Diesel engine D-245 malfunctions of the ZIL-5301 vehicle
Possible malfunctions of the ZIL-5301 diesel engine and its systems
Symptom of malfunction, cause of malfunction (Remedy)
The diesel engine does not develop full power:
- Incorrectly set fuel injection advance angle (knocking or smoking)
Adjust the fuel injection advance angle
- Incorrect adjustment or clogged injector
Adjust the injector on a special stand, wash and clean it if necessary
- Malfunction of the high-pressure fuel pump
Remove the high-pressure fuel pump from the diesel engine and send it for repair
- Insufficient supply fuel
Clean the system
Check the regulator lever drive and fix the problem
Replace the fine filter element
Bleed the system
Find the cause of the leak in the system, fix it and bleed the system with a fuel priming pump
- Boost pressure has decreased
Clean the air cleaner
Replace the turbocharger
Diesel smokes in all operating modes:
- - white smoke (indicates the presence of water or fuel vapor in the exhaust gases):
- - Poor tightness of the valve timing valves
- - Wear of the liners and piston rings (accompanied by increased smoking and consumption of crankcase gases)
Send the diesel engine for repair
- Diesel engine is overcooled
Warm up the diesel engine
Maintain the coolant temperature of 75-95˚С during operation
- Fuel injection advance angle adjustment is incorrect
Check and adjust the fuel injection advance angle setting
- Valve and rocker arm clearances are incorrect
Adjust the valve and rocker arm clearances
- Coolant entering the fuel
Replace the fuel, drain the sediment from the FGO
Blue smoke (indicates increased oil entering the combustion chamber):
- Excess oil in the crankcase diesel
Drain oil to the upper mark of the oil dipstick
- - Oil leak through turbocharger seals
- - Wear of valve stem seals
Replace valve stem seals
- - Clogged air cleaner
- - Reduced boost pressure
Replace turbocharger
Clean air cleaner
- Wear of cylinder-piston group parts
Injector malfunction:
- - injector nozzle needle is stuck;
- - other models of nozzles are installed;
- - nose is torn off atomizer;
Black smoke (indicates incomplete combustion of fuel):
- - Clogged air cleaner
- - Leaky fuel system, air
- - Clogged exhaust system
- - Injection pump drive adjustment is broken
Send diesel for repair
Check and adjust injectors on the stand
Identify faulty injector, flush or replace the atomizer, adjust the injector
Install atomizers mod145.1112110
Replace the atomizer, adjust the injectors on the stand
Increased fuel consumption
diesel does not picks up idle speed
- - wear of nozzle holes;
- - increased pressure of fuel injection start by the injector
Faulty fuel injection pump:
- - incorrectly adjusted regulator corrector and corrector for boost of the fuel injection pump;
- - excessive cyclic fuel supply;
- - incorrect adjustment of the fuel injection pump
- - Malfunction of the fuel injection pump;
- - the tightness of the injection section of the fuel injection pump is broken;
- - excessive speed of the camshaft of the fuel injection pump, corresponding to the start of the regulator action;
- - wear of the bushings of the weights of the speed regulator
- - wear of the pair of the guide bushing of the fuel pump rod pump
Adjust the cyclic feed with the nominal feed bolt
Remove the high-pressure fuel pump from the diesel engine and send it for repair
Replace the guide bushing-rod pair, check the tightness and performance of the fuel pump
Set the recommended fuel injection advance angle
Adjust the clearances between the valves and rocker arms
Adjust the high-pressure fuel pump drive
Remove the high-pressure fuel pump from the diesel engine and send it for repair
Knock during diesel operation:
The fuel injection advance angle is set incorrectly
Check the fuel injection advance angle adjustment, play in the high-pressure fuel pump drive
The clearances between the valves and rocker arms are not adjusted correctly. rocker arms
The fuel injection pump fuel supply control lever does not reach the maximum speed position when the fuel supply pedal is fully depressed
Faulty fuel injection pump:
- - stuck plungers;
- - faulty regulator
Violation of clearances between the rocker arms and valves
Breakage of valve springs apana
Seizure of valve stem in guide bushing
Worn pistons and piston pin bore surfaces.
Worn bushings in upper connecting rod heads and piston bosses
Worn connecting rod and main bearings, scoring of cylinder liners
Late fuel injection into unheated diesel cylinders (mild knocking and white smoke)
Early fuel injection into diesel cylinders (strong knocking and black smoke)
Check and adjust clearances
Replace springs, eliminate seizure
Eliminate seizure; if this cannot be done, send the diesel engine for repair.
Submit the diesel engine for repair, replace worn or faulty parts with new ones during the repair process
Remove the high-pressure fuel pump from the diesel engine and send it for repair (check the condition of the pusher springs in the high-pressure fuel pump sections, adjust the cyclic feeds of the high-pressure fuel pump sections)
Check the injector and adjust it on the stand (check the position of the needles in the injectors)
The diesel engine is overheating:
- High-pressure fuel pump malfunction: uneven distribution of injected fuel across individual cylinders of the diesel engine (knocking in individual cylinders)
Remove the high-pressure fuel pump from the diesel engine and send it for repair
- - Injector malfunction:
- - lack of a clear fuel cut-off injectors;
- - clogging of the injector drain line (loud knocking)
Adjust the injector on the stand
Break or strong stretching of the liquid pump drive belts
Check and adjust the belt tension; if necessary, replace the belts with new ones as a set, add coolant to the cooling system
Low coolant level
- Thermostat is faulty
Replace the thermostat
- Contamination of the outer surface of the radiator
Clean the radiator
- Contamination of the cooling system
Flush the cooling system
Clean and blow out the fuel lines
No oil pressure
The oil pressure on a warmed-up diesel engine is below the permissible limit, the oil pressure on a warmed-up diesel engine is above the permissible limit. Water in the lubrication system
- Oil pressure sensor or indicator is faulty (alarm does not work)
Replace the oil pressure sensor or indicator
- - Lubrication system pump drive faulty
- - Oil pressure sensor or indicator is faulty (alarm does not work)
Replace the oil pressure sensor or indicator
- Diesel crankcase filled with oil that does not meet the requirements of the operating manual
Change the oil in accordance with the operating manual
- Oil level in the crankcase is below the permissible level
Add oil to the required level
- Oil dilution by fuel, coolant or due to overheating
Eliminate the cause of oil dilution, change the oil
- Seized or incorrectly adjusted oil drain valve
Adjust or replace the valve.
- Oil pump malfunction
Send the diesel engine for repair
- Oil line connections are leaky
Identify the leaky location and restore it
- Wear of main and connecting rod journals and crankshaft liners
Send the diesel engine for repair
- High-viscosity oil is poured into the diesel crankcase
Change the oil in accordance with the lubrication chart
- Clogged or faulty safety valves
Check the valves, replace the valves if necessary
- Leakage along the rubber rings of the cylinder liners
Replace faulty seals rings
Send the diesel for repair
- Loose tightening of the cylinder head mounting bolts
Tighten the bolts
The diesel does not start or starts poorly:
Starter failure or decrease in crankshaft speed
Check the charge level of the batteries.
No fuel supply:
- - thickening of fuel in the fuel lines
- - clogged fuel lines or fuel tank intake
- - freezing of water in the fuel lines, in the cap of the fuel filter or the mesh of the fuel tank intake
- - no fuel supply to the high-pressure fuel pump
- - presence of air in the fuel system
- - malfunction Fuel injection pump
- - incorrect fuel injection advance angle adjustment
- Fuel system leaks
Fuel injection pump malfunction:
- - uneven fuel supply by sections;
- - plunger sticking;
- - rack sticking;
- - delivery valve malfunction;
- - tappet spring breakage
- - speed controller malfunction
- Low crankshaft speed
Unsatisfactory operation of individual injectors:
- - injector nozzle needle stuck;
- - other models of nozzles installed;
- - separation spray nozzle;
- - wear of nozzle holes;
- - pressure drop fuel injection start of the injectors.
Check the connections on the batteries and clean the contacts if necessary.
Check that the oil and fuel are suitable for the season, bleed the fuel supply system.
If necessary, dilute the fuel with kerosene depending on the ambient temperature in a ratio of up to 1:1 in accordance with the operating manual.
Flush the intake, blow out the fuel lines.
Carefully warm up the fuel pipes, filters, FGO and tank, placing them in rags and pouring hot water over them.
Drain the water from the FGO, fuel tank and bleed the system with a fuel priming pump
Check the tightness of the low-pressure fuel lines.
Drain the sediment from the FGO and FTO filters.
Flush or replace the FTO filter elements, clean them reflector with a mesh and blow it with compressed air.
