320D2 Troubleshooting8

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Table 26 Troubleshooting Test Steps

Values

Results Result: The fuel quality does not meet the engine specifications.

1. Test the Quality of the Fuel A. Test the quality level of the fuel, make sure the fuel quality meets the engine specifications.

Fuel quality

Remove the fuel from the fuel tank. Install a new fuel filter. Put a good grade of clean fuel in the fuel tank. Verify that the problem is resolved. Result: The fuel quality meets the engine specifications. Proceed to Test Step 2.

Result: The fuel pressure is low. 2. Measure the Fuel Pressure Make the necessary repairs. A. Make sure that sufficient fuel is in the fuel tank. Remove any air in the fuel system. Fuel B. Look for leaks or suspect bends in the fuel line between Pressure the fuel tank and the fuel transfer pump.

Verify that the problem is resolved. Result: The fuel pressure is not low.

C. Check the outlet pressure of the fuel transfer pump. Proceed to Test Step 3.

Result: There is a problem with the governor or the fuel injection linkage.

3. Inspect the Fuel Injection Linkage and the Governor A. Inspect the governor and the fuel injection linkage for damage or the fuel injection linkage for incorrect assembly in the timing gear case.

Governor and fuel injection linkage

Make the necessary repairs. Verify that the problem is resolved. Result: There is not a problem with the governor or the fuel

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injection linkage. Proceed to Test Step 4.

Result: The valve lash exceeds the specification. Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting.

4. Measure the Valve Lash A. Measure the valve lash.

Valve lash

Verify that the problem is resolved. Result: The valve lash is within the specification. Proceed to Test Step 5.

5. Inspect the Operation of the Fuel Injection Pump A. Check the timing of the fuel injection pump. Adjust the timing or replace the fuel injection pump. Refer to the Specifications Module, "Fuel Injection Pump" topic for additional information. The fuel injection pump must be repaired or replaced. B. Make sure that the linkage of the fuel rack operates correctly.

Result: The operation of the fuel injection pump is not correct. Make the necessary repairs. Fuel Injection Pump

C. Make sure that the high pressure fuel lines are connected to the fuel injection nozzles in the correct order.

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

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

Verify that the problem is resolved.

Proceed to Test Step 6.

Fuel Injection Nozzles

Result: A fuel injection nozzle is not operating correctly.

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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 before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder. B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved.

The engine has excessive vibration. Probable Cause Table 27 Troubleshooting Test Steps

Values

Results Result: The bolts for the pulleys are loose or the pulley is damaged.

1. Inspect the Engine Pulleys A. Inspect the engine pulleys for damage or loose bolts. Pulleys Refer to the Specifications Module, "Crankshaft Pulley" topic for additional information.

Tighten the bolts. If the pulley is worn or damaged, use new parts for replacement. Verify that the problem is resolved. Result: The bolts for the pulleys are not loose or the pulley is not damaged. Proceed to Test Step 2.

2. Inspect the Engine Mounts A. Inspect the engine mounts for loose bolts or damage.

Engine mounts

Result: The engine mounts are loose, worn, or suspect. Tighten all mounting bolts. Inspect the engine mounts for wear or for damage. Use new parts

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for replacement. Verify that the problem is resolved.

The engine has excessive combustion noise. Probable Cause Table 28 Troubleshooting Test Steps

Values

Results 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 clean fuel in the fuel tank.

1. Test the Quality of the Fuel A. Test the quality level of the fuel, make sure the fuel quality meets the engine specifications.

Fuel quality

Verify that the problem is resolved. Result: The fuel quality meets the engine specifications. Proceed to Test Step 2.

2. 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 before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the Fuel operation of the engine, the fuel injection nozzle is Injection probably suspect. Test the fuel injection nozzle for that Nozzles cylinder. B. Make sure that the fuel injection nozzles are properly sealed in the threaded ports. Make sure that the fuel injection nozzles are correctly aligned in the threaded ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat

Result: A fuel injection nozzle is not operating correctly. Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved.

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washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Result: The fuel injection nozzles are operating correctly. Proceed to Test Step 3.

Result: The piston height is incorrect. 3. Measure the Piston Height Piston height

A. Measure the engine piston height.

To obtain the correct piston height, the piston, the piston pin, the bearings, or the connecting rod should be replaced. Verify that the problem is resolved.

The engine has excessive valve compartment noise. Probable Cause Table 29 Troubleshooting Test Steps

Values

Results Result: Valve springs or locks are broken. Install new parts. Broken locks can cause the valve to slide into the cylinder. Major damage to the engine can occur.

1. Inspect the Valve Springs and Locks A. Inspect the valve springs and locks for damage.

Valve springs and locks

Verify that the problem is resolved. Result: Valve springs or locks are not broken. Proceed to Test Step 2.

2. Inspect the Rocker Arms A. Inspect the rocker arm assemblies for damage.

Rocker arm assemblies

Result: The bolts and nuts, which hold the rocker arm assembly, are loose. Tighten the bolts or nuts. Refer to the Specifications Module, "Rocker Shaft" topic for additional

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information. Verify that the problem is resolved. Result: The bolts and nuts, which hold the rocker arm assembly, are not loose. Proceed to Test Step 3.

Result: The valve lash exceeds the specification. 3. Measure the Valve Lash A. Measure the valve lash.

Valve lash

Adjust the valve lash. Refer to the Specifications Module, "Engine Design" topic for the valve lash setting. Verify that the problem is resolved.

Engine oil is in the cooling system. Probable Cause Table 30 Troubleshooting Test Steps

Values

Results Result: The engine oil cooler has leaks.

1. Inspect the Engine Oil Cooler Core A. Drain the coolant from the engine and the radiator. Drain the lubricating engine oil from the engine oil cooler. Refer to the Operation and Maintenance Manual for more Engine Oil information. Cooler Core B. Inspect the engine oil cooler core for leaks. Refer to Systems Operation, Testing and Adjusting, "Cooling System - Inspect" for the correct procedure.

Replace the oil cooler. Refer to Disassembly and Assembly, "Engine Oil Cooler - Remove" and Disassembly and Assembly, "Engine Oil Cooler - Install". Fit new seals between the oil cooler and the oil cooler cover. Refill the crankcase with clean engine oil to the correct level. Refer to the Operation and Maintenance Manual for more information. Verify that the problem is resolved. Result: The engine oil cooler does not have leaks. Proceed to Test Step 2.

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Result: The cylinder head gasket has faults or signs of leakage.

2. Inspect the Cylinder Head Gasket A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure.

Replace the cylinder head gasket. Head gasket

Verify that the problem is resolved. Result: The cylinder head gasket does not have faults or signs of leakage.

B. Inspect the cylinder head gasket for faults and any signs of leakage.

Proceed to Test Step 3.

Result: The cylinder head is not flat or has cracks. 3. Inspect the Cylinder Head Repair the cylinder head and/or replace the cylinder head.

A. Check the cylinder head for cracks. B. Check the cylinder head for flatness. Refer to Systems Operation, Testing and Adjusting, "Cylinder Head - Inspect" for the correct procedure.

Cylinder head

Verify that the problem is resolved. Result: The cylinder head is flat and does not have cracks. Proceed to Test Step 4.

Result: The cylinder block has faults or signs of leakage. 4. Inspect the Cylinder Block A. Inspect the top face of the cylinder block for faults and signs of leakage.

Cylinder block

Replace the cylinder block. If signs of leakage are found, determine the cause of the leakage. Refer to Systems Operation, Testing and Adjusting, "Cylinder Block - Inspect" for the correct procedure. Verify that the problem is resolved.

After the Repair A. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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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 Troubleshooting Test Steps

Values

Results Result: The main bearings are damaged. Replace damaged parts.

1. Inspect the Main Bearings A. Inspect the main bearings and the bearing surfaces of the crankshaft.

Main Bearings

Verify that the problem is resolved. Result: The main bearings are not damaged. Proceed to Test Step 2.

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

Crankshaft

Verify that the problem is resolved. Result: The crankshaft is not damaged. Proceed to Test Step 3.

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Result: The piston height is not correct. Replace the damaged component.

3. Inspect the Piston Height A. Check the piston height. B. Inspect the piston, the connecting rod, and the crankshaft for wear. Check for correct installation.

Piston Height

Verify that the problem is resolved. Result: The piston height is correct. Proceed to Test Step 4.

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 before the next fuel line nut is loosened. If loosening the fuel line nut does not affect the operation of the engine, the fuel injection nozzle is probably suspect. Test the fuel injection nozzle for that cylinder. B. Make sure that the fuel injection nozzles are properly Fuel sealed in the threaded ports. Make sure that the fuel Injection injection nozzles are correctly aligned in the threaded Nozzles ports. Make sure that the fuel injection nozzles are tightened to the correct torque. Ensure that the gaskets and the seat washers are installed on the fuel injection nozzles correctly. Make sure that the bottom of the threaded ports are clean and free of debris. Make sure that the bottom of the threaded ports do not contain extra gaskets.

Result: A fuel injection nozzle is not operating correctly. Replace the suspect fuel injection nozzle. Make sure that all of the fuel injection nozzles are the correct type for the engine. Test the pressure setting of the fuel injection nozzles. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for additional information. Verify that the problem is resolved.

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

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Table 32 Troubleshooting Test Steps

Values

Results Result: Lubrication of internal engine components is inadequate. Make the necessary repairs.

1. Check the Lubrication of Internal Components A. Check lubrication of the valves. There must be a strong flow of oil at high rpm. There must be a small flow of oil at low rpm. Oil passages in the engine must be clean.

Lubrication

Verify that the problem is resolved. Result: Lubrication of internal engine components is adequate. Proceed to Test Step 2.

Result: Rocker arm parts are worn. If there is too much wear, install new parts or rocker arms. Adjust the valve lash.

2. Check the Rocker Arms for Wear or Damage A.Visually inspect the rocker arms for wear or damage.

Damage or wear

Verify that the problem is resolved. Result: Rocker arm parts are not worn. Proceed to Test Step 3.

Result: The end of the valve stem is worn. 3. Inspect the Valve Stems A. Inspect the valve stems for wear.

Damage or wear

Install new valves. Adjust the valve lash. Verify that the problem is resolved. Result:The end of the valve

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stem is not worn. Proceed to Test Step 4.

Result: The valve lash is not correct. Adjust the valve lash. 4. Check the Valve Lash A. Check the engine valve lash.

Valve lash

Verify that the problem is resolved. Result: The valve lash is correct. Proceed to Test Step 5.

Result: The pushrods are worn. If there is too much wear, install new pushrods. Adjust the valve lash.

5. Inspect the Engine Pushrods A. Visually inspect the pushrods for wear or damage.

Damage or wear

Verify that the problem is resolved. Result: The pushrods are not worn. Proceed to Test Step 6.

Result: The valve lifters are worn. 6. Inspect the Valve Lifters A. Visually inspect the valve lifters for wear or damage.

Damage or wear

If there is too much wear, install new valve lifters. Adjust the valve lash. Verify that the problem is resolved.

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Result: The valve lifters are not worn. Proceed to Test Step 7.

Result: The components are worn. 7. Inspect the Camshaft Replace suspect parts. Adjust the valve lash.

A. Measure the valve lash. B. Check for free movement of the valves.

Damage or wear

Verify that the problem is resolved.

C. Check for bent valve stems. Result: The components are not worn.

D. Check for wear on the valve lifters.

Proceed to Test Step 8.

Result: The bolts and the nuts that hold the rocker arm assembly are loose.

8. Inspect the Rocker Arm Assembly A. Visually inspect the rocker arms for wear, damage or loose bolts..

Damage or wear

Tighten the bolts and the nuts. Verify that the problem is resolved.

A cylinder head valve is loose. Probable Cause Table 33 Troubleshooting Test Steps

Values

Result: The valve keeper for the valve is broken.

1. Inspect the Valve Keepers A. Inspect the engine valve keepers for damage.

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Results

Valve keepers

Replace the valve keeper. Broken keepers can cause the valve to slide into the cylinder. Major engine damage can result.

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Verify that the problem is resolved. Result: The valve keeper for the valve is not broken. Proceed to Test Step 2.

Result: The valve springs are broken or damaged.

2. Inspect the Valve Springs Valve A. Inspect the valve springs for springs damage..

Install new valve springs. Verify that the problem is resolved.

Oil condenses at the exhaust. Probable Cause

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Table 34 Troubleshooting Test Steps

Values

Results Result: The valve compartment contains too much oil. Look at both ends of the rocker arm shaft. Be sure that a plug is installed in each end.

1. Inspect the Valve Compartment A. Inspect the valve compartment for excessive oil..

Valve compartment

Verify that the problem is resolved. Result: The valve compartment does not contain too much oil. Proceed to Test Step 2.

Result: The valve guides are worn. Install new valve guides. Recondition the cylinder head.

2. Inspect the Valve Guides A. Measure the timing of the fuel injection pump.

Timing

Verify that the problem is resolved. Result: The valve guides are not worn.. Proceed to Test Step 3.

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