Diesel Fault Finding Chart

Symptom Key
# symptom
1 Engine Running Hot
2 Poor Transient Response
3 Smoke
4 Engine Lacks Power
5 Black Exhaust Smoke
6 Blue Exhaust Smoke
7 High Oil Consumption
8 Turbocharger Noisy
9 Cyclic Sound From the Turbocharger
10 Oil Leak from Compressor Seal
11 Oil Leak from Turbine Seal

 

Note: R = Refer to engine manufacturer’s manual Symptom#
1 2 3 4 5 6 7 8 9 10 11
Dirty air cleaner
Clean or replace element
* * * * * * *     *  
Restricted compressor intake duct
Remove restriction or replace damaged parts as required
* * *   * * * * * *  
Restricted air duct from compressor to intake manifold
Remove restriction or replace damaged parts as required
* *   * *     *      
Restricted intake manifold
R – and remove restriction
* *   * *     *      
Air leak in feed from air cleaner to compressor
Replace seals, gaskets or tighten fasteners as required
              *      
Air leak in feed from compressor to intake manifold
Replace seals, gaskets or tighten fasteners as required
* * * * * * * *      
Air leak between intake manifold and engine
R – and replace gaskets or tighten fasteners as required
*   * * * * * *      
Foreign object in exhaust manifold from engine)
R – and remove obstruction
      * * * * *   *  
Restricted exhaust system
Remove restriction or replace damaged parts as required
*     * *         *  
Exhaust manifold cracked, gaskets blown or missing . .
R – and replace gaskets or damaged parts as required
  * * * *     *      
Gas leak at turbine inlet/exhaust manifold joint
Replace gasket or tighten fasteners as required
  * * * *     *      
Gas leak in ducting after turbine outlet
R – and repair leak
  *           *      
Restricted turbocharger oil drain line
Remove restriction or replace damaged parts as required
          * *     * *
Restricted engine crankcase breather
R – clear restriction
          * *     * *
Turbocharger bearing housing sludged or coked
Change engine oil an(foil filter, overhaul or replace turbocharger as required
          * *     * *
Fuel injection pump or fuel Injectors incorrectly set
R – and replace or adjust faulty components as required
  * * * *            
Engine valve timing Incorrect
R – for correct settings and adjust as required
      * *            
Worn engine piston rings or liners
R – and repair as required
      * * * *     * *
Burnt valves and/or pistons
R – and repair as required
      * * * *     * *
Excessive dirt build up on compressor wheel and/or diffuser vanes
Clean in accordance with details in the appropriate Holset publication
      * * * * * * * *
Turbocharger damaged
Find and correct cause of failure, repair or replace turbocharger as necessary
      * * * * *   * *
Failed diaphragm
Replace using correct actuator Service Kit
*                    
Seized valve
Free valve/replace complete turbine housing subassembly
* *           *      
Leaking hose Replace hose and clips *             *      
Wastegate mechanism set incorrectly. Contact approved agent for correct setting details * * * *       *      

[thanks to Fritz used with permission]

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