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  • Crdi - Symptom Troubleshooting Guide Table

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    Jonnifer Bunda
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    This document provides a troubleshooting guide for common engine symptoms with possible causes. Symptoms addressed include: (1) engine not starting; (2) engine starting with difficulty or stalling; (3) poor starting when hot. For each symptom, multiple possible causes are listed such as fuel supply issues, sensor faults, contaminated valves, electrical faults, and more. The guide aims to aid technicians in diagnosing engine issues by pointing to potential root causes associated with specific symptoms.

    Original Description:

    CRDI

    Original Title

    CRDI_SYMPTOM TROUBLESHOOTING GUIDE TABLE

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    This document provides a troubleshooting guide for common engine symptoms with possible causes. Symptoms addressed include: (1) engine not starting; (2) engine starting with difficulty or stalling; (3) poor starting when hot. For each symptom, multiple possible causes are listed such as fuel supply issues, sensor faults, contaminated valves, electrical faults, and more. The guide aims to aid technicians in diagnosing engine issues by pointing to potential root causes associated with specific symptoms.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    Download as pdf or txt
    70 views6 pages

    Crdi - Symptom Troubleshooting Guide Table

    Uploaded by

    Jonnifer Bunda
    This document provides a troubleshooting guide for common engine symptoms with possible causes. Symptoms addressed include: (1) engine not starting; (2) engine starting with difficulty or stalling; (3) poor starting when hot. For each symptom, multiple possible causes are listed such as fuel supply issues, sensor faults, contaminated valves, electrical faults, and more. The guide aims to aid technicians in diagnosing engine issues by pointing to potential root causes associated with specific symptoms.

    Copyright:

    © All Rights Reserved
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    of 6

    GENERAL FL -17

    SYMPTOM TROUBLESHOOTING GUIDE TABLE

    (SYMPTOM 1) ENGINE DOES NOT START

    Possible Cause

    • Run out of fuel


    • Inversion of low pressure fuel connections
    • Starter faulty
    • Fuel filter not adapted
    • Fuel pump hose supply cut
    • Low pressure fuel circuit sealed
    • High pressure leakage
    • Sealed fuel filter
    • Fuse out of order
    • Intermittent fault connection
    • Drift of the rail pressure sensor not detected
    • Air ingress in the low pressure fuel circuit
    • Cam and Crank signals missing simultaneously
    • Fuel return circuit of the pump sealed
    • Battery voltage too low
    • Engine compression too low
    • Faulty immobilizer
    • Leakage at the injector
    • Electric EGR control valve blocked open
    • Low pressure fuel pump faulty
    • Fuel pressure regulator valve contaminated,
    • High pressure fuel pump faulty
    stuck, jammed
    • Injector jammed open
    • Rail pressure regulator valve contaminated,
    • Bug software or hardware fault not detected
    stuck, jammed
    • Glow system faulty
    • Fuel quality / presence of water

    (SYMPTOM 2) ENGIEN STARTS WITH DIFFICULTY OR STARTS AND STALLS

    Possible Cause

    • Run out of fuel


    • Inversion of low pressure fuel connections
    • Fuel return hose of injector cut
    • Low pressure fuel circuit sealed
    • High pressure leakage
    • Sealed fuel filter
    • Fuse faulty
    • Oil level too high/too low
    • Air filter sealed
    • Catalytic converter sealed or damaged
    • Alternator or voltage regulator faulty
    • Intermittent fault connection
    • The compensation of individual injector not adapted
    • Air ingress in the low pressure fuel circuit
    • Drift of the engine coolant temperature
    • Fuel return circuit of the pump sealed
    sensor not detected
    • Glow system faulty
    • Drift of the rail pressure sensor not detected
    • Engine compression too low
    • Battery voltage too low
    • Fuel return hose of injector sealed
    • Electric EGR control valve blocked open
    • Carbon deposit on the injector (sealed holes)
    • Fuel pressure regulator valve contaminated,
    • Needle stuck (injection possible over a
    stuck, jammed
    certain pressure)
    • Rail pressure regulator valve contaminated,
    • Gasoline in fuel
    stuck, jammed
    • Bug software or hardware fault not detected
    • Fuel quality / presence of water
    FL -18 FUEL SYSTEM

    (SYMPTOM 3) POOR STARTING WHEN HOT

    Possible Cause

    • The compensation of individual injector not adapted


    • Fuel return circuit of the pump sealed
    • Drift of the rail pressure sensor not detected
    • Sealed fuel filter
    • Electric EGR control valve blocked open
    • Engine compression too low
    • Fuel pressure regulator valve contaminated,
    • Intermittent fault connection
    stuck, jammed
    • Carbon deposit on the injector (sealed holes)
    • Rail pressure regulator valve contaminated,
    • Needle stuck (injection possible over a
    stuck, jammed
    certain pressure)
    • Air filter sealed
    • Gasoline in fuel
    • Air ingress in the low pressure fuel circuit
    • Bug software or hardware fault not detected
    • Fuel quality / presence of water

    (SYMPTOM 4) UNSTABLE IDLING

    Possible Cause

    • Fuel return hose of injector cut • Glow system faulty


    • The compensation of individual injector not adapted • Engine compression too low
    • Drift of the rail pressure sensor not detected • Bad flanging of the injector
    • Harness resistance increased • High pressure pump out of order
    • Air ingress in the low pressure fuel circuit • Injector not adapted
    • Fuel quality / presence of water • Carbon deposit on the injector (sealed holes)
    • Sealed fuel filter • Needle stuck (injection possible over a
    • Air filter sealed certain pressure)
    • Fuel return hose of injector sealed • Injector jammed open
    • High pressure leakage • Electric EGR control valve blocked open

    (SYMPTOM 5) IDLE SPEED TOO HIGH OR TOO LOW

    Possible Cause

    • Drift of the engine coolant temperature • Clutch not well set


    sensor not detected • Bug software or hardware fault not detected
    • Incorrect state of the electrical pack devices • Electric EGR control valve blocked open
    • Alternator or voltage regulator faulty • Throttle control actuator faulty

    (SYMPTOM 6) BLUE, WHITE, OR BLACK SMOKES

    Possible Cause

    • The compensation of individual injector not adapted • Catalytic converter sealed or damaged
    • Drift of the engine coolant temperature • Air filter sealed
    sensor not detected • Oil suction (engine racing)
    • Drift of the rail pressure sensor not detected • Glow system faulty
    • Electric EGR control valve blocked open • Engine compression too low
    • Fuel pressure regulator valve contaminated, • Bad flanging of the injector
    stuck, jammed • Injector washer not adapted, forgotten, doubled
    • Rail pressure regulator valve contaminated, • Injector not adapted
    stuck, jammed • Carbon deposit on the injector (sealed holes)
    • Oil level too high/too low • Injector jammed open
    • Fuel quality / presence of water • Gasoline in fuel
    GENERAL FL -19

    (SYMPTOM 7) ENGINE RATTLING, NOISY ENGINE

    Possible Cause

    • The compensation of individual injector not adapted • Drift of the rail pressure sensor not detected
    • Electric EGR control valve blocked closed • Injector washer not adapted, forgotten, doubled
    (noisy engine) • Injector not adapted
    • Electric EGR control valve blocked open • Carbon deposit on the injector (sealed holes)
    • Drift of the engine coolant temperature • Needle stuck (injection possible over a
    sensor not detected certain pressure)
    • Glow system faulty • Injector jammed open
    • Engine compression too low • Drift of engine coolant temperature sensor
    • Fuel return hose of injector sealed not detected

    (SYMPTOM 8) BURST NOISE

    Possible Cause

    • Fuel pressure regulator valve contaminated,


    • The compensation of individual injector not adapted
    stuck, jammed
    • Intermittent fault connection
    • Rail pressure regulator valve contaminated,
    • Exhaust system sealed
    stuck, jammed
    • Drift of the rail pressure sensor not detected
    • Bug software or hardware fault not detected

    (SYMPTOM 9) UNTIMELY ACCELERATION/DECELERATION AND ENGINE RACING

    Possible Cause

    • Accelerator position sensor blocked • Oil suction (engine racing)


    • Electric EGR valve blocked open • Drift of the rail pressure sensor not detected
    • Intermittent fault connection • Bug software or hardware fault not detected

    (SYMPTOM 10) GAP WHEN ACCELERATING AND AT RE-COUPLING (RESPONSE TIME)

    Possible Cause

    • Engine compression too low


    • High pressure leakage
    • Air inlet circuit open
    • Fuel pressure regulator valve contaminated,
    • Incorrect state of the electrical pack devices
    stuck, jammed
    • Accelerator position sensor blocked
    • Rail pressure regulator valve contaminated,
    • Electric EGR valve blocked open
    stuck, jammed
    • Turbo charger damaged, vacuum hose line leakage
    • Needle stuck (injection possible over a
    • Sealed fuel filter
    certain pressure)
    • Bug software or hardware fault not detected
    FL -20 FUEL SYSTEM

    (SYMPTOM 11) ENGINE STOP OR STALLING

    Possible Cause

    • Run out of fuel


    • Fuel pump hose supply cut • Rail pressure regulator valve contaminated,
    • High pressure leakage stuck, jammed
    • Fuse faulty • Alternator or voltage regulator faulty
    • Fuel quality / presence of water • Intermittent fault connection
    • Low pressure fuel circuit sealed • Catalytic converter sealed or damaged
    • Sealed fuel filter • Low pressure fuel pump faulty
    • Crank signals missing simultaneously • High pressure pump faulty
    • Electric EGR valve blocked open • Gasoline in fuel
    • Fuel pressure regulator valve contaminated, • Bug software or hardware fault not detected
    stuck, jammed

    (SYMPTOM 12) ENGINE JUDDER

    Possible Cause

    • Glow system faulty


    • Run out of fuel
    • Engine compression too low
    • Fuel return hose of injector cut
    • Fuel return hose of injector sealed
    • Incorrect state of the electrical pack devices
    • Valve clearance
    • The compensation of individual injector not adapted
    • Low pressure fuel pump faulty
    • Electric EGR valve blocked open
    • Injector washer not adapted, forgotten, doubled
    • Fuel filter not adapted
    • Carbon deposit on the injector (sealed holes)
    • Air ingress in the low pressure fuel circuit
    • Needle stuck (injection possible over a
    • Fuel quality / presence of water
    certain pressure)
    • Sealed fuel filter
    • Injector jammed open
    • Intermittent fault connection
    • Gasoline in fuel
    • Harness resistance increased
    • Bug software or hardware fault not detected

    (SYMPTOM 13) LACK OF POWER

    Possible Cause

    • Sealed fuel filter


    • The compensation of individual injector not adapted • Leakage at the injector
    • Accelerator position sensor blocked • Fuel return circuit of the pump sealed
    • Incorrect state of the electrical pack devices • Fuel return hose of injector sealed
    • Electric EGR valve blocked open • Engine compression too low
    • Air inlet circuit open • Injector not adapted
    • Air filter sealed • Carbon deposit on the injector (sealed holes)
    • Oil level too high/too low • Valve clearance
    • Catalytic converter sealed or damaged • Throttle control actuator faulty
    • Turbo charger damaged, vacuum hose line leakage • Engine coolant temperature too high
    • Fuel temperature too high

    (SYMPTOM 14) TOO MUCH POWER

    Possible Cause

    • The compensation of individual injector not adapted


    • Bug software or hardware fault not detected
    • Oil suction (engine racing)
    GENERAL FL -21

    (SYMPTOM 15) EXCESSIVE FUEL CONSUMPTION

    Possible Cause

    • Fuel return hose of injector cut


    • Incorrect state of the electrical pack devices
    • Leakage at the Fuel pressure regulator valve
    • Oil level too high/too low
    • Leakage at fuel temperature sensor
    • Fuel quality / presence of water
    • Leakage at the spacers
    • Catalytic converter sealed or damaged
    • High pressure leakage
    • Turbo charger damaged
    • Air inlet circuit open
    • Engine compression too low
    • Air filter sealed
    • Injector not adapted
    • The compensation of individual injector not adapted
    • Bug software or hardware fault not detected
    • Electric EGR valve blocked open

    (SYMPTOM 16) OVER SPEED ENGINE WHEN CHANGING THE GEAR BOX RATIO

    Possible Cause

    • Accelerator position sensor blocked • Oil suction (engine racing)


    • The compensation of individual injector not adapted • Turbo charger damaged
    • Intermittent fault connection • Injector not adapted
    • Clutch not well set • Bug software or hardware fault not detected

    (SYMPTOM 17) EXHAUST SMELLS

    Possible Cause

    • Electric EGR control valve leakage • Injector washer not adapted, forgotten, doubled
    • Oil suction (engine racing) • Injector not adapted
    • Turbo charger damaged • Carbon deposit on the injector (sealed holes)
    • Oil level too high/too low • Needle stuck (injection possible over a
    • The compensation of individual injector not adapted certain pressure)
    • Catalytic converter sealed or damaged • Injector jammed open
    • Bad flanging of the injector • Bug software or hardware fault not detected

    (SYMPTOM 18) SMOKES (BLACK, WHITE, BLUE) WHEN ACCELERATING

    Possible Cause

    • The compensation of individual injector not adapted • Intermittent fault connection


    • Electric EGR valve blocked open • Bad flanging of the injector
    • Air filter sealed • Injector washer not adapted, forgotten, doubled
    • Fuel quality / presence of water • Injector not adapted
    • Oil level too high/too low • Carbon deposit on the injector (sealed holes)
    • Turbo charger damaged • Needle stuck (injection possible over a
    • Catalytic converter sealed or damaged certain pressure)
    • Oil suction (engine racing) • Injector jammed open
    • Air heaters out of order • Gasoline in fuel
    • Engine compression too low • Bug software or hardware fault not detected
    • High pressure leakage • Catalyzed Particulate Filter (CPF) fail
    FL -22 FUEL SYSTEM

    (SYMPTOM 19) FUEL SMELLS

    Possible Cause

    • Fuel pump hose supply cut • Leakage at fuel temperature sensor


    • Fuel return hose of injector cut • Leakage at the spacers
    • Leakage at the Fuel pressure regulator valve • High pressure leakage

    (SYMPTOM 20) THE ENGINE COLLAPSES AT TAKE OFF

    Possible Cause

    • Catalytic converter sealed or damaged


    • Accelerator position sensor blocked • Clutch not well set
    • Incorrect state of the electrical pack devices • Intermittent fault connection
    • Air filter sealed • Drift of the rail pressure sensor not detected
    • Inversion of low pressure fuel connections • Fuel pressure regulator valve contaminated,
    • Fuel filter not adapted stuck, jammed
    • Fuel quality/presence of water • Rail pressure regulator valve contaminated,
    • Air ingress in the low pressure fuel circuit stuck, jammed
    • Sealed fuel filter • Gasoline in fuel
    • Bug software or hardware fault not detected

    (SYMPTOM 21) THE ENGINE DOES NOT STOP

    Possible Cause

    • Oil suction (engine racing)


    • Bug software or hardware fault not detected

    (SYMPTOM 22) DIFFERENT MECHANICAL NOISES

    Possible Cause

    • Buzzer noise (discharge by the injectors)


    • Bad flanging of the injector
    • Clip broken (vibrations, resonance, noises)
    • Clutch not well set
    • Incorrect state of the electrical pack devices
    • Turbo charger damagedValve clearance
    • Catalytic converter sealed or damaged
    • Valve clearance
    • Air inlet circuit open

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