5.
Maintenance Section
2.9 Troubleshooting
Complaint Cause Corrective Action
Malfunctioning thermostat Replace thermostat
Coolant temperature sensor malfunction Replace coolant temperature sensor
Check for leakages in coolant hoses, if
Low coolant level or coolant leakage from found repair or replace. Check coolant
engine/cooling system level in de-aeration tank, refill coolant if
necessary.
Blocked or damaged radiator fins Clean, repair and replace if necessary
Broken fan blades Replace fan assembly
Choked radiator fins (externally or
Clean the radiator fins
internally)
Worn or cut fan belt or oil deposits in the
Replace fan belt
fan belt
Work Tools information
Damaged cylinder head gasket causing
Replace gasket
coolant overflow
Troubleshooting
Engine Water pump air vent hole coolant leak Replace water pump assembly
Overheating
Crack in cylinder block Inspect, repair and replace if necessary
Oil cooler mounting loose or O-ring Retighten the oil cooler mounting or
defective replace the defective O-ring
Choked CAC assembly (externally or
Clean the CAC assembly
internally)
Improper functioning of pressure relief
Replace the pressure relief cap
cap
Improper functioning viscous fan Replace viscous fan assembly
Improper injector injection pressure and Adjust for correct injection pressure
spray pattern and spray pattern
2-57 Service Manual - Engine
5. Maintenance Section
Complaint Cause Corrective Action
Improper tightness of engine mounting
Retighten to the specified torque
and auxiliaries mounted on it
Inspect auto belt tensioner, repair or
Improper belt condition/tension replace if found defective.
Adjust or replace if necessary
Improper valve clearance Adjust, if necessary
Damaged valve spring/valve seat
Replace, if necessary
Unusual noise condition
from engine
Improper timing gear backlash Replace timing gear, if necessary
Noise from internal components of the Dismantle the engine and check for
engine defects and repair if necessary
Worn tappets Replace worn tappets
Push rod(s) bent Replace bent push rod(s)
Work Tools information
Worn out exhaust manifold gasket Replace gasket
Bent connecting rod Replace connecting rod
Troubleshooting
Improper electrical connections Reconnect if found disconnected
Recharge the battery, replace if
Low battery
necessary
Engine not
cranking Starter motor not working Repair or replace starter motor
Dismantle the engine and check for
Engine seizure internally
defects and repair if necessary
2-58 Service Manual - Engine
5. Maintenance Section
Complaint Cause Corrective Action
Insufficient fuel level in fuel tank Fill fuel to sufficient level
Fuel leak/air trap in fuel line Repair as necessary
Choked fuel tank breather Replace if necessary
Worn flywheel ring gear Replace flywheel
Refer engine repair procedure for
Improper compression pressure
overhauling
Improper injector injection pressure and Adjust for correct injection pressure
spray pattern and spray pattern
Adjust for proper functioning of fuel
Improper functioning of fuel pump
Engine cranking, pump
but not starting
Inspect and repair constant throttle
Constant throttle valve stuck open
valve
Camshaft and crankshaft position sensor Inspect and repair the camshaft and
malfunctioning crankshaft position sensor
Troubleshooting
Blocked air intake system Clean, replace if necessary
Troubleshooting
Clean the clogged components in
Clogged exhaust system
exhaust system
ECU failure Replace ECU
Lubricating oil leakage from engine or Repair or replace to eliminate the
auxiliaries leakages from engine assembly
Valve stem seal not intact Replace, if necessary
Defective valve guide seal Replace, if necessary
Excessive engine
oil consumption Worn piston rings and ring groove in Replace piston ring and piston, if
piston necessary
Worn cylinder liner and poor Dismantle the engine and check for
compression pressure defects and repair if necessary
Improper tightness of engine mounting Retighten to the specified torque
Excessive engine
Damaged engine mounting cushion Replace and check
vibration
Damaged vibration damper Replace vibration damper
Oil cooler plates mounting loose or O- Retighten oil cooler mounting or
Oil mix with ring defective replace the defective o-ring
coolant
Cylinder head and block internal leak Replace defective parts
2-59 Service Manual - Engine
5. Maintenance Section
Complaint Cause Corrective Action
Fuel leak in fuel line Repair as necessary
Choked air cleaner element(s) Replace the choked element
Brake dragging Inspect and adjust or repair
Repair or replace clutch system
Low fuel mileage Improper functioning of clutch system
components as necessary
Worn piston rings and ring groove in Replace piston ring and piston, if
piston necessary
Air cleaner element choked Check and replace
Fuel leak in fuel line Repair as necessary
Replace with proper quality of fuel and
Improper quality of fuel check condition of fuel system
components
Fuel Injection pump defective, irregular
Replace if necessary
fuel spray pattern.
Troubleshooting
Choked air cleaner element(s) Replace the choked element
Troubleshooting
Clogged muffler Clean or replace the muffler
Insufficient tyre pressure Maintain proper tyre pressure
Low clearance between brake lining and
Adjust for proper clearance
brake drum
Replace clutch disc and check flywheel
Check for clutch disc slippage
mating surface
Worn piston rings and ring groove in Replace piston ring and piston, if
Poor pickup piston necessary
Improper valve clearance Adjust as necessary
Damaged cylinder head gasket Replace cylinder head gasket
Defective turbocharger Repair turbocharger as necessary
Choked CAC assembly (externally or
Clean the CAC assembly
internally)
Dismantle the engine and check for
Poor compression pressure
defects and repair if necessary
Improper injector injection pressure and Adjust for correct injection pressure
Excessive black spray pattern and spray pattern
smoke from
Improper functioning of the fuel pump Calibrate the fuel pump to specification
exhaust gas
Improper valve clearance Adjust, if necessary
2-60 Service Manual - Engine
5. Maintenance Section
Complaint Cause Corrective Action
Excessive white Improper for valve clearance Adjust, if necessary
smoke from
exhaust gas Improper injector injection pressure and Adjust for correct injection pressure
spray pattern and spray pattern
Improper engine oil level and oil quality Rectify if any leaks observed and top-
(viscosity) up or replace accordingly
Improper electrical connections Reconnect the electrical connections
Replace oil pressure sensor if found
Oil pressure sensor not functioning
defective
Low oil pressure Clean the oil strainer/replace the oil
Clogged oil strainer/filter/oil supply hose
filter /oil supply hose if necessary
Oil filter bye pass valve defective Replace if necessary
Oil cooler mounting loose or O-ring Retighten oil cooler mounting or
defective replace the defective O-ring
Troubleshooting
Choked air cleaner Inspect, replace if necessary
Choked fuel filter Replace filter
Troubleshooting
Leakage in fuel lines Repair or replace if necessary
Damaged turbocharger Replace
No power supply to unit pumps Check unit pump power terminals
Blockage in exhaust passages Clean exhaust passages
Engine running Improper adjustment of exhaust butterfly
Adjust the linkages properly
poorly valve
Inspect and repair constant throttle
Constant throttle valve stuck open
valve
Poor compression Inspect and repair
Recharge the battery, replace if
Poor battery charge
necessary
Thermostat malfunction Replace thermostat
Viscous fan unit malfunction Inspect, repair and replace if necessary
Engine overcools
Clean, refill with OEM recommended
Ungraded coolant used
coolant
Engine stops
Air lock
immediately after Check and clean/bleed the fuel system
starting Water mixes with fuel
2-61 Service Manual - Engine
5. Maintenance Section
Complaint Cause Corrective Action
Worn tappets Replace tappets
Bent or broken push rods Replace push rods
Engine noise Bent connecting rod Replace connecting rod
Loose or worn drive belts Replace drive belt
Worn out exhaust manifold gasket Replace gasket
Air or vacuum in fuel lines Bleed fuel system
Unit pump cam lobes on the camshaft
Replace camshaft
worn
Fuel temperature sensor failure Replace fuel temperature sensor
Engine misfires Fuel flow regulator valve failure Replace fuel flow regulator valve
Check ECU fault codes, calibrate to
Fuel pump solenoid improper connection
correct settings
Crack in cylinder head near coolant
Troubleshooting
Inspect, replace if necessary
passages
Troubleshooting
Coolant leak from Injector heat protection
Inspect, replace if necessary
sleeve thread
Crack in cylinder block near coolant
Replace
passages
2-62 Service Manual - Engine