Diagnostics and Checks (Diesel Fuel Injection)

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Inspection and verification


WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.


WARNING: This procedure is related to fuel handling. Always be prepared for splashing fuel. Failure to follow these instructions may result in injury.


CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, when working with these elements, it is especially important to observe absolute cleanliness. Always insert plugs into any open holes or lines.


NOTE: In addition to its normal function, the glow plug warning light also functions as a check engine light, which flashes continuously when the powertrain control module (PCM) registers a diagnostic code (DTC) serious malfunction. Minor DTCs are also stored in the PCM memory, but are only displayed when a system check for DTCs is performed using WDS.


NOTE: If a DTC is found after the problem is corrected, all DTCs should be cleared. If all DTCs are not cleared, this may cause problems with the overall drivability of the vehicle.


NOTE: If the fuel level in the fuel tank drops below approximately 4 liters, the result is erratic engine operation. This is a signal to the driver that the car needs refueling to prevent the fuel system from working «dry».


1. Check the customer's complaint.


2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Table


Mechanical factors

Electrical Factors

leak (And) fuel

Starter interlock relay fuse.

Fuel filter

Power Relay Fuse

Air filter element

Glow plug relay fuse.

vacuum line (And) / vacuum line connections

Relay

Hose (And) / hose connections

Wiring harness

Piping/piping connections

Plug connector (s)

Fuel contamination

LED operation (LED) passive anti-theft system (PATS)

Fuel supply line (s)

Sensor (And)

Fuel return line (s)

Control lamp for glow plugs

Fuel supply line (s) high pressure

Nozzle control module (IDM)

Fuel burner (And)

Powertrain control module (PCM)

fuel manifold

Fuel pump



3. If an obvious cause for a reported or received complaint is identified, resolve it before proceeding to the next action (if possible).

4. If the cause is not visually obvious, check the symptom and refer to WDS to retrieve the DTC.

5. If no problem DTCs are found, refer to the Symptom Table below to continue diagnosis.

Symptom table


State

Possible Causes

Action

• Engine does not crank and glow plug warning light flashes

•DTC registered.

• REFER to WDS.

•Engine does not crank

•PATS

• CHECK if the PATS LED goes out within 3 seconds of turning the ignition on. Refer to Section 419-01A / 419-01B for more information.

• Starting system

• For more information, see Section 303-06.

•Ignition switch

• For more information, see Section 211-05.

•PCM.

• REFER to WDS.

•Engine cranks but does not start and glow plug warning light flashes

•DTC registered.

• REFER to WDS.

•Engine cranks but does not start

•Low fuel level in the fuel tank.

•CHECK if the fuel level in the fuel tank is more than 4 liters. If the fuel level in the fuel tank is less than 4 liters, ADD fuel.

• Clogged fuel filter.

• Install a new fuel filter. Refer to Section 310-01A for more information.

• Damaged or blocked fuel lines.

• For more information, see Section 310-00A.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

• Relay for glow plugs.

• REFER to WDS.

•IDM relay.

•PERFORM Relay Test. REFER to Wiring Diagrams.

• Glow plugs.

• REFER to WDS.

• Incorrect valve timing.

• Check valve timing. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

•Low compression in the cylinders.

• For more information, see Section 303-00.

• Crankshaft position sensor (CKP)

• REFER to WDS.

•Camshaft position sensor (SMR)

• REFER to WDS.

• Cylinder head temperature sensor (SNT)

• REFER to WDS.

•PCM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

• Dosing inlet fuel valve.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

• Poor start and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Bad start

•Low fuel level in the fuel tank.

•CHECK if the fuel level in the fuel tank is more than 4 liters. If the fuel level in the fuel tank is less than 4 liters, ADD fuel.

• Clogged fuel filter.

• Install a new fuel filter. Refer to Section 310-01A for more information.

•Clogged air filter element.

• INSTALL a new air filter element.

• Relay for glow plugs.

• REFER to WDS.

• Glow plugs.

• REFER to WDS.

• Leakage in the fuel system.

•CHECK the system for leaks (ek) fuel. REPAIR the system if necessary.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

•Restriction of the capacity of the fuel system.

• For more information, see Section 310-00A.

• Wrong type of engine oil.

• INSTALL a new oil filter and fill with engine oil. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Incorrect power steering fluid.

• DRAIN the power steering system fluid and FILL the system with the correct fluid. Refer to Section 211-00 for more information.

• Clogged catalytic converter.

• If necessary, REMOVE and visually INSPECT the catalytic converter. Refer to Section 309-00 for more information.

•Low compression in the cylinders.

• For more information, see Section 303-00.

• CKP sensor.

• REFER to WDS.

•CHT sensor.

• REFER to WDS.

• Fuel temperature sensor.

• REFER to WDS.

• Air intake temperature sensor (IAT).

• REFER to WDS.

•Manifold absolute pressure sensor (MAP)

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

• Dosing inlet fuel valve.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

• Engine starts but stops immediately and glow plug warning light flashes

•DTC registered.

• REFER to WDS.

• Engine starts but stops immediately

•Clogged air filter element.

• INSTALL a new air filter element.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

• PCM relay.

•PERFORM Relay Test. REFER to Wiring Diagrams.

•IDM relay.

•PERFORM Relay Test. REFER to Wiring Diagrams.

• Double flywheel.

• Visually INSPECT the dual flywheel for damage. INSTALL new items as needed.

• Air damper

• REFER to WDS.

• CKP sensor.

• REFER to WDS.

• CMP sensor.

• REFER to WDS.

•CHT sensor.

• REFER to WDS.

•PCM.

• REFER to WDS.

•IDM.

• REFER to WDS.

• Dosing inlet fuel valve.

• REFER to WDS.

• Poor idling and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Poor idling performance

•Low fuel level in the fuel tank.

•CHECK if the fuel level in the fuel tank is more than 4 liters. If the fuel level in the fuel tank is less than 4 liters, ADD fuel.

•Clogged air filter element.

• INSTALL a new air filter element.

• Clogged fuel filter.

• Install a new fuel filter. Refer to Section 310-01A for more information.

• Wrong type or contamination of fuel.

•CHECK for signs of contamination such as strange odors from the fuel tank.

•CHECK for signs of water or gasoline in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

• Double flywheel.

• Visually INSPECT the dual flywheel for damage. INSTALL new items as needed.

•IDM.

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IAT sensor.

• REFER to WDS.

• MAP sensor.

• REFER to WDS.

• CKP sensor.

• REFER to WDS.

•Knock sensor (KS)

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

• Dosing inlet fuel valve.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

• Engine jerking and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Jerking when the engine is running

•Low fuel level.

•CHECK if the fuel level in the fuel tank is more than 4 liters. If the fuel level in the fuel tank is less than 4 liters, REFILL fuel.

• Double flywheel.

• Visually INSPECT the dual flywheel for damage. INSTALL new items as needed.

• Accelerator pedal position sensor (APP).

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

•Loss of engine power and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Loss of engine power

• Sticking brakes.

•CHECK the brake system. Refer to Section 206-00 for more information.

•Vehicle overloaded or increased aerodynamic drag (roof racks, towing, etc.).

• TELL the customer about the impact of vehicle overload and aerodynamic drag on fuel consumption.

•Clogged air filter element.

• If necessary, INSTALL a new air filter element.

• Clogged fuel filter.

• Install a new fuel filter. Refer to Section 310-01A for more information.

•Twisted condition or narrowing of the section of the fuel lines.

• For more information, see Section 310-00A.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

•Turbocharger

• Turbocharger vacuum control.

•Vacuum diaphragm block of the turbocharger.

• Electromagnetic valve for adjusting the position of the blades.

• INSPECT the vacuum line (And) for visible signs of damage or blockage. CLEAN, REPAIR or INSTALL new items as needed. Refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

• Incorrect valve timing.

•CHECK valve timing. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

•Low compression in the cylinders.

• For more information, see Section 303-00.

• Clogged catalytic converter.

• REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter if necessary. Refer to Section 309-00 for more information.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

•Clogged or cracked charge air cooler.

• Cracking in charge air cooler lines.

•Missing or loose fastening of charge air cooler clamps.

• INSPECT for signs of damage or blockage. CLEAN, REPAIR or INSTALL new items as needed.

• Wrong type or contamination of fuel.

•CHECK for signs of contamination such as strange odors from the fuel tank.

•CHECK for signs of water or gasoline in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

• Vehicle speed sensor (VSS)

• REFER to WDS.

•CHT sensor.

• REFER to WDS.

•IAT sensor.

• REFER to WDS.

• MAP sensor.

• REFER to WDS.

•APP sensor.

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

• Fuel temperature sensor.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

• Dosing inlet fuel valve.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

•Black smoke at idle and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

• Black smoke when the engine is idling

•Clogged air filter element.

• If necessary, INSTALL a new air filter element.

• Relay for glow plugs.

• REFER to WDS.

• Incorrect valve timing.

•CHECK valve timing. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Turbocharger vacuum control.

• Electromagnetic valve for adjusting the position of the blades.

• INSPECT for signs of damage or blockage. CLEAN, REPAIR or INSTALL new items as needed. Refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for more information.

• Clogged catalytic converter.

• REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter if necessary. Refer to Section 309-00 for more information.

•CHT sensor.

• REFER to WDS.

•IAT sensor.

• REFER to WDS.

• MAP sensor.

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

•Increased black smoke on acceleration (overclocking), and the glow plug warning lamp flashes

•DTC registered.

• REFER to WDS.

•Increased black smoke on acceleration

•Clogged air filter element.

• If necessary, INSTALL a new air filter element.

• Wrong type or contamination of fuel.

•CHECK for signs of contamination such as strange odors from the fuel tank.

•CHECK for signs of water or gasoline in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

• Clogged catalytic converter.

• REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter if necessary. Refer to Section 309-00 for more information.

•APP sensor.

• REFER to WDS.

• CKP sensor.

• REFER to WDS.

•KS

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

•Black smoke when driving «cruising» speed and the glow plug warning light flashes

•DTC registered.

• REFER to WDS.

•Black smoke when driving «cruising» speed

•Clogged air filter element.

• INSTALL a new air filter element.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

•Vacuum diaphragm block of the turbocharger.

• Electromagnetic valve for adjusting the position of the blades.

• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

• Clogged catalytic converter.

• REMOVE and visually INSPECT the catalytic converter for damage. INSTALL a new catalytic converter if necessary. Refer to Section 309-00 for more information.

•CHT sensor.

• REFER to WDS.

•IAT sensor.

• REFER to WDS.

• MAP sensor.

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

• Blue smoke and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Blue smoke

• Combustion of oil in the engine.

•PERFORM a 1000 km controlled oil flow test (600 miles). MAKE SURE that the oil consumption is less than 0.1 l per 1000 km (600 miles).Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Wrong type or contamination of fuel.

•CHECK for signs of contamination such as strange odors from the fuel tank.

•CHECK for signs of water or gasoline in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

• Worn or damaged valve guides, piston rings, cylinders, cylinder head or gasket.

• Remove the cylinder head. INSPECT cylinder head, pistons and cylinders for signs of wear or damage. See Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Forced crankcase ventilation system (PCV).

• INSPECT for signs of damage or blockage. CLEAN, REPAIR or INSTALL new items as needed.

•Clogged or damaged turbocharger oil return line.

• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

•White smoke and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•White smoke

•Water in fuel.

•CHECK for signs of water in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

•KS

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

• Incorrect valve timing.

•CHECK valve timing. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Coolant in the combustion chamber.

• PERFORM a pressure test of the cooling system. Refer to Section 303-03 for more information. Remove the cylinder head. INSPECT cylinder head, cylinder head gasket and cylinder bores for wear or damage.

• Engine misfire and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Misfire

•Low fuel level in the tank.

•CHECK if the fuel level in the fuel tank is more than 4 liters. If the fuel level in the fuel tank is less than 4 liters, REFILL fuel.

• Wrong type or contamination of fuel.

•CHECK for signs of contamination such as strange odors from the fuel tank.

•CHECK for signs of water or gasoline in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

•Low compression in the cylinders.

• For more information, see Section 303-00.

• Worn or damaged valve (ov), tappets or camshaft (ov).

• Remove the cylinder head. INSPECT cylinder head, valves, tappets and camshafts for signs of wear or damage. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Damage to the cylinder head gasket.

• Remove the cylinder head. INSPECT cylinder head gasket and cylinders for wear or damage. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for additional information.

• Engine operating temperature too high.

• For more information, see Section 303-03.

•CHT sensor.

• REFER to WDS.

• CKP sensor.

• REFER to WDS.

• CMP sensor.

• REFER to WDS.

•IAT sensor.

• REFER to WDS.

• MAP sensor.

• REFER to WDS.

•KS

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

•Engine knocking at idle and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Engine knocking when idling

•Low engine oil level.

•Check the engine oil level. REFILL engine oil if necessary.

• Wrong type or contamination of fuel.

•CHECK for signs of contamination such as strange odors from the fuel tank.

•CHECK for signs of water or gasoline in diesel fuel.

• If fuel contamination is found, empty the entire fuel system. FLUSH the fuel system with clean diesel fuel. Install a new fuel filter. See Section 310-00A / 310-01A for more information. INSTALL a new fuel pump, fuel injectors, fuel manifold, and high pressure fuel feed lines. For more information refer to the Fuel pump / Fuel injectors / Fuel manifold available in this section.

• Double flywheel.

• Visually INSPECT the dual flywheel for damage. INSTALL new items as needed.

• Incorrect valve timing.

•CHECK valve timing. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

•Excessive carbon deposits.

• Remove the cylinder head. INSPECT cylinder head and pistons for signs of carbon deposits. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Worn or damaged oil pump.

• Worn or damaged timing chain or sprocket.

• Serious engine failure of a mechanical nature.

•KS

• REFER to WDS.

• CKP sensor.

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

• Engine knock on acceleration (overclocking), and the glow plug warning lamp flashes

•DTC registered.

• REFER to WDS.

• Engine knock on acceleration

•KS

• REFER to WDS.

•Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

• Serious engine failure of a mechanical nature.

• Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

• Dosing inlet fuel valve.

• REFER to WDS.

•Fuel pump

• REFER to WDS.

•Excessive fuel consumption and glow plug warning light flashing

•DTC registered.

• REFER to WDS.

•Increased fuel consumption

• Sticking brakes.

•CHECK the brake system. Refer to Section 206-00 for more information.

•Vehicle overloaded or increased aerodynamic drag (roof racks, towing, etc.).

• TELL the customer about the impact of vehicle overload and aerodynamic drag on fuel consumption.

•Clogged air filter element.

• INSTALL a new air filter element.

• Clogged fuel filter.

• Install a new fuel filter. Refer to Section 310-01A for more information.

•Leakage (And) in the fuel system

•CHECK the system for fuel leaks. Repair or install new elements as necessary.

• Double flywheel.

• Visually INSPECT the dual flywheel for damage. INSTALL new items as needed.

• Wrong type of engine oil.

• INSTALL a new oil filter and fill with engine oil. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

•Generator.

• For more information, see Section 414-00.

• EGR valve stuck open.

• EGR vacuum control valve.

• Refer to Section 303-08A / 303-08B for more information.

•Vacuum diaphragm block of the turbocharger.

• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

• Penetration of air into fuel lines.

• For more information, see Section 310-00A.

• Incorrect valve timing.

•CHECK valve timing. Refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E for more information.

•Turbocharger

• For more information, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G.

• Clutch slip.

• For more information, see Section 308-00.

• Low compression in the cylinders.

• For more information, see Section 303-00.

• CHT sensor.

• REFER to WDS.

• IAT sensor.

• REFER to WDS.

• MAP sensor.

• REFER to WDS.

• Fuel burner (And)

• REFER to WDS.

•IDM.

• REFER to WDS.

•Engine cuts out on hard acceleration

• CMP sensor.

• REFER to WDS.

• CKP sensor.

• REFER to WDS.

•Fuel manifold pressure sensor.

• REFER to WDS.

• Dosing inlet fuel valve.

• REFER to WDS.

•Fuel pump

• REFER to WDS.








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