Professional Documents
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ENGINES PROBLEMS &main CAUSES
ENGINES PROBLEMS &main CAUSES
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1a. Engine Crankshaft Will Not Turn
When Start Switch Is On
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1b. Engine Crankshaft Will Not Turn
When Start Switch Is On
Cause Correction
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2a. Engine will not start
Cause Correction
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2b. Engine will not start
Cause Correction
No Fuel to Cylinders
Put fuel in fuel tank. “Prime” (remove
the air and/or low quality fuel from the
fuel system)
Bad Quality Fuel Remove the fuel from the fuel tank.
Install a new fuel filter element. Put a
good grade of clean fuel in the fuel
tank.
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3a. Misfiring Or Running Rough
Cause Correction
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3b. Misfiring Or Running Rough
Cause Correction
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3c. Misfiring Or Running Rough
Cause Correction
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4a. Stall At Low RPM
Cause Correction
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4b. Stall At Low RPM
Cause Correction
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4c. Stall At Low RPM
Cause Correction
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5. Sudden Changes In Engine Speed (rpm)
Cause Correction
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6a. Not Enough
Cause
Power Correction
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6b. Not Enough Power
Correction
Cause
Check the pressure in the air intake
Leaks in Air Inlet System
manifold. Look for restrictions in the air
cleaner.
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6c. Not Enough Power
Cause Correction
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6d. Not Enough Power
Correction
Cause
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7. Too Much Vibration
Cause Correction
Vibration damper or Pulley is Loose Check vibration damper and pulley for
damage. Tighten bolts or nuts. If
vibration damper or pulley bolt holes
have damage or wear, replace with
new parts.
Vibration Damper Has A Defect Install a new vibration damper
Engine Supports Are Loose, Worn or Tighten all mounting bolts. Install new
Have a Defect components if necessary.
Driven Equipment is not in Alignment Check alignment and balance, correct
or is Out of Balance if needed.
Flexible Coupling Between Engine Repair or replace coupling
and Driven equipment Has a Defect
components.
Misfiring or Running Rough
Make reference to item 3.
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8. Loud Combustion Noise (Sound)
Cause Correction
Bad Quality Fuel Remove the fuel from the fuel tank.
Install a new fuel filter element. Put a
good grade of clean fuel in the fuel
tank.
Defect in Fuel Injection Valve(s) or Run engine at rpm that gives
Fuel Injection Pump(s) maximum misfiring or rough running.
Then loosen a fuel line nut on the
injection pump for each cylinder, one
at a time. Find the cylinder where
loosening the fuel line nut does not
change the way the engine runs. Test
the injection pump and injection valve
for that cylinder. Install new parts
Wrong Fuel Injection Timing where needed.
Make adjustment to timing.
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9. Valve Train Noise (Clicking)
Correction
Cause
Install new parts where necessary.
Broken Valve Spring(s) or Locks Broken locks can cause the valve to
slide into the cylinder. This will cause
much damage.
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10. Oil In Cooling System
Cause Correction
Defect In Core of Oil Cooler Install a new core in the oil cooler
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11. Mechanical Noise (Knock) In Engine
Cause Correction
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12. Fuel Consumption Too High
Cause Correction
Fuel and Combustion Noise (Knock) Make Reference to Item 3 and Item 6.
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13. Loud Valve Train Noise
Cause Correction
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14a. Too Much Valve Lash
Correction
Cause
Check lubrication in valve
Not Enough Lubrication compartment. There must be a strong
flow of oil at engine high rpm, but
only a small flow at low rpm. Oil
passages must be clean, especially
those sending oil to the cylinder head.
Rocker Arm Worn at Face That If there is too much wear, install new
Contacts End of Valve parts or rocker arms. Make adjustment
of valve clearance according to
Testing and Adjusting.
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14b. Too Much Valve Lash
Correction
Cause
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14c. Too Much Valve Lash
Cause Correction
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14d. Too Much Valve Lash
Cause Correction
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15. Valve Rotocoil Or Spring Lock Is Free
Cause Correction
Broken Locks
Broken locks can cause the valve to
slide into the cylinder. This will cause
much damage.
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16. Oil At The Exhaust
Cause Correction
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17. Little Or No Valve Clearance
Cause Correction
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18. Engine Has Early Wear
Correction
Cause
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19. Coolant In Lubrication Oil
Correction
Cause
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20. Too Much Black Or Gray Smoke
Correction
Cause
Not Enough Air For Combustion Check air cleaner for restrictions.
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21a. Too Much White or Blue Smoke
Cause Correction
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21b. Too Much White or Blue Smoke
Cause Correction
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22a. Engine Has Low Oil Pressure
Cause Correction
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22b. Engine Has Low Oil Pressure
Cause Correction
Pressure Regulating Valve Does Not Clean valve and housing. Install new
Close parts as necessary.
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22c. Engine Has Low Oil Pressure
Cause Correction
Too Much Clearance Between Check the oil filter for correct
Crankshaft and Crankshaft Bearings operation. Install new parts if
necessary.
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23a. Engine Uses Too Much Lubrication Oil
Cause Correction
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23b. Engine Uses Too Much Lubrication Oil
Cause Correction
Too Much Oil in the Valve Look at both ends of the rocker arm
Compartment. shaft. Be sure that there is a plug in
each end.
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24a. Engine Coolant Is Too Hot
Cause Correction
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24b. Engine Coolant Is Too Hot
Cause Correction
Combustion Gases in Coolant Find out where gases get into the
cooling system. Make repairs as
needed.
Water Temperature Regulators
(Thermostats) or Temperature Gauge
Has a Defect Check water temperature regulators
for correct operation. Check
temperature gauge operation. Install
Water Pump Has A Defect new parts as necessary.
Too Much Load On The System Make repairs to the water pump as
necessary.
Wrong Fuel Injection Timing
Make a reduction to the load.
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25. Starting Motor Does Not Turn
Cause Correction
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26. Alternator Gives No Charge
Cause Correction
Loose Drive Belt For Alternator Make an adjustment to put the correct
tension on the drive belt.
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27a. Alternator Charge Rate Is Low Or Not Regular
Cause Correction
Make an adjustment or
Alternator Regulator Has A Defect replacement of alternator
regulator.
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27b. Alternator Charge Rate Is Low |Or Not Regular
Cause Correction
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28. Alternator Charge Too High
Cause Correction
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29. Alternator Has Noise
Cause Correction
Drive Belt For Alternator is Worn Or Install a new drive belt for the
Has A Defect. alternator.
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30. Exhaust Temperature Is Too High
Cause Correction
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