Table 8, Trouble-shooting Chart
If the following complaints occur, check the marked test steps more closely:
Customer complaint (fault symptoms) part 1
| 1 Diagnosis lamp illuminates | |||||||||
|---|---|---|---|---|---|---|---|---|---|
| 2 Starter turns, engine starts poorly or not at all (warm and cold) | |||||||||
| 3 Engine surges at idle speed | |||||||||
| 4 Irregular idle when engine is warm | |||||||||
| 5 High fuel consumption in conjunction with inadequate engine output and smoke formation | |||||||||
| 6 Performance unsatisfactory | |||||||||
| 7 Black smoke emissions in full load range in conjunction with dieseling, possibly lack of output | |||||||||
| 8 Engine diesels | |||||||||
| Cause | Remedy | ||||||||
| · | Self-diagnosis | - | |||||||
| · | Battery voltage | Section 5.2 F0:Data List no.01, and section 5.4 Table 1 | |||||||
| · | Pump actuator | Section 5.2 F0:Data List no. 20, 21, 36, 37, 38, 39, 40, and section 5.5 | |||||||
| F2:Trouble Code Table no. 64 | |||||||||
| · | Injection quantity sensor | Section 5.2 F0:Data List no. 20, 21, and section 5.5 | |||||||
| F2:Trouble Code Table no. 61 | |||||||||
| · | Fuel cutoff solenoid valve | Section 5.2 F0:Data List no. 32, and section 5.5 | |||||||
| F2:Trouble Code Table no. 54 | |||||||||
| · | · | · | Replace control unit | Section 5.5 F2:Trouble Code Table no. 55 | |||||
| · | · | Injection adjuster | Section 5.2 F0:Data List no. 22, and section 5.5 | ||||||
| F2:Trouble Code Table no. 64 | |||||||||
| · | EGR valve | Section 5.2 F0:Data List no. 33 | |||||||
| · | Actual start of injection | Section 5.2 F0:Data List no. 23, 24, and section 5.5 | |||||||
| F2:Trouble Code Table no. 81, 82 | |||||||||
| · | Computer coupling | Section 5.5 F2:Trouble Code Table no. 55 | |||||||
| · | · | Engine speed | Section 5.2 F0:Data List no. 25, and section 5.5 | ||||||
| F2:Trouble Code Table no. 19, 31 | |||||||||
| Engine speed sensor and start of injection sensor | Section 5.2 F0:Data List no. 23, 24, and section 5.5 | ||||||||
| F2:Trouble Code Table no. 81, 82 | |||||||||
| · | Tank empty, tank ventilation | Top up tank, tank ventilation see Service Instructions | |||||||
| · | · | · | Injection sequence does not equal ignition sequence | See Service Instructions | |||||
| · | Fuel return connector | See Service Instructions | |||||||
| · | · | Air in fuel system | Bleed fuel system (see Service Instructions) | ||||||
| · | Paraffin deposits | Replace filter (Service Instructions), check filter heating (section 5. | |||||||
| · | · | Fuel lines leaky | Check fuel system (see Service Instructions) | ||||||
| · | Supply lines blocked | Check fuel system (see Service Instructions) | |||||||
| · | · | · | · | Injector nozzle | Check injection nozzles (see Service Instructions) | ||||
| · | · | · | · | Allocation of pump to engine | Adjustment see Service Instructions | ||||
| · | Fuel filter | Check fuel filter (see Service Instructions) | |||||||
| · | Preheater system | Section 5.2 F0:Data List no. 28, 29, and section 5.5 | |||||||
| F2:Trouble Code Table no. 49 | |||||||||
| · | · | · | Engine compression | Compression check see Service Instructions | |||||
| · | Engine air cleaner | Check air cleaner (see Service Instructions) | |||||||
| · | Engine timing | See Service Instructions |
Customer complaint (fault symptoms) part 2
| 9 Engine misfires in operation | ||||||||
|---|---|---|---|---|---|---|---|---|
| 10 Engine switches itself off | ||||||||
| 11 Engine runs at constant engine speed | ||||||||
| 12 Engine speed does not increase when cold | ||||||||
| 13 Increased idle speed or irregular running at high engine speeds | ||||||||
| 14 Black smoke emission in full load operation | ||||||||
| 15 Mist-like smoke emissions in full load operation (white) | ||||||||
| Cause | Remedy | |||||||
| · | Pedal position sensor | Section 5.2 F0:Data List no. 18, 19, and section 5.5 | ||||||
| F2:Trouble Code Table no. 21, 23 | ||||||||
| · | Pump actuator | Section 5.2 F0:Data List no. 20, 21, 36, 37, 38, 39, 40, and section 5.5 | ||||||
| F2:Trouble Code Table no. 64 | ||||||||
| · | · | Injection quantity sensor | Section 5.2 F0:Data List no. 20, 21, and section 5.5 | |||||
| F2:Trouble Code Table no. 61 | ||||||||
| · | Replace control unit | Section 5.5 F2:Trouble Code Table no. 55 | ||||||
| · | Engine speed sensor and start of injection sensor | Section 5.2 F0:Data List no. 23, 24, and section 5.5 | ||||||
| F2:Trouble Code Table no. 81, 82 | ||||||||
| · | · | · | · | Tank empty, tank ventilation | Top up tank, tank ventilation see Service Instructions | |||
| · | · | · | Injection sequence does not equal ignition sequence | See Service Instructions | ||||
| · | · | · | Fuel return connector | See Service Instructions | ||||
| · | · | · | Air in fuel system | Bleed fuel system (see Service Instructions) | ||||
| · | Paraffin deposits | Replace filter (Service Instructions), check filter heating (section 5.3, no. 01) | ||||||
| · | Fuel lines leaky | Check fuel system (see Service Instructions) | ||||||
| · | · | · | Supply lines blocked | Check fuel system (see Service Instructions) | ||||
| · | · | Allocation of pump to engine | Adjustment see Service Instructions | |||||
| · | · | Fuel filter | Check fuel filter (see Service Instructions) | |||||
| · | Engine compression | Compression check see Service Instructions | ||||||
| · | Fuel heating | Check filter heating (section 5.3, no.01) |
Customer complaint (fault symptoms) part 3
| 16 Severe juddering, no idle increase during operation (manual shifting) | ||||||||
|---|---|---|---|---|---|---|---|---|
| 17 No fault storage in self-diagnosis | ||||||||
| 18 Exhaust gas recirculation does not function | ||||||||
| 19 No idle speed increase | ||||||||
| 20 Black smoke emissions in full load operation in conjunction with dieseling, possibly lack of output | ||||||||
| 21 Performance unsatisfactory | ||||||||
| 22 Starter turns, engine starts poorly or not at all (warm and cold) | ||||||||
| Cause | Remedy | |||||||
| · | Replace control unit | Section 5.5 F2:Trouble Code Table no. 55 | ||||||
| · | Injection adjuster | Section 5.2 F0:Data List no. 22, and section 5.5 | ||||||
| F2:Trouble Code Table no. 64 | ||||||||
| · | EGR valve | Section 5.2 F0:Data List no. 33 | ||||||
| · | Actual start of injection | Section 5.2 F0:Data List no. 23, 24, and section 5.5 | ||||||
| F2:Trouble Code Table no. 81, 82 | ||||||||
| · | · | Engine speed | Section 5.2 F0:Data List no. 25, and section 5.5 | |||||
| F2:Trouble Code Table no. 19, 31 | ||||||||
| · | · | Vehicle speed sensor | Section 5.2 F0:Data List no. 16, and section 5.5 | |||||
| F2:Trouble Code Table no. 24 | ||||||||
| · | Clutch or brake switch | Section 5.2 F0:Data List no. 07, 08, 10, and section 5.5 | ||||||
| F2:Trouble Code Table no. 37 | ||||||||
| · | Charge air temperature | Section 5.2 F0:Data List no. 04, and section 5.5 | ||||||
| F2:Trouble Code Table no. 73, 74 | ||||||||
| · | Coolant temperature | Section 5.2 F0:Data List no. 02, and section 5.5 | ||||||
| F2:Trouble Code Table no. 14, 15 | ||||||||
| · | AC info switch | Section 5.2 F0:Data List no. 13 | ||||||
| · | Turbocharger | Section 5.2 F0:Data List no. 22, and section 5.5 | ||||||
| F2:Trouble Code Table no. 34 | ||||||||
| · | Turbocharger | Check turbocharger (see Service Instructions) | ||||||
| · | Charge pressure | Section 5.2 F0:Data List no. 05, and section 5.5 | ||||||
| F2:Trouble Code Table no. 41, 42, 43, 44 | ||||||||
| · | Fuel heating | Check filter heating (section 5.3, no.01) | ||||||
| · | EGR valve | Section 5.2 F0:Data List No. 04 |