Symptom | Possible Sources | Action |
Engine does not turn over and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine does not turn over | * PATS. | * |
* Starter inhibit relay fuse. * Relay start ground fuse. * Power relay start enable fuse. * Power relay ignition fuse. | * CHECK the fuse. If the fuse is blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS. |
* Starter inhibit relay. * Relay start ground. * Power relay start enable. * Power relay. | * CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams. |
* Ignition switch. | * |
* PCM. | * REFER to WDS. |
Engine turns over but does not start and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine turns over but does not start | * The fuel injection pump control unit and the PCM are not matched. | * |
* Fuel injection pump control unit electrical connector. | * CHECK the fuel injection pump control unit electrical connector locking tang is correctly installed. |
* Inertia fuel shutoff (IFS) switch . | * RESET the IFS switch. |
* Fuel injection pump relay fuse. | * CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS. |
* Fuel injection pump relay. | * CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams. |
* Blocked fuel filter element. | * |
* Air ingress into the fuel lines. | * |
* Damaged or blocked fuel lines. | * |
* Crankshaft position (CKP) sensor. * Fuel injection pump timing. | * REFER to WDS. |
* Incorrect valve timing. | * |
* Fuel injection pump. * PCM. | * REFER to WDS. |
Intermittent start (engine turns over) and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Intermittent start (engine turns over) | * PATS. | * |
* Fuel injection pump control unit electrical connector. | * CHECK the fuel injection pump control unit electrical connector locking tang is correctly installed. |
* CKP sensor. | * REFER to WDS. |
* Fuel injection pump fuse. | * CHECK the fuse. If the fuse is blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS. |
* Fuel injection pump relay. | * CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams. |
* Fuel injection pump. * PCM. | * REFER to WDS. |
Intermittent crank (engine does not turn over) and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Intermittent crank (engine does not turn over) | * PATS transceiver. * PATS transponder key. | * |
* Ignition switch. | * |
* Starter enable relay. | * CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams. |
* PCM. | * REFER to WDS. |
Poor starting and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Poor starting | * Fuel filter element blocked. | * |
* Air cleaner element blocked. | * |
* Glow plug relay fuse. | * CHECK the fuse. If fuse blown, INSTALL a new fuse. If the fuse blows again, REFER to WDS. |
* Glow plug relay. | * CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams. |
* Glow plugs. | * |
* Fuel system leak. | * CHECK the system for fuel leak(s). REPAIR the system as necessary. |
* Air ingress into the fuel lines. | * |
* Fuel injection pump timing. | * REFER to WDS. |
* Incorrect engine oil. | * INSTALL a new engine oil filter and 5W/30 engine oil. |
* Fuel system restriction. | * |
* CHT sensor. * Temperature and manifold absolute pressure (T-MAP) sensor. | * REFER to WDS. |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump fuel return valve. | * INSTALL a suitable clear pipe to the fuel injection pump return line and place in a suitable container for 15 minutes. CHECK that no extra fuel has drained from the fuel injection pump. |
Engine starts but immediately stops and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine starts but immediately stops | * Air cleaner element blocked. | * |
* Air ingress into the fuel lines. | * |
* PCM relay. | * CARRY OUT the Relay Component Test. REFER to the Wiring Diagrams. |
* CKP sensor. | * REFER to WDS. |
* Fuel injection pump control unit. * PCM. | * REFER to WDS. |
Poor idling and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Poor idling | * Low fuel tank level. | * CHECK the fuel tank level is greater than 4 liters. If fuel tank level is less than 4 liters, FILL with fuel. |
* Air cleaner element blocked. | * |
* Fuel filter element blocked. | * |
* Water in fuel. | * CHECK the water-in-fuel warning lamp is not illuminated, if the lamp is illuminated, DRAIN the water from the fuel filter. |
* T-MAP sensor. * CKP sensor. | * REFER to WDS. |
* Air ingress into the fuel lines. | * |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odors from the fuel tank. |
* Fuel injection pump timing. * Fuel injection pump. | * REFER to WDS. |
Engine stumbling and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine stumbling | * Low fuel level. | * CHECK the fuel tank level is greater than 4 liters. If the fuel tank level is less than 4 liters, FILL with fuel. |
* Accelerator pedal position (APP) sensor. | * REFER to WDS. |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump. | * REFER to WDS. |
Engine lacks power and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine lacks power | * Air cleaner element blocked. | * |
* Fuel filter element blocked. | * |
* Kinked or restricted fuel lines | * |
* Air ingress into the fuel lines. | * |
* APP sensor. * T-MAP sensor. * CHT sensor. | * REFER to WDS. |
* Exhaust gas recirculation (EGR) valve. | * |
* Fuel injection pump timing. | * REFER to WDS. |
* Incorrect valve timing. | * |
* Turbocharger. | * |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Catalytic converter blocked. | * CHECK if the catalytic converter rattles if gently hit. If noise is present, REMOVE and visually INSPECT the catalytic convertor for damage. INSTALL a new catalytic converter as necessary. REFER to Section 309-00 Exhaust System. |
* Charge air cooler blocked or cracked. * Charge air cooler pipes split or cracked. | * INSPECT for visible signs of damage. REPAIR as necessary. |
* Incorrect or contaminated fuel. | * CHECK for signs of contamination such as strange odors from the fuel tank. |
* Fuel injection pump | * REFER to WDS. |
Black smoke at idle and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Black smoke at idle | * Air cleaner element blocked. | * |
* Fuel injection pump timing. * CHT sensor. * T-MAP sensor. | * REFER to WDS. |
* Incorrect valve timing. | * |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump. | * REFER to WDS. |
Excessive black smoke during acceleration and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Excessive black smoke during acceleration | * APP sensor. * CKP sensor. | * REFER to WDS. |
* Fuel contamination. | * CHECK for signs of contamination such as strange odors from the fuel tank. |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump timing piston. * Fuel injection pump. | * REFER to WDS. |
Black smoke at cruising speeds and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Black smoke at cruising speeds | * Air cleaner element restricted. | * |
* T-MAP sensor. | * REFER to WDS. |
* Vacuum lines. | * CHECK all vacuum lines are installed and no signs of air leaks are present. REPAIR as necessary. |
* EGR valve sticking open. * EGR vacuum switching valve. | * DISCONNECT the vacuum line from the EGR vacuum switching valve lower vacuum line and start the engine. Using a hand vacuum/pressure pump, CHECK that a vacuum is present. RECONNECT the vacuum line and DISCONNECT the vacuum line to the EGR valve. CHECK that a vacuum is present. If no vacuum is present, INSTALL a new EGR vacuum switching valve. If vacuum is present, APPLY a vacuum to the EGR valve and CHECK that it holds a vacuum. If EGR valve does not hold a vacuum, INSTALL a new EGR valve. If EGR valve holds vacuum, REFER to WDS. |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump. | * REFER to WDS. |
Blue smoke and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Blue smoke | * Engine burning oil. | * CARRY OUT a controlled oil consumption test over 1000 km (600 miles). CONFIRM that the oil consumption is less than 0.1 litres per 1000 km (600 miles). REFER to Section 303-01A Engine / 303-01B Engine / 303-01C Engine. |
* Incorrect fuel. | * CHECK for signs of contamination such as strange odors from the fuel tank. |
* Worn or damaged valve guides, piston rings, cylinder bores, cylinder head or gasket. | * |
* Engine breather system. | * CHECK engine breather pipes for signs of restriction or blockage. |
* Turbocharger oil seals leaking. * Turbocharger oil return pipe blocked or damaged. | * |
White smoke and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
White smoke | * Water in fuel. | * |
* Retarded fuel injection pump timing. | * REFER to WDS. |
* Incorrect valve timing. | * |
* Coolant in the combustion chamber. | * |
Engine misfire and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine misfire | * Low fuel tank level. | * CHECK the fuel tank level is greater than 4 liters. If fuel tank level is less than 4 liters, FILL with fuel. |
* Cracked or damaged high-pressure fuel supply lines. | * CHECK the high-pressure fuel supply lines for signs of damage INSTALL new high - pressure fuel supply lines as necessary. |
* Water in Fuel. | * |
* Air ingress into the fuel lines. | * |
* CHT sensor. | * REFER to WDS. |
* Fuel injector(s). * Injector seals. | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Low cylinder compression. | * |
* Worn or damaged valve, tappets or camshafts. | * |
* Damaged cylinder head gasket. | * |
* Engine operating temperature too high. | * |
* Fuel injection pump timing piston stuck in full advance. * Fuel injection pump. | * REFER to WDS. |
Engine knock at idle and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine knock at idle | * Low engine oil level. | * CHECK the engine oil level. REFILL as necessary. |
* Petrol in the fuel tank. | * CHECK for signs of contamination such as strange odors from the fuel tank. |
* Incorrect valve timing. | * |
* Fuel injection pump timing. * CKP sensor. | * REFER to WDS. |
* Excessive carbon build up. | * |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump timing piston stuck in full advance. | * REFER to WDS. |
* Worn or damaged oil pump. * Worn or damaged timing chain or sprocket. * Major mechanical engine failure. | * |
Engine knock during acceleration and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Engine knock during acceleration | * Fuel injection pump timing. | * REFER to WDS. |
* Fuel injectors. | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Major mechanical engine failure. | * |
* Fuel injection pump timing piston. * Fuel injection pump. | * REFER to WDS. |
Excessive fuel consumption and glow plug lamp is illuminated | * DTC detected. | * CHECK the glow plug lamp illuminates when starting the engine and then goes out and stays out. If the glow plug lamp starts flashing, REFER to WDS. |
Excessive fuel consumption | * Brakes binding, vehicle overloaded, or excessive wind resistance (roof racks, towing etc). | * * ADVISE the customer about the effects of overloading the vehicle and wind resistance on the fuel consumption. |
* Air cleaner element blocked. | * |
* Fuel filter element blocked. | * |
* Fuel system leaks. | * CHECK the system for fuel leak(s). REPAIR the system as necessary. |
* CHT sensor. * T-MAP sensor. | * REFER to WDS. |
* Incorrect engine oil. | * INSTALL a new oil filter and 5W/30 engine oil. |
* Low engine oil level. | * CHECK the engine oil level. REFILL as necessary. |
* Clutch worn or slipping. | * |
* Generator. | * |
* EGR valve stuck open. | * DISCONNECT the vacuum line from the EGR vacuum switching valve lower vacuum line and start the engine. Using a hand vacuum/pressure pump, CHECK that a vacuum is present. RECONNECT the vacuum line and DISCONNECT the vacuum line to the EGR valve. CHECK that a vacuum is present. If no vacuum is present, INSTALL a new EGR vacuum switching valve. If vacuum is present, APPLY a vacuum to the EGR valve and CHECK that it holds a vacuum. If EGR valve does not hold a vacuum, INSTALL a new EGR valve. If EGR valve holds vacuum, REFER to WDS. |
* Air ingress into the fuel lines. | * |
* Fuel injection pump timing. | * REFER to WDS. |
* Incorrect valve timing. | * |
* Turbocharger. * Turbocharger wastegate actutator. | * |
* Low cylinder compression. | * |
* Fuel injector(s). | * Have the fuel injectors checked by an appropriate fuel injection specialist agent. CLEAN or INSTALL a new set of injectors as required only after the specialist agent checks have been carried out. |
* Fuel injection pump. | * REFER to WDS. |