320D2 Troubleshooting6

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The supply line must be repaired or replaced. Verify that the problem is resolved. A. Inspect the oil supply line for leaks.

Result: The oil supply line does not have leaks. 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 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. The bearing housing must be repaired or the turbocharger must be replaced.

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

Restriction

Verify that the problem is resolved. Result: The turbocharger has a restriction in the bearing housing. Proceed to Test Step 12.

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Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.

12. Inspect the Engine Oil Filter A. Inspect the engine oil filter for a restriction.

Oil Filter Verify that the problem is resolved. Result: The engine oil filter does not have a restriction. Proceed to Test Step 13.

13. Correct Engine Operation The engine may have stopped too soon from a high load condition. A. Check the following components for correct operation or damage: · · · · · ·

Compressor impeller of the turbocharger Cooling system Fuel injection pump Air/fuel ratio control Valve lash Fuel injection nozzles

Result: The components listed are not operating properly. Engine operation

The component must be repaired or replaced. Verify that the problem is resolved.

The inside of the intake manifold is wet. Probable Cause Table 15 Troubleshooting Test Steps 1. Check for Restrictions in the Air Filter Element A. Check the condition of the air filter

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Values

Air filter element

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

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or replaced. Verify that the problem is resolved. element.

Result: The air filter element is not dirty or does not have restrictions. Proceed to Test Step 2.

Result: The crankcase breather has restrictions. The crankcase breather (if equipped), or the tubing must be 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: The air filter element is not sealed properly. Inspect the air filter element and the air supply line to the turbocharger for correct installation.

3. Check for Proper Installation of the Air Filter Element A. Verify that the air filter element is sealed properly.

Air filter

Verify that the problem is resolved. Result: The air filter element is sealed properly. Proceed to Test Step 4.

4. Check for a Restriction in the Tube between the Air Filter and the Turbocharger A. Check for damage or a restriction in the

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Restriction/damage

Result: There is damage or a restriction to the tube between the air filter and the turbocharger. Find the restriction and repair or

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replace the component. Verify that the problem is resolved. tube between the air filter and the turbocharger.

Result: There is not damage or a restriction to the tube between the air filter and the turbocharger. Proceed to Test Step 5.

Result: There is a leak or a restriction to the tube between the intake manifold and the turbocharger. 5. 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 6.

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

6. 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 7.

7. Check for Proper Installation of the Turbocharger

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Turbocharger

Result: The turbocharger is loose or the clamps and bolts on the

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turbocharger are loose. Correctly position the turbocharger and tighten the clamps and bolts. Verify that the problem is resolved.

A. Verify that turbocharger is not loose or the clamps and bolts on the turbocharger are not loose.

Result: The turbocharger is not loose or the clamps and bolts on the turbocharger are not loose. Proceed to Test Step 8. Result: The exhaust manifold has cracks, loose bolts, or a distorted flange. The exhaust manifold must be repaired or replaced.

8. Inspect the Exhaust Manifold A. Inspect the exhaust manifold for cracks, loose bolts, or a distorted flange.

Exhaust manifold

Verify that the problem is resolved. Result: The exhaust manifold does not have cracks, loose bolts, or a distorted flange. Proceed to Test Step 9.

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

9. 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 10.

10. Inspect the Turbocharger

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Restriction/damage

Result: The turbine housing is damaged or has a restriction.

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The turbine housing must be repaired or the turbocharger must be replaced. Verify that the problem is resolved. A. Inspect the turbine housing for damage or a restriction.

Result: The turbine housing is not damaged or does not have a restriction. Proceed to Test Step 11.

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

11. 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 12. Result: The turbocharger bearings are not OK. Replace the turbocharger.

12. 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 13. Result: The compressor housing contains debris.

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

Clean the compressor housing. Debris

Verify that the problem is resolved. Result: The compressor housing does not contain debris.

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Proceed to Test Step 14. Result: The piston rings have wear. Replace the piston rings. 14. 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 15. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.

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

Verify that the problem is resolved. Restriction Result: The turbocharger does not have a restriction in the bearing housing. Proceed to Test Step 16. Result: The air inlet heater has fuel leaks. Repair the leaks.

16. Inspect the Air Inlet Heater A. Test the air inlet heater for leakage.

Verify that the problem is resolved. Leaks Result: The air inlet heater does not have fuel leaks. Proceed to Test Step 17. Result: The back plate of the compressor is cracked.

17. Inspect the Compressor A. Inspect the back plate of the

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Compressor

The back plate of the compressor must

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be repaired or the turbocharger must be replaced.

compressor.

Verify that the problem is resolved.

Damaged compressor impeller of the turbocharger Probable Cause Table 16 Troubleshooting Test Steps

Values

Results Result: The air filter element is not sealed properly. Inspect the air filter element and the air supply line to the turbocharger for correct installation.

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

Air filter

Verify that the problem is resolved. Result: The air filter element is sealed properly. Proceed to Test Step 2.

Result: There is damage or a restriction to the tube between the air filter and the turbocharger. 2. Check for a Restriction in the Tube between the Air Filter and the 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 3.

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Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. 3. Check for Proper Installation of the 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.

4. Check for Turbocharger for Proper Lubrication Result: The components listed are not operating properly.

The flow of engine oil is delayed to the turbocharger when the engine is started. Insufficient oil flows to the turbocharger when the engine is running. A. Check the following components for correct operation: · · · · ·

The component must be repaired or replaced. Turbocharger lubrication

Verify that the problem is resolved. Result: The components listed are operating properly.

Engine oil pump Engine oil bypass valve Engine oil filter Viscosity of the engine oil Restrictions in oil lines

Proceed to Test Step 5.

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

5. 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 oil is being used. Proceed to Test Step 6.

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Result: The oil supply line is restricted. The oil supply line must be repaired or replaced.

6. Check the Engine Oil Supply Line A. Inspect the oil supply line from the engine oil pan for a restriction.

Restrictions

Verify that the problem is resolved. Result: The oil supply line is not restricted. Proceed to Test Step 7. 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 Verify that the problem is resolved. A. Inspect the compressor housing for debris.

Debris Result: The compressor housing does not contain debris. Proceed to Test Step 9.

Result: The engine rpm increases too rapidly when the engine is started.

9. Verify the Engine RPM A. Verify the engine RPM during startup.

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Engine RPM Check the fuel injection pump for correct operation and settings.

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Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 10. Result: The high idle operates for an excessive time. Check the fuel injection pump for correct operation and settings.

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 oil supply line has leaks. The supply line must be repaired or replaced.

11. 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 12. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.

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

Restriction

Verify that the problem is resolved. Result: The turbocharger does not have a restriction in the bearing housing. Proceed to Test Step 13.

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Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.

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

Oil Filter Verify that the problem is resolved. Result: The engine oil filter does not have a restriction. Proceed to Test Step 14.

14. Correct Engine Operation The engine may have stopped too soon from a high load condition. Result: The components listed are not operating properly.

A. Check the following components for correct operation or damage: · Compressor impeller of the turbocharger · Cooling system · Fuel injection pump · Air/fuel ratio control · Valve lash · Fuel injection nozzles

Engine operation

The component must be repaired or replaced. Verify that the problem is resolved.

Damage to the turbine Probable Cause Table 17 Troubleshooting Test Steps 1. Check for Restriction in the Exhaust System

Values

Restriction/damage

Results Result: There is damage or a restriction in the exhaust system components.

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

Result: There is not damage or a restriction in the exhaust system components. Proceed to Test Step 2.

Result: The turbocharger is loose or the clamps and bolts on the turbocharger are loose. 2. 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 3.

3. Check for Turbocharger for Proper Lubrication Result: The components listed are not operating properly.

The flow of engine oil is delayed to the turbocharger when the engine is started. Insufficient oil flows to the turbocharger when the engine is running. A. Check the following components for correct operation: · · · · ·

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Engine oil pump Engine oil bypass valve Engine oil filter Viscosity of the engine oil Restrictions in oil lines

The component must be repaired or replaced. Turbocharger lubrication

Verify that the problem is resolved. Result: The components listed are operating properly. Proceed to Test Step 4.

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Result: The engine oil is dirty. Drain the engine oil. Install the correct type of engine oil. Replace the engine oil filter.

4. Inspect the Engine Oil A. Inspect the engine oil.

Engine Oil

Verify that the problem is resolved. Result: The engine oil is not dirty. Proceed to Test Step 5.

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

5. 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 oil is being used. Proceed to Test Step 6.

Result: The oil supply line is restricted. The oil supply line must be repaired or replaced.

6. Check the Engine Oil Supply Line A. Inspect the oil supply line from the engine oil pan for a restriction.

Restrictions

Verify that the problem is resolved. Result: The oil supply line is not restricted. Proceed to Test Step 7. Result: The turbine housing is damaged or has a restriction.

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

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Restriction/damage

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

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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. Replace the turbocharger. 8. 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 9. Result: The turbocharger rotor has carbon build-up. Remove the carbon.

9. 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. Proceed to Test Step 10.

Result: The engine rpm increases too rapidly when the engine is started. Check the fuel injection pump for correct operation and settings.

10. Verify the Engine RPM A. Verify the engine RPM during startup.

Engine RPM

Verify that the problem is resolved. Result: The engine rpm does not increase too rapidly when the engine is started. Proceed to Test Step 11.

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Result: The high idle operates for an excessive time. Check the fuel injection pump for correct operation and settings.

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 fuel injection pump is not operating correctly. The fuel injection pump must be repaired or replaced.

12. Inspect the Fuel Injection Pump for Proper Operation A. Test the fuel injection pump for proper operation.

Fuel pump

Verify that the problem is resolved. Result: The fuel injection pump is operating correctly. Proceed to Test Step 13. Result: The inlet valves and the exhaust valves are burned. Replace the inlet valves and the exhaust valves. Determine the cause of the damage to the valves.

13. Inspect the Intake and Exhaust Valves A. Inspect the intake and exhaust valves.

Burned valves

Verify that the problem is resolved. Result: The inlet valves and the exhaust valves are not burned. Proceed to Test Step 14. Result: The oil supply line has leaks.

14. Inspect the Oil Supply Line A. Inspect the oil supply line for leaks.

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Leaks

The supply line must be repaired or replaced.

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Verify that the problem is resolved. Result: The oil supply line does not have leaks. Proceed to Test Step 15. Result: The turbocharger has a restriction in the bearing housing. The bearing housing must be repaired or the turbocharger must be replaced.

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

Restriction

Verify that the problem is resolved. Result: The turbocharger has a restriction in the bearing housing. Proceed to Test Step 16. Result: The engine oil filter has a restriction. Clean the engine oil filter base and the housing for the engine oil filter. Check the operation of the engine oil bypass valve in the engine oil filter base. Replace the engine oil filter.

16. Inspect the Engine Oil Filter A. Inspect the engine oil filter for a restriction.

Oil Filter Verify that the problem is resolved. Result: The engine oil filter does not have a restriction. Proceed to Test Step 17.

17. Correct Engine Operation Result: The components listed are not operating properly.

The engine may have stopped too soon from a high load condition. A. Check the following components for correct operation or damage:

Engine operation

The component must be repaired or replaced. Verify that the problem is resolved.

· Compressor impeller of the

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