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#
Note: R = Refer to engine manufacturer’s manual	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]

Diesel Fault Finding Chart

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