the
Turbocharger turbocharger.
A. Check for a leak or a restriction in Find the leak or restriction and

the tube between the intake manifold repair or replace the
and the turbocharger. component.

resolved.
Result: There is not a leak or

a restriction to the tube
between the intake manifold
01
Proceed to Test Step

loose or the clamps and bolts

23456 789 :98;49 <=>?@AA@?B8= 87
5.
turbocharger and tighten the
clamps and bolts.
the Turbocharger
A. Verify that turbocharger is not loose Fuel Nozzle
resolved.
not loose.


resolved.
leaks.

7. Inspect the Turbocharger Bearings Verify that the problem is

bearings are OK.

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

debris.
resolved.

housing does not contain
debris.

wear.

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

excessive anti-corrosion fluid.

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

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

resolved.


housing.
Restriction
resolved.
Engine oil exists in the exhaust manifold.
Probable Cause
Table 13

has restrictions.

equipped), or the tubing must be
Crankcase Breather
Restrictions
A. Check the crankcase breather
resolved.
for restrictions.

components.
A. Check for damage or a
restriction in the exhaust system The component must be repaired
components. or replaced.
resolved.

components.

restrictions.
The drain pipe must be repaired or

3. Inspect the Engine Oil Drain replaced.
Pipe
Restrictions
for restrictions.


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

5. Inspect the Turbocharger Turbocharger are not OK.
Bearings Bearings
A. Inspect the turbocharger
bearings. Verify that the problem is
resolved.

are OK.

contains debris.

resolved.
Debris
Result: The turbocharger rotor has

carbon build-up.
Remove the carbon.

Rotor Verify that the problem is
resolved.
Carbon build-up
A. Inspect the turbocharger rotor
for carbon build-up. Result: The turbocharger rotor

wear.

8. Inspect the Piston Rings
resolved.
A. Inspect the piston rings for Piston rings
wear.
have wear.
Result: The high idle operates for

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

resolved.


a Restriction
Restriction be replaced.
resolved.
Lack of lubrication to the turbocharger
Probable Cause
Table 14
Result: The turbocharger is loose or

the clamps and bolts on the
1. Check for Proper Installation of Correctly position the turbocharger

the Turbocharger and tighten the clamps and bolts.
A. Verify that turbocharger is not Turbocharger Verify that the problem is resolved.
loose or the clamps and bolts on the
turbocharger are not loose. Result: The turbocharger is not loose
2. Check for Turbocharger for Turbocharger Result: The components listed are
Proper Lubrication lubrication not operating properly.
The flow of engine oil is delayed to The component must be repaired or

the turbocharger when the engine is replaced.
started. Insufficient oil flows to the
turbocharger when the engine is Verify that the problem is resolved.
running.
Result: The components listed are
A. Check the following components operating properly.
for correct operation:

· Engine oil pump
· Engine oil bypass valve
· Engine oil filter
· Viscosity of the engine oil
· Restrictions in oil lines
Result: The engine oil is dirty.

correct type of engine oil. Replace the
3. Inspect the Engine Oil engine oil filter.
Engine Oil
A. Inspect the engine oil. Verify that the problem is resolved.
Result: The engine oil is not dirty.
Result: The incorrect type of engine

oil is being used.

correct quantity and type of engine
4. Check the Engine Oil
oil.
A. Verify that the correct type of Engine oil
Result: The correct type of engine oil
is being used.
Result: The oil supply line is

restricted.
The oil supply line must be repaired

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

A. Verify the high idle speed of the High idle
engine.
Result: The oil supply line has leaks.
The supply line must be repaired or

replaced.
A. Inspect the oil supply line for Leaks
leaks. Result: The oil supply line does not
have leaks.
Result: The piston rings have wear.

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

wear.
Result: The high idle operates for an

excessive time.

engine.

The bearing housing must be repaired

11. Inspect the Turbocharger for a or the turbocharger must be replaced.
Restriction
Restriction
restriction in the bearing housing. Result: The turbocharger has a
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
12. Inspect the Engine Oil Filter bypass valve in the engine oil filter
base. Replace the engine oil filter.
A. Inspect the engine oil filter for a Oil Filter
restriction. Verify that the problem is resolved.
Result: The engine oil filter does not

have a restriction.
13. Correct Engine Operation Engine

operation Result: The components listed are
The engine may have stopped too not operating properly.
soon from a high load condition.
The component must be repaired or
A. Check the following components replaced.
for correct operation or damage:
· Compressor impeller of the Verify that the problem is resolved.

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


Filter Element
filter element.
restrictions.

has restrictions.

equipped), or the tubing must be
Crankcase Breather
Restrictions
A. Check the crankcase breather for
resolved.
restrictions.
3. Check for Proper Installation of Air filter Result: The air filter element is
CDE FDGHIE JGIKILH

the not sealed properly.
MANOPQRS TUVT TUO VQP RQWTOP OWOXOYT QZ Inspect the air filter element and
sealed properly. the air supply line to the
turbocharger for correct
installation.

resolved.

sealed properly.

turbocharger.
4. Check for a Restriction in the Find the restriction and repair or

Tube between the Air Filter and replace the component.
the Turbocharger
Restriction/damage
in the tube between the air filter and
the turbocharger. Result: There is not damage or a
turbocharger.
5. Check for an Air Leak or Air leak or Result: There is a leak or a

Restriction in the Tube between the restriction restriction to the tube between
Intake Manifold and the the intake manifold and the
Turbocharger turbocharger.
A. Check for a leak or a restriction in Find the leak or restriction and

the tube between the intake manifold repair or replace the component.
resolved.
Result: There is not a leak or a

turbocharger.

components.
The component must be repaired

6. Check for Restriction in the or replaced.
Exhaust System
Restriction/damage
in the exhaust system components.
components.

the turbocharger are loose.



8. Inspect the Exhaust Manifold Exhaust manifold has cracks, loose bolts, or a
distorted flange.
A. Inspect the exhaust manifold for
cracks, loose bolts, or a distorted The exhaust manifold must be
flange. repaired or replaced.

resolved.


restrictions.
The drain pipe must be repaired

9. Inspect the Engine Oil Drain or replaced.
Pipe
Restrictions
for restrictions.


must be replaced.
restriction.


resolved.
leaks.

12. Inspect the Turbocharger bearings are not OK.
Bearings
Turbocharger Replace the turbocharger.
resolved.

bearings are OK.

contains debris.

resolved.
Debris

wear.

resolved.
Piston rings
have wear.

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

restriction in the bearing housing. repaired or the turbocharger
must be replaced.

resolved.

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
resolved.
A. Test the air inlet heater for Leaks
leakage.
Result: The air inlet heater does
not have fuel leaks.
Result: The back plate of the

compressor is cracked.
The back plate of the

17. Inspect the Compressor
compressor must be repaired or
the turbocharger must be
A. Inspect the back plate of the Compressor
replaced.
compressor.
resolved.
Damaged compressor impeller of the turbocharger
Probable Cause
Table 16
1. Check for Proper Installation Air filter Result: The air filter element is not
of the Air Filter Element sealed properly.
A. Verify that the air filter element Inspect the air filter element and
is sealed properly. the air supply line to the
installation.

sealed properly.
[\

]^_`a bcd e f_ghdi`hicj ij h^_
2.
Find the restriction and repair or
Tube between the Air Filter and
replace the component.
the Turbocharger
Restriction/damage Verify that the problem is resolved.
restriction in the tube between the

3. Check for Proper Installation Correctly position the turbocharger

of the Turbocharger and tighten the clamps and bolts.
the turbocharger are not loose. Result: The turbocharger is not
The flow of engine oil is delayed The component must be repaired or

to the turbocharger when the replaced.
engine is started. Insufficient oil
flows to the turbocharger when the Verify that the problem is resolved.
engine is running.
A. Check the following operating properly.
components for correct operation:
· Engine oil pump
Result: The incorrect oil is being

used.
Drain the engine oil. Replace the

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

restricted.
The oil supply line must be

Line
restricted.

are not OK.

Bearings
Turbocharger
A. Inspect the turbocharger Bearings
bearings.
are OK.

8. Inspect the Compressor for Debris contains debris.
Debris
for debris. Verify that the problem is resolved.

Result: The engine rpm increases

too rapidly when the engine is
started.
Check the fuel injection pump for

9. Verify the Engine RPM correct operation and settings.
Engine RPM
A. Verify the engine RPM during Verify that the problem is resolved.
start-up.
increase too rapidly when the
engine is started.

an excessive time.

engine.

leaks.

replaced.
leaks.
not have leaks.

12. Inspect the Turbocharger for Restriction restriction in the bearing housing.
a Restriction

A. Inspect the turbocharger for a repaired or the turbocharger must
restriction in the bearing housing. be replaced.
Result: The turbocharger does not

have a restriction in the bearing
housing.

restriction.

Check the operation of the engine
oil bypass valve in the engine oil
13. Inspect the Engine Oil Filter
filter base. Replace the engine oil
filter.
restriction.
Result: The engine oil filter does

not have a restriction.
14. Correct Engine Operation
The engine may have stopped too

A. Check the following Result: The components listed are

components for correct operation not operating properly.
or damage:
Engine operation
· Compressor impeller of the replaced.
turbocharger
· Cooling system Verify that the problem is resolved.
· Valve lash
Damage to the turbine
Probable Cause
Table 17

components.
1. Check for Restriction in the The component must be repaired or

Exhaust System replaced.
A. Check for damage or a Restriction/damage Verify that the problem is resolved.

components. Result: There is not damage or a
components.



engine is running.
· Engine oil pump


correct type of engine oil. Replace
4. Inspect the Engine Oil the engine oil filter.
Engine Oil

used.

type of engine oil.
used.

restricted.

Line
restricted.

7. Inspect the Turbocharger Restriction/damage damaged or has a restriction.
A. Inspect the turbine housing for The turbine housing must be

damage or a restriction. repaired or the turbocharger must
be replaced.

restriction.

are not OK.

Bearings
Turbocharger
A. Inspect the turbocharger Bearings
bearings.
are OK.

carbon build-up.
Remove the carbon.

Rotor
Carbon build-up
for carbon build-up.
Engine RPM
10. Verify the Engine RPM Result: The engine rpm increases
A. Verify the engine RPM during started.
start-up.

engine is started.

an excessive time.

engine.
Result: The fuel injection pump is

not operating correctly.

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

exhaust valves are burned.
Replace the inlet valves and the

exhaust valves. Determine the
13. Inspect the Intake and
cause of the damage to the valves.
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.

14. Inspect the Oil Supply Line Leaks leaks.
A. Inspect the oil supply line for The supply line must be repaired or
leaks. replaced.

not have leaks.


be replaced.
a Restriction
Restriction Verify that the problem is resolved.

restriction.

filter.
restriction.


Engine operation Result: The components listed are
A. Check the following replaced.
components for correct operation
or damage: Verify that the problem is resolved.
· Compressor impeller of the

turbocharger
· Cooling system
· Valve lash
The rotating assembly of the turbocharger does not rotate freely.
Probable Cause
Table 18
Result: The air filter element is not

sealed properly.
Inspect the air filter element and

the air supply line to the
1. Check for Proper Installation
of the Air Filter Element
installation.
Air filter
A. Verify that the air filter element
is sealed properly.
sealed properly.

the Turbocharger

components.
restriction in the exhaust system The component must be repaired or
components. replaced.
kVerify that the problem is resolved

components.


5. Check for Turbocharger for

Proper Lubrication
The flow of engine oil is delayed
not operating properly.
to the turbocharger when the
flows to the turbocharger when the
replaced.
engine is running.
Turbocharger
A. Check the following lubrication
operating properly.
· Engine oil pump
6. Check the Engine Oil Engine oil Result: The incorrect type of
A. Verify that the correct type of
engine oil is being used. Drain the engine oil. Install the
oil.
Result: The correct type of engine

oil is being used.

restricted.

Line
restricted.

Engine Oil


be replaced.
restriction.

Bearings Bearings
bearings. Verify that the problem is resolved.

are OK.

contains debris.

Debris
Debris
for debris.

carbon build-up.
Remove the carbon.

Rotor
Carbon build-up
Engine RPM
start-up.

engine is started.

an excessive time.

engine.

leaks.

replaced.
leaks.
not have leaks.


be replaced.
a Restriction
Restriction Verify that the problem is resolved.

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



or damage:
Engine operation
turbocharger
· Valve lash
Worn bearings, bearing bores, and journals
Probable Cause
Table 19

the Turbocharger
lmnop qrs tnuvswovwrx wx vmn

2. Restriction/damage Result: There is damage or a
components.
yAz{|}~ |

components.


4. Check for Turbocharger for

Proper Lubrication
The flow of engine oil is delayed
not operating properly.
to the turbocharger when the
flows to the turbocharger when the
replaced.
engine is running.
Turbocharger
A. Check the following lubrication
operating properly.
· Engine oil pump
5. Check the Engine Oil Engine oil Result: The incorrect type of
A. Verify that the correct type of
engine oil is being used. Drain the engine oil. Install the
oil.

oil is being used.

restricted.

Line
restricted.

Engine Oil
Engine RPM
start-up.

engine is started.

an excessive time.

engine.

leaks.

replaced.
leaks.
not have leaks.

restriction.

filter.
restriction.


Engine operation Result: The components listed are
A. Check the following replaced.
components for correct operation
or damage: Verify that the problem is resolved.
· Compressor impeller of the

turbocharger
· Cooling system
· Valve lash
The turbocharger makes excessive noise.
Probable Cause
Table 20


Air Filter Element
Air filter element Verify that the problem is resolved.
filter element.
Result: The air filter element is not
dirty or does not have restrictions.
2. Check for Proper Installation Air filter Result: The air filter element is not
of the Air Filter Element sealed properly.
A. Verify that the air filter element Inspect the air filter element and
is sealed properly. the air supply line to the
installation.
sealed properly.

the Turbocharger
Result: There is a leak or a

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

components.

components.



6. Correctly position the turbocharger

flange.

7. Inspect the Intake Manifold
A. Inspect the intake manifold for
Intake manifold Verify that the problem is resolved.
flange.
Result: The intake manifold does
distorted flange.
Result: The exhaust manifold has

flange.
The exhaust manifold must be

8. Inspect the Exhaust Manifold repaired or replaced.
A. Inspect the exhaust manifold for Verify that the problem is resolved.
Exhaust manifold
flange. Result: The exhaust manifold does
distorted flange.

engine is running.
· Engine oil pump

used.

type of engine oil.
used.

restricted.

Line
restricted.

Bearings Bearings

bearings. Verify that the problem is resolved.

are OK.

contains debris.

Debris
Debris
for debris.

carbon build-up.
Remove the carbon.

Rotor
Carbon build-up

started.

Engine RPM
start-up.
engine is started.

16. Verify the High Idle Speed High idle an excessive time.
A. Verify the high idle speed of the Check the fuel injection pump for
engine. correct operation and settings.


leaks.

replaced.
leaks.
not have leaks.


18. Inspect the Turbocharger for be replaced.
a Restriction
Restriction
restriction in the bearing housing. Result: The turbocharger does not
have a restriction in the bearing
housing.

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



or damage:
Engine operation
turbocharger
· Valve lash
Sludge or carbon deposits in the bearing housing
Probable Cause
Table 21
Result: The crankcase breather has

restrictions.

1. Check for Restrictions in the equipped), or the tubing must be
Crankcase Breather cleaned or replaced.
Restrictions
A. Check the crankcase breather Verify that the problem is resolved.
for restrictions.
The flow of engine oil is delayed to The component must be repaired

the turbocharger when the engine or replaced.
is started. Insufficient oil flows to
the turbocharger when the engine Verify that the problem is resolved.
is running.
· Engine oil pump
Result: The incorrect type of


oil.
oil is being used.

Engine Oil
5. Check the Engine Oil Supply Restrictions Result: The oil supply line is
Line restricted.
A. Inspect the oil supply line from The oil supply line must be
the engine oil pan for a restriction. repaired or replaced.

restricted.


be replaced.
restriction.

started.

Engine RPM
start-up.
engine is started.

8. Inspect the Oil Supply Line Leaks leaks.
A. Inspect the oil supply line for The supply line must be repaired or
leaks. replaced.

not have leaks.

restriction.

filter.
restriction.



or damage:
The component must be repaired
Engine operation
· Compressor impeller of the or replaced.
turbocharger
· 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 starting

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

followed.
Ensure that the engine
starting procedure is
correctly followed.

resolved.
Result: The engine starting

procedure was correctly
followed.
Result: The manual valve

in the fuel line is closed.
Open the valve.

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

not low in the fuel tank.
4. Check the Fuel Quality Contamination Result: The fuel contains

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

resolved.
Result: The fuel does not

contain water, dirt, ice, or
wax.
Result: Engine cranking

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

the fuel injection pump do
not operate correctly.
6. Check the Engine Glow Plugs Make the necessary

repairs.
A. Inspect the cable connections and the
electrical connections of the glow plugs and Engine Glow Verify that the problem is
the electrical components of the starting aid Plugs resolved.
circuit. Test the glow plugs for correct
operation. Result: The glow plugs for
the fuel injection pump
operate correctly.
7. Check the Fuel Shutoff Solenoid Solenoid Result: The fuel shutoff
solenoid is not operating
A. Ensure that the fuel shutoff solenoid correctly.
operates correctly.
Replace a fuel shutoff
solenoid that is suspect.

resolved.
Result: The fuel shutoff

solenoid is operating
correctly.
Result: The operation of

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

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

the fuel lines are restricted.
Replace the suspect

component.
9. Check the Fuel Filter
A. Check the fuel filter and fuel lines for Fuel filter/fuel
resolved.
restrictions. lines
Drain any water from the fuel filter.
Result: The fuel filter or
the fuel lines are not
restricted.
10. Check the Timing for the Fuel Injection Fuel injection Result: The operation of
Pump pump timing the fuel injection pump is
not correct.
A. Check the timing of the fuel injection pump.
Adjust the timing or replace the fuel injection The fuel injection pump
pump. Refer to the Specifications Module, must be repaired or

"Fuel Injection Pump" topic for additional replaced.
information.
B. Check the operation of the fuel rack linkage. resolved.
C. Make sure that the high-pressure fuel lines Result: The operation of
are connected to the fuel injection nozzles in the fuel injection pump is
the correct order. correct.
D. Make sure that the mounting bolts of the Proceed to Test Step 11.
fuel injection pump are tightened to the correct
torque. Inspect the fuel lines for leaks or for
restrictions. The damaged fuel lines or fittings
must be repaired or replaced.
Result: There is a problem

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

11. Inspect the Fuel Injection Linkage and repairs.
the Governor
Governor and Verify that the problem is
A. Inspect the governor and the fuel injection fuel injection resolved.
linkage for damage or the fuel injection linkage linkage
for incorrect assembly in the timing gear case. Result: There is not a
problem with the governor
or the fuel injection
linkage.
12. Inspect the Fuel Injection Nozzles Fuel Injection Result: A fuel injection
Nozzles nozzle is not operating
A. Run the engine at the rpm that gives correctly.
maximum misfiring or rough running. Then,
loosen a fuel line nut on the injection line for Replace the suspect fuel
each cylinder. Loosen one nut at a time. Then, injection nozzle.
tighten that nut before the next fuel line nut is Make sure that all of the
loosened. If loosening the fuel line nut does not fuel injection nozzles are
affect the operation of the engine, the fuel the correct type for the
injection nozzle is probably suspect. Test the engine. Test the pressure
fuel injection nozzle for that cylinder. setting of the fuel injection
nozzles. Refer to the
B. Make sure that the fuel injection nozzles are Specifications Module,
properly sealed in the threaded ports. Make "Fuel Injection Nozzles"
sure that the fuel injection nozzles are correctly topic for additional
aligned in the threaded ports. Make sure that information.
the fuel injection nozzles are tightened to the

correct torque. Ensure that the gaskets and the Verify that the problem is
seat washers are installed on the fuel injection resolved.
nozzles correctly. Make sure that the bottom of
the threaded ports are clean and free of debris. Result: The fuel injection
Make sure that the bottom of the threaded ports nozzles are operating
do not contain extra gaskets. correctly.
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
Result: The cylinders have
caused by the following conditions:
low compression.
· Piston rings are worn or broken.
Make the necessary
· The piston height is incorrect. Cylinder
repairs.
· The piston is damaged. compression
· The fuel injection nozzles are not seated
correctly.
resolved.
· The valve lash requires adjustment.
· The fuel injection pump timing is incorrect.
· The engine timing is incorrect.
· When an inlet valve or an exhaust valve is
fully seated, gases leak past the valve head.
The engine starts and the engine runs for a brief period of time and the engine
stops.
Probable Cause
Table 23
1. Inspect the Fuel System Fuel Result: The fuel filter or the fuel
System lines are restricted.
A. Check the fuel filter or the fuel lines for
restrictions. Excess water can build up in the Check the fuel lines and the fuel
fuel filter. filter. Replace the fuel filter.
Drain any water from the fuel
filter.

resolved.
Result: The fuel filter or the fuel
lines are not restricted.
Result: The operation of the fuel

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

2. Check the Operation of the Fuel the fuel pressure is too low. The
Transfer Pump fuel transfer pump must be
Fuel
A. Check the fuel pressure when the engine
transfer
is cranking. Refer to the Specifications Verify that the problem is
pump
Module, "Fuel Transfer Pump" topic for resolved.
additional information.
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 Verify that the problem is
and exhaust resolved.
A. Check the air inlet and exhaust system for
system
restrictions..
Result: The air inlet or the
exhaust system is not restricted.
Result: Air is in the fuel system.

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

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

system.

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

fuel system.
Result: The valve lash is

not correct.
Adjust the valve lash.

3. Check the Valve Lash
Valve lash resolved.
A. Check the engine valve lash.
correct.
4. Check the Timing for the Fuel Injection Fuel injection Result: The operation of
Pump pump timing the fuel injection pump is
not correct.
Adjust the timing or replace the fuel injection The fuel injection pump
pump. Refer to the Specifications Module, must be repaired or
"Fuel Injection Pump" topic for additional replaced.
information.
B. Check the operation of the fuel rack linkage. resolved.
C. Make sure that the high-pressure fuel lines Result: The operation of
are connected to the fuel injection nozzles in the fuel injection pump is
the correct order. correct.
D. Make sure that the mounting bolts of the Proceed to Test Step 5.
Result: A fuel injection

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

are correctly tightened and
the engine mounts are
mounted correctly.
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
Contamination
A. Check the fuel for contamination. resolved.
Result: The fuel does not

contain water, dirt, ice, or
wax.
8. Check the Cylinder Compression
A. Starting the engine may be difficult in warm

weather. The engine may not start in cold
caused by the following conditions: Result: The cylinders have
low compression.
· The piston height is incorrect. Cylinder Make the necessary repairs.
· The piston is damaged. compression
· The fuel injection nozzles are not seated Verify that the problem is
correctly. resolved.
· The valve lash requires adjustment.
· The engine timing is incorrect.
The engine runs evenly, but the engine loses power.
Probable Cause
Table 25
1. Check the Engine for Low Compression
A. Starting the engine may be difficult in warm Result: The cylinders have
weather. The engine may not start in cold low compression.
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.
correctly. Result: The cylinders do
· The valve lash requires adjustment. not have low compression.
· The engine timing is incorrect. Proceed to Test Step 2.
2. Check the Timing for the Fuel Injection

Pump
Result: The operation of the
A. Check the timing of the fuel injection pump. fuel injection pump is not
Adjust the timing or replace the fuel injection correct.
pump. Refer to the Specifications Module,
"Fuel Injection Pump" topic for additional The fuel injection pump
information. must be repaired or
replaced.
B. Check the operation of the fuel rack linkage.
Fuel injection
pump timing
C. Make sure that the high-pressure fuel lines resolved.
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 correct.
torque. Inspect the fuel lines for leaks or for Proceed to Test Step 3.
3. Check the Valve Lash Valve lash Result: The valve lash is
not correct.
A. Check the engine valve lash. Adjust the valve lash.

resolved.

correct.
Result: The air filter

element is dirty or has
restrictions.
The air filter element must

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

system.

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

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

resolved.
The engine lacks power.
Probable Cause
Table 26
Result: The fuel quality does

not meet the engine
specifications.
Remove the fuel from the

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

meets the engine
specifications.
Result: The fuel pressure is

2. Measure the Fuel Pressure low.
A. Make sure that sufficient fuel is in the fuel tank. Make the necessary repairs.
Remove any air in the fuel system.
Fuel
B. Look for leaks or suspect bends in the fuel line resolved.
Pressure
between the fuel tank and the fuel transfer pump.
Result: The fuel pressure is
C. Check the outlet pressure of the fuel transfer not low.
pump.
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3. Governor Result: There is a problem
Governor and fuel with the governor or the fuel
injection injection linkage.
¬A®¯°±²³ ³´± µ¶·±¸®¶¸ ¹®º ³´± »¼±½ ¾®¿±²³¾¶® linkage
linkage for damage or the fuel injection linkage for Make the necessary repairs.
incorrect assembly in the timing gear case.
resolved.
Result: There is not a

problem with the governor or
the fuel injection linkage.
Result: The valve lash

exceeds the specification.
Adjust the valve lash. Refer

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

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

injection pump are tightened to the correct torque.
Inspect the fuel lines for leaks or for restrictions.
The damaged fuel lines or fittings must be repaired
or replaced.
6. Inspect the Fuel Injection Nozzles
A. Run the engine at the rpm that gives maximum

misfiring or rough running. Then, loosen a fuel
nozzle is not operating
line nut on the injection line for each cylinder.
correctly.
Loosen one 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
injection nozzle.
operation of the engine, the fuel injection nozzle is
Make sure that all of the fuel
probably suspect. Test the fuel injection nozzle for
injection nozzles are the
that cylinder.
Fuel correct type for the engine.
Injection Test the pressure setting of
B. Make sure that the fuel injection nozzles are
Nozzles the fuel injection nozzles.
properly sealed in the threaded ports. Make sure
Refer to the Specifications
that the fuel injection nozzles are correctly aligned
Module, "Fuel Injection
in the threaded ports. Make sure that the fuel
Nozzles" topic for additional
injection nozzles are tightened to the correct
information.
torque. Ensure that the gaskets and the seat
washers are installed on the fuel injection nozzles
correctly. Make sure that the bottom of the
resolved.
threaded ports are clean and free of debris. Make
sure that the bottom of the threaded ports do not
contain extra gaskets.
The engine has excessive vibration.
Probable Cause
Table 27
1. Inspect the Engine Pulleys Pulleys Result: The bolts for the pulleys are loose
or the pulley is damaged.
A. Inspect the engine pulleys for
damage or loose bolts. Tighten the bolts. If the pulley is worn or
Refer to the Specifications Module, damaged, use new parts for replacement.
"Crankshaft Pulley" topic for
additional information. Verify that the problem is resolved.
Result: The bolts for the pulleys are not

loose or the 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
A. Inspect the engine mounts for loose engine mounts for wear or for damage.
mounts
bolts or damage. Use new parts for replacement.
The engine has excessive combustion noise.
Probable Cause
Table 28
Result: The fuel quality does

not meet the engine
specifications.
Remove the fuel from the

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

meets the engine
specifications.
2. 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 Nozzles correctly.
misfiring or rough running. Then, loosen a fuel line
nut on the injection line for each cylinder. Loosen Replace the suspect fuel
one nut at a time. Then, tighten that nut before the injection nozzle.
next fuel line nut is loosened. If loosening the fuel Make sure that all of the fuel
line nut does not affect the operation of the engine, injection nozzles are the
the fuel injection nozzle is probably suspect. Test correct type for the engine.
the fuel injection nozzle for that cylinder. Test the pressure setting of
the fuel injection nozzles.

B. Make sure that the fuel injection nozzles are Refer to the Specifications
properly sealed in the threaded ports. Make sure Module, "Fuel Injection
that the fuel injection nozzles are correctly aligned Nozzles" topic for additional
in the threaded ports. Make sure that the fuel information.
injection nozzles are tightened to the correct torque.
Ensure that the gaskets and the seat washers are Verify that the problem is
installed on the fuel injection nozzles correctly. resolved.
Make sure that the bottom of the threaded ports are
clean and free of debris. Make sure that the bottom Result: The fuel injection
of the threaded ports do not contain extra gaskets. nozzles are operating
correctly.
Result: The piston height is

incorrect.
To obtain the correct piston

3. Measure the Piston Height height, the piston, the piston
Piston pin, the bearings, or the
A. Measure the engine piston height. height 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

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

rocker arm assembly, are not loose.
Result: The valve lash exceeds the

specification.
3. Measure the Valve Lash
Adjust the valve lash. Refer to the
Valve lash Specifications Module, "Engine Design" topic
A. Measure the valve lash.
for the valve lash setting.
Engine oil is in the cooling system.
Probable Cause
Table 30
1. Inspect the Engine Oil Cooler Core Engine Result: The engine oil cooler has leaks.
Oil Cooler
A. Drain the coolant from the engine Core Replace the oil cooler. Refer to
and the radiator. Drain the lubricating Disassembly and Assembly, "Engine
engine oil from the engine oil cooler. Oil Cooler - Remove" and Disassembly
Refer to the Operation and Maintenance and Assembly, "Engine Oil Cooler -
Manual for more information. Install". Fit new seals between the oil
cooler and the oil cooler cover.
B. Inspect the engine oil cooler core for Refill the crankcase with clean engine
leaks. Refer to Systems Operation, oil to the correct level. Refer to the
Testing and Adjusting, "Cooling Operation and Maintenance Manual for
System - Inspect" for the correct more information.
procedure.
Result: The engine oil cooler does not

have leaks.
ÀÁ
Result: The cylinder head gasket has

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2. faults or signs of leakage.
A. Remove the cylinder head. Refer to Replace the cylinder head gasket.
Disassembly and Assembly, "Cylinder
Head - Remove" for the correct Head Verify that the problem is resolved.
procedure. gasket
Result: The cylinder head gasket does
B. Inspect the cylinder head gasket for not have faults or signs of leakage.
faults and any signs of leakage.
Result: The cylinder head is not flat or

has cracks.
3. Inspect the Cylinder Head
Repair the cylinder head and/or replace
A. Check the cylinder head for cracks. the cylinder head.
Cylinder
B. Check the cylinder head for flatness. Verify that the problem is resolved.
head
Refer to Systems Operation, Testing
and Adjusting, "Cylinder Head - Result: The cylinder head is flat and
Inspect" for the correct procedure. does not have cracks.
Result: The cylinder block has faults or

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

4. Inspect the Cylinder Block leakage are found, determine the cause
of the leakage. Refer to Systems
Cylinder
A. Inspect the top face of the cylinder Operation, Testing and Adjusting,
block
block for faults and signs of leakage. "Cylinder 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
Result: The main bearings

are damaged.
Replace damaged parts.

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

damaged.
Replace the crankshaft.

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

not damaged.
3. Inspect the Piston Height Piston Result: The piston height is

Height not correct.
A. Check the piston height.
Replace the damaged
B. Inspect the piston, the connecting rod, and the component.
crankshaft for wear. Check for correct installation. Verify that the problem is
resolved.
Result: The piston height is

correct.
4. Inspect the Fuel Injection Nozzles
A. Run the engine at the rpm that gives maximum

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

nozzles are positioned correctly in the
precombustion chamber.
The rocker arm has insufficient movement and the valve lash exceeds the
specification.
Probable Cause
Table 32
1. Check the Lubrication of Internal Lubrication Result: Lubrication of

Components internal engine
components is inadequate.
A. Check lubrication of the valves. There must be
a strong flow of oil at high rpm. There must be a Make the necessary
small flow of oil at low rpm. Oil passages in the repairs.
engine must be clean.
resolved.
Result: Lubrication of
internal engine
components is adequate.
Result: Rocker arm parts

are worn.
If there is too much wear,

install new parts or rocker
arms. Adjust the valve
2. Check the Rocker Arms for Wear or Damage
lash.
Damage or
A.Visually inspect the rocker arms for wear or
wear Verify that the problem is
damage.
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.
4. Check the Valve Lash Valve lash Result: The valve lash is
not correct.
A. Check the engine valve lash.
Adjust the valve lash.
resolved.

correct.
Result: The pushrods are

worn.

install new pushrods.
5. Inspect the Engine Pushrods Adjust the valve lash.
Damage or
A. Visually inspect the pushrods for wear or Verify that the problem is
wear
damage. resolved.
Result: The pushrods are

not worn.
Result: The valve lifters

are worn.

install new valve lifters.
6. Inspect the Valve Lifters Adjust the valve lash.
Damage or
A. Visually inspect the valve lifters for wear or Verify that the problem is
wear
damage. resolved.
Result: The valve lifters

are not worn.
7. Inspect the Camshaft Damage or Result: The components

wear are worn.
A. Measure the valve lash.
Replace suspect parts.
B. Check for free movement of the valves. Adjust the valve lash.
C. Check for bent valve stems. Verify that the problem is

resolved.
D. Check for wear on the valve lifters.
Result: The components
are not worn.
ÔÕ
Result: The bolts and the

nuts that hold the rocker
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8.
arm assembly are loose.
Damage or Tighten the bolts and the

A. Visually inspect the rocker arms for wear,
wear nuts.
damage or loose bolts..
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 the cylinder. Major
1. Inspect the Valve
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
Values Results
Steps
Result: The valve compartment contains too

much oil.
1. Inspect the Valve Look at both ends of the rocker arm shaft. Be
Compartment sure that a plug is installed in each end.
Valve
A. Inspect the valve Verify that the problem is resolved.
compartment
compartment for excessive
oil.. Result: The valve compartment does not
contain too much oil.
Result: The valve guides are worn.
Install new valve guides. Recondition the

2. Inspect the Valve
cylinder head.
Guides
Timing Verify that the problem is resolved.
A. Measure the timing of
the fuel injection pump.
Result: The valve guides are not worn..
Result: The piston rings are worn.

3. Inspect the Engine
Replace worn parts.
Piston Rings
The piston rings are worn. Refer to the
Piston rings Specifications Module, "Pistons and Rings"
A. Inspect the engine piston
topic for additional information.
rings for wear.
The valve lash is less than the required specification.
Probable Cause
Table 35
1. Inspect the Engine Valves Valves Result: The valve seat or the face of the
valve is worn.
A. Inspect the engine valve seats and
valves. Adjust the valve lash.
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.
1. Inspect the Engine Oil
Oil
A. Inspect the engine oil. resolved.
Result: Dirt is not in the engine

oil.
Result: Leaks exist in the air

inlet system.
The components must be

2. Inspect the Air Inlet System
Air inlet Verify that the problem is
A. Inspect all gaskets and connections. system resolved.
Result: Leaks do not exist in

the air inlet system.
3. Inspect the Engine Oil for Fuel Fuel leak Result: Fuel is in the engine oil.
A. Fuel leaks will cause high fuel consumption Replace the damaged
and low engine oil pressure. Inspect the engine component.
for the following leaks:

· Fuel leaks into the crankcase from the fuel resolved.
transfer pump.
· Fuel leaks past the valve in a fuel injection
nozzle.
· The pressure setting of the fuel injection
nozzles is too high.
· The drive is broken on the fuel injection pump.
Coolant is in the engine oil.
Probable Cause
Table 37
Result: The cylinder head gasket is

damaged.
1. Inspect the Cylinder Head Install a new cylinder head gasket.

Gasket
Head gasket
A. Inspect the cylinder head gasket
for 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 Verify that the problem is resolved.
A. Inspect the cylinder head for
head
damage.
Result: The cylinder head is not
cracked or damaged.
3. Inspect the Cylinder Block Cylinder Result: The cylinder block is cracked
block or damaged.
A. Inspect the cylinder block for
damage. Install a new cylinder 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
A. Starting the engine may be difficult in warm Result: The cylinders have
weather. The engine may not start in cold low compression.
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.
correctly. Result: The cylinders do
· The valve lash requires adjustment. not have low compression.
· The engine timing is incorrect. Proceed to Test Step 2.
· When an inlet valve or an exhaust valve is fully
seated, gases leak past the valve head.
2. Inspect the Fuel Injection Nozzles Fuel Result: A fuel injection

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

Pump

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

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
2. Inspect the Fuel Injection Pump
Injection Pump" topic for additional
Timing
information.
Timing
A. Check the fuel injection pump for
the correct timing.
pump is correct.
Result: The valve guides are worn.
Replace the valve guides.

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

wear. The piston rings are worn. Refer to
the Specifications Module, "Pistons
and Rings" topic for additional
information.
Result: The piston rings are not

worn.
Result: The water temperature

regulator is suspect.
5. Operating Conditions Replace the water temperature

regulator.
A. If the engine consistently runs
Operating
below the normal operating Verify that the problem is resolved.
Temperature
temperature, inspect the water
temperature regulator. Result: The water temperature
regulator is not suspect.
Result: The breather hose or the

vent hole in the breather assembly is
6. Inspect the Breather Hose or the obstructed.
Vent Hole in the Breather Assembly
Restrictions Clean the vent hole, the breather
A.Visually inspect the components. assembly, and the breather hose.
The engine has low oil pressure.
Probable Cause
Table 40
1. Check the Oil Level Oil level Result: The engine oil level is
low.
A. Check the engine oil level.
Fill the engine oil to the correct
level.

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

restricted.
Install a new engine oil filter.

Replace the oil in the engine with
clean engine oil. Check the
2. Inspect the Engine Oil Filter operation of the engine oil bypass
valve for the engine oil filter.
A. Inspect the engine oil filter for Oil filter
restrictions. Verify that the problem is
resolved.
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 engine oil pressure.
Replace the damaged component.
Inspect the engine for the following leaks:
· Fuel leaks into the crankcase from the
resolved.
fuel transfer pump. Fuel leak
· Fuel leaks past the valve in a fuel
Result: Fuel is not in the engine
injection nozzle.
oil.
· The pressure setting of the fuel injection
nozzles is too high.
· The drive is broken on the fuel injection
pump.
4. Inspect the Clearance of the Rocker Clearance Result: The clearance is not
Arm within specifications.
A. Measure the clearance.between the bore Make the necessary repairs.

of the rocker arm and the rocker shaft.
resolved.
Result: The clearance is within

specifications.
Result: The rocker assembly

does not have proper lubrication.
Replace parts which are worn.

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

proper lubrication.
Result: The suction tube is loose

or damaged.
The suction tube must be repaired

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

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

the bypass valve if the spring is
7. Inspect the Oil Pump Bypass Valve broken or the plunger is damaged.
Oil pump
A. Inspect oil pump bypass valve for Verify that the problem is
bypass valve
proper operation. resolved.

valve operates correctly.
èéêëìíî îïì ðéñòéì óòô õö÷ë

8. Oil pump Result: The engine oil pump does
not operate correctly.
øAùúûüýþÿ ÿ ý ýúúý üü üüý
operation. The components must be repaired
or replaced.
B. Check the distance of the face of the
cover of the oil pump above the face of the Verify that the problem is
idler gear. Refer to the Specifications resolved.
Module, "Engine Oil Pump" topic. Check
the wear of the lobe on the oil pump. Result: The engine oil pump
operates correctly.
Result: The clearance is not

within specifications.
Replace the crankshaft or the

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

specifications.
Result: The clearance is not

within specifications.
10. Inspect the Camshaft
Replace the camshaft or the
A. Measure the clearance between the Clearance camshaft bearings.
camshaft and the camshaft bearings.
resolved.
The engine oil pressure is too high.
Probable Cause
Table 41

valve does not open.
1. Inspect the Engine Oil Bypass Valve
Bypass The bypass valve must be cleaned
A. Inspect the engine oil bypass valve for
valve or replaced.
proper 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 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

2. Inspect the Engine fitting.
A. Inspect the engine for Oil leaks Verify that the problem is resolved.
oil leaks.
Result: The engine oil lines do not have leaks.
3. Inspect the Engine Valve Result: The valve guides are worn.
Valve Guides guides
Replace the valve guides.
A. Inspect the engine valve
guides for wear. Verify that the problem is resolved.
Result: The valve guides are not worn.
Result: The piston rings are worn.

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

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

engine is low.
Add coolant into the radiator to the

correct level.
2. Check the Coolant Level
Coolant Verify that the problem is resolved.
A. Check the coolant level.
Result: The coolant level in the
engine is not low.
3. Inspect the Coolant Pressure Cap Coolant Result: The coolant pressure cap is
Pressure Cap not working properly.
A. Test the operation of the pressure
cap. Replace the faulty pressure cap.
Result: The coolant pressure cap is

working properly.
Result: Gases from combustion are

in the coolant.
Find the source of the entry of the

gases from combustion into the
4. Inspect the Cooling System coolant system. Repair the source of
the problem.
Cooling
A. Inspect the cooling system for gases
System
from combustion. Verify that the problem is resolved.
Result: Gases from combustion are

not in the coolant.

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

suspect.
Result: The engine is operating with

too much load.
Reduce the load.

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

pump is incorrect.
8. Inspect the Fuel Injection Pump
Timing Adjust the timing. Refer to the
Specifications Module, "Fuel
Timing
A. Check the fuel injection pump for the Injection Pump" topic for additional
correct timing. 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
A. Inspect the air inlet and Restriction
exhaust system, look for a
Result: There is not a restriction in the air inlet
restriction.
or exhaust system.

2. Timing Result: The timing of the fuel injection pump is
Injection Pump Timing incorrect.
A ! Adjust the timing of the fuel injection pump.
fuel injection pump. Refer to the Specifications Module, "Fuel
Injection Pump" topic for additional information.
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
1. Measure the Charge of the
on the cable clamps and to battery posts. Tighten
Battery
Battery the cable clamps on the battery posts.
voltage
A. Measure the battery voltage.
Result: The battery does not have a low charge.
Result: A short circuit was found.
2. Inspect the Starting Motor Repair the short circuit.

Starting
A. Inspect the brushes for the Verify that the problem is resolved.
motor
starting motor. Inspect the
brushes
brushes for a short circuit. Result: A short circuit was not found.
3. Inspect the Ignition Switch, Starter Result: The ignition switch, the start relay, or
the Start Relay, and the circuit the starting motor solenoid are not operating
Starting Motor Solenoid properly.
A. Inspect the ignition switch, Replace or repair the components that are not
the start relay, and the starting operating properly.

motor solenoid for proper
operation. Verify that the problem is resolved.
Result: The ignition switch, the start relay, or

the starting motor solenoid are operating
properly.
4. Inspect the Starting Motor

Circuit
Result: An excessive voltage drop exists in the
cables or across the terminals in the circuits for
A. Inspect the starting motor
the starting motor.
circuit for a voltage drop.
Voltage
drop Replace the damaged parts.
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
drive
pinion drive.
Result: The overrunning clutch for
the pinion drive does not slip.
2. Inspect the Flywheel Ring Gear Flywheel Result: The ring gear of the flywheel
is damaged.
A. Inspect the flywheel ring gear for
damage.. Replace the flywheel.
Result: The ring gear of the flywheel

is not damaged.
Result: The shift lever or the linkage

is damaged.
Replace the shift lever or the linkage.

3. Inspect the Shift Lever
A. Inspect the shift lever and linkage for Shift lever
damage.
Result: The shift lever or the linkage
is not damaged.
Result: The starting motor solenoid

is not operating properly.
Replace or repair the components

4. Inspect the Starting Motor Solenoid that are not operating properly.
Starter
A. Inspect the starting motor solenoid for Verify that the problem is resolved.
solenoid
proper operation.
Result: The starting motor solenoid
is operating properly.
Result: The armature or idler gear of

5. Inspect the Armature or Idler Gear
the starting motor is damaged.
of the Starting Motor
Starting
Replace the starting motor.
A. Inspect the armature or idler gear of motor
the starting motor for damage.
The engine does not crank or the engine rotates slowly when the keyswitch is in
the start position.
Probable Cause
Table 47
Result: The battery has a low charge.
Charge the battery. Replace a faulty battery.

Clean all cable terminals and battery posts. Apply
the 1U-8267 Battery Saver and Cleaner on the
1. Measure the Charge of the
cable clamps and to battery posts. Tighten the
Battery
Battery cable clamps on the battery posts.
voltage
A. Measure the battery voltage.
Result: The battery does not have a low charge.
Result: The start relay is not operation properly.
Replace the start relay.

2. Inspect the Start Relay
Start Verify that the problem is resolved.
A. Check the start relay for
relay
proper operation.
Result: The start relay is operation properly.
Result: An excessive voltage drop exists in the

cables or across the terminals in the circuits for
3. Inspect the Starting Motor
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
battery terminals for loose
in the cables or across the terminals in the circuits
connections, corrosion, or other
for the starting motor.
damage.
Result: The overrunning clutch for the pinion

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

1. Inspect the Ignition Switch, the Start relay, or the starting motor solenoid are
Relay, and the Starting Motor Solenoid not operating properly.
Starter
A. Inspect the ignition switch, the start Replace or repair the components that
circuit
relay, and the starting motor solenoid for are not operating properly.
proper operation.
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.
Replace the return spring of the pinion

1. Inspect the Return Spring of the
solenoid.
Pinion Solenoid
Return
A. Inspect the return spring of the pinion Spring
solenoid for damage.
Result: The return spring of the pinion
solenoid is not damaged.
2. Inspect the Shift Lever Shift Result: The shift lever or the linkage is
lever 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 ignition switch, the start

$%&'()* *+( $,%-*-.% /0-*)+1 *+( /*23*
3. relay, or the starting motor solenoid are
Relay, and the Starting Motor Solenoid not operating properly.
Starter
A. Inspect the ignition switch, the start Replace or repair the components that
circuit
relay, and the starting motor solenoid for are not operating properly.
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
B. Inspect the drive belt for
loose.
wear and for damage.
Result: The drive pulley for the alternator is

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

2. Inspect the Alternator
torque. Replace a damaged pulley.
Drive Pulley
Drive pulley Verify that the problem is resolved.
A. Inspect the pulley for wear
or for damage.
Result: The drive pulley for the alternator is
not loose or worn.
3. Inspect the Electrical Electrical Result: The electrical cables and connections
Connections connections in the charging and starting circuits are loose
or damaged.
A. Inspect the electrical
cables and connections in the Inspect all cables and connections. All
charging and starting circuits. connections must be clean and tight. Apply the
1U-8267 Battery Saver and Cleaner on the
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
Alternator
properly.
· 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:
Replace the component that is not
Alternator
operating properly.
· Regulator or the field winding of the
rotor
· Brushes
· Rectifier
The alternator is noisy.
Probable Cause
Table 52
Result: The drive belt for the alternator is

loose.
1. Inspect the Alternator Drive
Belt The drive belt must be adjusted or
replaced.
A. Verify that the tension is correct
on the drive belt. Drive belt Verify that the problem is resolved.
B. Inspect the drive belt for wear Result: The drive belt for the alternator is
and for damage. not loose.
Result: The drive pulley for the alternator

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

2. Inspect the Alternator Drive
correct torque. Replace a damaged pulley.
Pulley
Drive
A. Inspect the pulley for wear or for 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
alignment
pulley and drive belt.
Result: The drive belt and the drive
pulley are in alignment.
4. Check the Alternator for Alternator Result: The bearings of the alternator are
Proper Operation worn or damaged.
A. Inspect the alternator bearings. Replace the alternator.
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Troubleshooting: Testing and Adjusting

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Service Information System Página 1 de 119

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

Make sure that the gaskets, the insert,

Result: The fuel injection nozzle is

Proceed to Test Step 2.

Result: There is debris on the mounting

Proceed to Test Step 3.

A. Check for a damaged or leaking Repair or replace the high-pressure fuel

Verify that the problem is resolved.

Result: A high-pressure fuel line is not

Proceed to Test Step 4.

Result: The correct fuel nozzles are not

The Engine Exhaust has too Much Black Smoke

Result: There is debris on the mounting

Proceed to Test Step 2.

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

Result: The correct fuel nozzles are not

Result: The fuel injection nozzle does

Make sure that the gaskets, the insert,

Result: The fuel injection nozzle is

Proceed to Test Step 2.

nozzle. mounting surface of the cylinder head

Proceed to Test Step 3.

Result: A high-pressure fuel line is

Repair or replace the high-pressure fuel

Proceed to Test Step 4.

4. Check for Correct Operation of

Verify that the problem is resolved.

Result: The correct fuel nozzles are

Proceed to Test Step 6.

Result: A low-pressure fuel line is

The Engine is Misfiring, Running Rough, or Running Poorly

Result: The fuel injection nozzle

Make sure that the gaskets, the insert,

Result: The fuel injection nozzle is

Proceed to Test Step 2.

injection nozzle. mounting surface of the cylinder head

Proceed to Test Step 3.

Result: A high-pressure fuel line is

Repair or replace the high-pressure

Proceed to Test Step 4.

4. Check for Correct Operation of

Verify that the problem is resolved.

Result: The correct fuel nozzles are

Proceed to Test Step 6.

Result: A high-pressure fuel line is

Repair or replace the high-pressure

Proceed to Test Step 7.

Result: The seat washer is not

Troubleshooting Fuel Injection Nozzles on a Nozzle Tester

Result: There are no fuel

Proceed to Test Step 2.

Result: The valve has debris or is

Result: The opening pressure is not

Proceed to Test Step 2.

Verify that the problem is resolved.

Result: The fuel injection nozzle is not

Proceed to Test Step 3.

Result: The orifices are blocked or

! "#$ % &'($) ()#* )* (