320D2 Troubleshooting5.pdf

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The crankcase breather (if equipped), or the tubing must be cleaned or replaced. A. Check the crankcase breather for restrictions.

Verify that the problem is resolved. Result: The crankcase breather does not have restrictions. Proceed to Test Step 3.

Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. 3. Check for Proper Installation of the Turbocharger A. Verify that turbocharger is not loose or the clamps and bolts on the turbocharger are not loose.

Correctly position the turbocharger and tighten the clamps and bolts. Turbocharger

Verify that the problem is resolved. Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 4.

Result: The incorrect type of engine oil is being used. Drain the engine oil. Install the correct quantity and type of engine oil.

4. Check the Engine Oil A. Verify that the correct type of engine oil is being used.

Engine oil

Verify that the problem is resolved. Result: The correct type of engine oil is being used. Proceed to Test Step 5.

5. Inspect the Engine Oil Drain Pipe

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Restrictions

Result: The engine oil pipe has restrictions.

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The drain pipe must be repaired or replaced. A. Inspect the engine oil drain pipe for restrictions.

Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions. Proceed to Test Step 6.

Result: The engine oil pipe has restrictions. The drain pipe must be repaired or replaced.

6. Inspect the Engine Oil Drain Pipe A. Inspect the engine oil drain pipe for restrictions.

Restrictions

Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions. Proceed to Test Step 7. Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced.

7. Inspect the Turbocharger A. Inspect the turbine housing for damage or a restriction.

Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 8. Result: The turbocharger bearings are not OK.

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

Turbocharger Bearings

Replace the turbocharger. Verify that the problem is resolved.

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Result: The turbocharger bearings are OK. Proceed to Test Step 9. Result: The piston rings have wear. Replace the piston rings. 9. Inspect the Piston Rings A. Inspect the piston rings for wear.

Verify that the problem is resolved. Piston rings

Result: The piston rings do not have wear. Proceed to Test Step 10. 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.

Verify that the problem is resolved. Leaks Result: The oil supply line does not have leaks. Proceed to Test Step 11. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.

11. Verify the High Idle Speed A. Verify the high idle speed of the engine.

High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 12.

12. Inspect the Turbocharger for a Restriction

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

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The bearing housing must be repaired or the turbocharger must be replaced.

A. Inspect the turbocharger for a restriction in the bearing housing.

Verify that the problem is resolved.

Excessive engine oil exists at the end of the turbine. Probable Cause Table 11 Troubleshooting Test Steps

Values

Results Result: The crankcase breather has restrictions. The crankcase breather (if equipped), or the tubing must be cleaned or replaced.

1. Check for Restrictions in the Crankcase Breather A. Check the crankcase breather for restrictions.

Restrictions

Verify that the problem is resolved. Result: The crankcase breather does not have restrictions. Proceed to Test Step 2.

Result: There is damage or a restriction in the exhaust system components. The component must be repaired or replaced.

2. Check for a Restriction in the Exhaust System A. Check for damage or a restriction in the exhaust system components.

Restriction/damage

Verify that the problem is resolved. Result: There is not damage or a restriction in the exhaust system components. Proceed to Test Step 3.

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Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. Correctly position the turbocharger and tighten the clamps and bolts.

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

Turbocharger

Verify that the problem is resolved. Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 4.

Result: The engine oil pipe has restrictions. The drain pipe must be repaired or replaced.

4. Inspect the Engine Oil Drain Pipe A. Inspect the engine oil drain pipe for restrictions.

Restrictions

Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions. Proceed to Test Step 5. Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced.

5. Inspect the Turbocharger A. Inspect the turbine housing for damage or a restriction.

Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction.

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Proceed to Test Step 6. Result: The turbocharger bearings are not OK. Replace the turbocharger. 6. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.

Turbocharger Bearings

Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 7. Result: The turbocharger rotor has carbon build-up. Remove the carbon.

7. Inspect the Turbocharger Rotor A. Inspect the turbocharger rotor for carbon build-up.

Carbon build-up

Verify that the problem is resolved. Result: The turbocharger rotor does not have carbon build-up. Proceed to Test Step 8. Result: The piston rings have wear. Replace the piston rings.

8. Inspect the Piston Rings A. Inspect the piston rings for wear.

Piston rings

Verify that the problem is resolved. Result: The piston rings do not have wear. Proceed to Test Step 9.

9. Inspect the Turbocharger for Fluid

Anti-corrosion fluid

Result: The turbocharger has excessive anti-corrosion fluid.

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

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

Result: The turbocharger does not have excessive anti-corrosion fluid. Proceed to Test Step 10. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced.

10. Verify the High Idle Speed A. Verify the high idle speed of the engine.

High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 11. Result: The turbocharger has a restriction in the bearing housing.

11. Inspect the Turbocharger for a Restriction A. Inspect the turbocharger for a restriction in the bearing housing.

Restriction

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

Excessive engine oil exists at the compressor end of the turbocharger. Probable Cause Table 12 Troubleshooting Test Steps

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Values

Results

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

1. Check for Restrictions in the Air Filter Element A. Check the condition of the air filter element.

Air filter element

Verify that the problem is resolved. Result: The air filter element is not dirty or does not have restrictions. Proceed to Test Step 2.

Result: The crankcase breather has restrictions. The crankcase breather (if equipped), or the tubing must be cleaned or replaced.

2. Check for Restrictions in the Crankcase Breather Restrictions A. Check the crankcase breather for restrictions.

Verify that the problem is resolved. Result: The crankcase breather does not have restrictions. Proceed to Test Step 3.

Result: There is damage or a restriction to the tube between the air filter and the turbocharger. 3. Check for a Restriction in the Tube between the Air Filter and the Turbocharger A. Check for damage or a restriction in the tube between the air filter and the turbocharger.

Find the restriction and repair or replace the component. Restriction/damage

Verify that the problem is resolved. Result: There is not damage or a restriction to the tube between the air filter and the turbocharger. Proceed to Test Step 4.

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

Find the leak or restriction and repair or replace the component. Air leak or restriction

Verify that the problem is resolved. Result: There is not a leak or a restriction to the tube between the intake manifold and the turbocharger. Proceed to Test Step 5.

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

Correctly position the turbocharger and tighten the clamps and bolts. Fuel Nozzle

Verify that the problem is resolved. Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 6.

Result: The turbocharger has combustion gas or air leaks. Replace the turbocharger.

6. Inspect the Turbocharger Seals A. Inspect the turbocharger for combustion gas or air leaks.

Leaks

Verify that the problem is resolved. Result: The turbocharger does not have combustion gas or air leaks. Proceed to Test Step 7.

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Result: The turbocharger bearings are not OK. Replace the turbocharger. 7. Inspect the Turbocharger Bearings A. Inspect the turbocharger bearings.

Turbocharger Bearings

Verify that the problem is resolved. Result: The turbocharger bearings are OK. Proceed to Test Step 8. Result: The compressor housing contains debris. Clean the compressor housing.

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

Verify that the problem is resolved. Debris Result: The compressor housing does not contain debris. Proceed to Test Step 9. Result: The piston rings have wear. Replace the piston rings.

9. Inspect the Piston Rings A. Inspect the piston rings for wear.

Verify that the problem is resolved. Piston rings

Result: The piston rings do not have wear. Proceed to Test Step 10. Result: The turbocharger has excessive anti-corrosion fluid.

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

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

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Result: The turbocharger does not have excessive anti-corrosion fluid. Proceed to Test Step 11. Result: The high idle operates for an excessive time. The fuel injection pump must be repaired or replaced. 11. Verify the High Idle Speed A. Verify the high idle speed of the engine.

High idle

Verify that the problem is resolved. Result: The high idle does not operate for an excessive time. Proceed to Test Step 12. Result: The turbocharger has a restriction in the bearing housing.

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

Restriction

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

Engine oil exists in the exhaust manifold. Probable Cause Table 13 Troubleshooting Test Steps

Values

Result: The crankcase breather has restrictions.

1. Check for Restrictions in the Crankcase Breather Restrictions A. Check the crankcase breather for restrictions.

Results

The crankcase breather (if equipped), or the tubing must be cleaned or replaced. Verify that the problem is resolved. Result: The crankcase breather does not

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have restrictions. Proceed to Test Step 2.

Result: There is damage or a restriction in the exhaust system components. The component must be repaired or replaced.

2. Check for Restriction in the Exhaust System A. Check for damage or a restriction in the exhaust system components.

Restriction/damage

Verify that the problem is resolved. Result: There is not damage or a restriction in the exhaust system components. Proceed to Test Step 3.

Result: The engine oil pipe has restrictions. The drain pipe must be repaired or replaced.

3. Inspect the Engine Oil Drain Pipe A. Inspect the engine oil drain pipe for restrictions.

Restrictions

Verify that the problem is resolved. Result: The engine oil pipe does not have restrictions. Proceed to Test Step 4. Result: The turbine housing is damaged or has a restriction. The turbine housing must be repaired or the turbocharger must be replaced.

4. Inspect the Turbocharger A. Inspect the turbine housing for damage or a restriction.

Restriction/damage

Verify that the problem is resolved. Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 5.

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