8 - TROUBLESHOOTING 8 - TROUBLESHOOTING SYMPTOM(S) Engine - Troubleshooting Problem Possible Cause, Correction FThe engine does not start Partally discharged batteries (Check, charge the batteries and, neces sary. replace them [Corroded or loose connections to the bat tery terminals (Clean, inspect, tighten the nuts and, finec Jessary, replace the excessively corrodea| terminals and nuts Dir or water accumulations in fuel ines Disconnect the ines and the injection pump| Jand carefully clean them; if necessary, [clean and dry the fuel tank No fuel in the tank FI the tank. INo-supply to the injection pump [Check and, ifnecessary, replace the supply] pump [Aira the fuel system (Check the nes, the @ings, the supply] pump, the fiters and the injection pump for the presence of air, then bleed the system [Damaged starter motor [Repair or replace the starter motor [The engine stops Ireqular delivery of the supply pump [Check delivery on the workbench Dirt or water accumulations in uel ines Disconnect the ines and the injection pump] Jand carefully clean them; if necessary, [clean and dry the fuel tank Restricted fuel fiters Replace the fiter cartridges [Burned or cracked valves [Replace the valves. [Air in the fuel system (Check the Tines, the fings, the supply] pump, the fters and the injection pump for the presence of ar, then bleed the system [Damaged injection pump controls Replace the damaged parts [The engine overheats The centrifugal pump of the cooling system is faulty [Overhaul the pump and, if necessary, re- place it Faulty temperature switch [Replace the temperature switch Radiator partially faully Eliminate possible scales by washing [check and repair possible tube leaks [Scales in coolant passage compartments in cylinder heads and crankcase (Carefully wash (Centritugal pump drive belt and Tan dive| belt too slack. [Cheek and adjust belt tension [Coolant (insufficient quantity) Restore the level nthe expansion tank by] adding the prescribed fluid mearrect ming of the engine [Check and correctly time the engine Restricted air fiter (Clean the assembly and, if necessary, re- place the fiter element [The engine has Janomalous knocks Partially obstructed or damaged injectors (Clean, overhaul and correctly calibrate the| injectors [Dir accumulations in fuel ines (Clean the lines and replace the visi] Jdented pipes; if necessary, clean the injec-| tion pump Drive shaft Knocks caused by an exces} sive clearance of one or more crankshat| bearings or big end bearings or excessive| shoulder clearance Recify the drive shaft pins, assemble big} ]ger shoulder bearings and rings [Unbalanced drive shaft [Check the alignment and the balance of he| rive shaft and, ifnecessary, replace it Loose fywheal retaining screws Replace the loose screws and tighten all screws to the prescribed torque + angle et8 - TROUBLESHOOTING Problem Possible Cause Correction: [Connecting rod axes not parallel [Straighten the connecting rods, check thal the axes are parallel and, if necessary, re-| place the connecting rods [Cylinder knocks due to anomalous wear Bore the cylinder barrels and assemble Dig lger cylinders Noisy cylinder pin due to excessive clear lance in hub and connecting rod bushing, [Bushings free in their seat on the connect ing rod Replace the pin wih a bigger one, repro |cess the hubs on the cylinder and the bus ing on the connecting rod. Replace the| bushing Ticking due to noisy distribution [Check that there are no broken springs, that there is no excessive clearance be- tween the rods and the rails, tappets and seats; adjust the clearance between vaives| land rockers [Anomalous engine smoke| [Contact your Dealer Difficult starting and poor performance under all lconditions igh-pressure pump faulty |Contact your Dealer Difficult start, poor performance, the engine uns with one cylinder loss. Injector with shutler or solenoid core (me [chanical part) stuck open. [Contact your Dealer Starting takes tens of lseconds, much white lexhaust smoke, smell of luo! Injector (irreversibly) stuck open |Contact your Dealer [Broken high-pressure line from pump to common rail [Anomalous vibrations caused by a Toose| line clamping [Contact your Dealer [The engine operates with la cylinder less, without lsaving failures in the lcontrof unit Injector stuck closed [Contact your Dealer 828 - TROUBLESHOOTING Starter motor - Troubleshooting Problem Possible Cause: ‘Correction The starter motor does not run Too Tow specific gravity and battery level Inspect the battery Poor ignition switch circuit connection or contact [Replace the winng hamess and the ignition] switch or starter motor runs too slow) [Malfunction of the coll or of the magnetic [switch pullin cylinder Replace the magnetic switen "The starter motor running Jeannot crank the engine FThe pinion gear does nat engage wih the] ring gear Repair or replace the clutch and the contra] lever Sliding clutch [Replace the clutch lAnomarous noise [Anomalous bushing wear Replace starter [Wear on pinion gear or ring gear tooth tps| For ring gear damage contact Dealer Poor pinion gear sliding Replace starter [The pinion gear springs Poor ignition switch return [Replace the ignition switch Field coll loss. Magnetic [switch coil burnt, etc. Pinion gear disengagement fault caused by| a coil short circuit in the magnetic switch Replace the magnetic switch ery