Possible malfunctions of ZIL 5301 with engine D 245E3

Table of possible faults ZIL - 5301 with engine D 245 E3

Troubleshooting algorithm (Remedy)

Problems starting the engine

• 1.1 Engine won't start
• 1.1.1 Check that there is fuel in the fuel tank and that it is the correct brand of fuel

Fill the fuel tank

1.1.2 Check the operation of the starter and its control circuits

Make necessary repairs

• 1.1.3 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 1.1.4 Check for leaks in the high pressure circuit

Make necessary repairs

• 1.1.5 Check the electrical circuit
• - check battery charge

Repair or replace the battery as needed

• - check fuses

Make necessary repairs

• - check the wire for ground

Replace wire with ground

• 1.1.6 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 1.1.7 Check intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 1.1.8 Check the reliability of the glow plugs

Replace glow plugs or glow plug control unit

• 1.1.9 Check harness condition (open or shorted)

Make necessary repairs

• 1.1.10 Check cylinder compression

Make necessary repairs

• 1.1.11 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 1.1.12 Check the high pressure pump
• - run the high pressure pump test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• - check that the low pressure circuit is working;
• - check for leaks in the high pressure circuit

Make necessary repairs

• 1.1.13 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

1.2 Engine starts with difficulty or starts and then stops

• 1.2.1 Check that there is fuel in the fuel tank and that it is the correct brand of fuel

Fill the fuel tank

• 1.2.2 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings

Make necessary repairs

• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 1.2.3 Check for leaks in the high pressure circuit

Make necessary repairs

• 1.2.4 Check the electrical circuit
• - check battery charge

Repair or replace the battery as needed

• - check fuses

Make necessary repairs

• - check the wire for ground

Replace wire with ground

• 1.2.5 Check intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 1.2.6 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 1.2.7 Check the reliability of the glow plugs

Replace glow plugs or glow plug control unit

• 1.2.8 Check harness condition (open or shorted)

Make necessary repairs

• 1.2.9 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 1.2.10 Check cylinder compression

Make necessary repairs

• 1.2.11 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

1.3 Hot engine starts with difficulty

• 1.3.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 1.3.2 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 1.3.3 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 1.3.4 Check intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 1.3.5 Check cylinder compression

Make necessary repairs

• 1.3.6 Check the condition of the wiring harness (broken or pinched)

Make necessary repairs

• 1.3.7 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

Unstable idling

• 2.1 Erratic idle speed
• 2.1.1 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in fuel

Bleed the low pressure circuit

• 2.1.2 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 2.1.3 Check the condition of the wiring harness (open or shorted)

Make necessary repairs

• 2.1.4 Check for leaks in the high pressure circuit

Make necessary repairs

• 2.1.5 Check cylinder compression

Make necessary repairs

• 2.1.6 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 2.1.7 Check the high pressure pump
• - run the high pressure pump test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• - check that the low pressure circuit is working;
• - check for leaks in the high pressure circuit

Make necessary repairs

• 2.2 Idle speed too high or too low
• 2.2.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the condition of the electrical consumers of the CRS system

Perform diagnostics and necessary repairs

• 2.2.2 Check the electrical circuit
• - check battery charge

Repair or replace the battery as needed

• - check fuses

Make necessary repairs

• - check the wire for ground

Replace wire with ground

• 2.2.3 Check clutch adjustment

Make necessary repairs

• 2.2.4 Check the condition of the wiring harness (open or shorted)

Make necessary repairs

• 2.2.5 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

3 Behavior of the engine when the vehicle is moving

3.1 Unstable engine operation during acceleration/deceleration

• 3.1.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the condition of the electrical consumers of the CRS system

Perform diagnostics and necessary repairs

• 3.1.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.1.3 Check harness condition (open or shorted)

Make necessary repairs

• 3.1.4 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

3.1.5 Checking the control unit

• - check the reliability of fastening of the control unit connectors

Fix connectors

• 3.2 Dips during acceleration and when engaging the clutch
• 3.2.1 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.2.2 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the condition of the electrical consumers of the CRS system

Perform diagnostics and necessary repairs

• 3.2.3 Determine the health status of the turbocharger
• 3.2.4 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 3.2.5 Check cylinder compression

Make necessary repairs

• 3.2.6 Check for leaks in the high pressure circuit

Make necessary repairs

• 3.2.7 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device

• 3.2.8 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

3.3 Stopping the engine

• 3.3.1 Check fuel tank

Fill the fuel tank

• 3.3.2 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 3.3.3 Check for leaks in the high pressure circuit

Make necessary repairs

• 3.3.4 Check the electrical circuit
• - check battery charge

Make necessary repairs or replace the battery

• - check fuses

Make necessary repairs

• - check the wire for ground

Replace wire with ground

• 3.3.5 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 3.3.6 Check intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.3.7 Check the condition of the wiring harness (broken or pinched)

Make necessary repairs

• 3.3.8 Check the high pressure pump
• - run the high pressure pump test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• - check that the low pressure circuit is working;
• - check for leaks in the high pressure circuit

Make necessary repairs

• 3.3.9 Control block test
• - check the reliability of fastening of the control unit connectors

Fix connectors

• 3.4 Motor erratic (motor erratic during acceleration/deceleration and motor overload)
• 3.4.1 Check Check the presence of fuel in the fuel tank

Fill the fuel tank

• 3.4.2 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 3.4.3 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 3.4.4 Check harness condition (open or shorted)

Make necessary repairs

• 3.4.5 Check cylinder compression

Make necessary repairs

• 3.4.6 Check valve clearances

Adjust valve clearances

• 3.4.7 Check the high pressure pump
• - run the high pressure pump test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• - check that the low pressure circuit is working;
• - check for leaks in the high pressure circuit

Make necessary repairs

• 3.4.8 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

3.5 Insufficient Power

• 3.5.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 3.5.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.5.3 Check engine oil level

Refill with oil to the correct level

• 3.5.4 Determine the health status of the turbocharger
• 3.5.5 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 3.5.6 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 3.5.7 Check cylinder compression

Make necessary repairs

• 3.5.8 Check valve clearances

Adjust valve clearances

• 3.6 Excess power
• 3.6.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

In Perform diagnostics and necessary repairs

• 3.6.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.6.3 Check oil consumption (engine overload) Repair as necessary if oil consumption is high
• 3.6.4 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device

• 3.6.5 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

3.7 Excessive fuel consumption

• 3.7.1 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 3.7.2 There are leaks in the diesel fuel temperature sensor

Replace diesel fuel temperature sensor

• 3.7.3 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 3.7.4 Check for leaks in the high pressure circuit

Make necessary repairs

• 3.7.5 Check intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.7.6 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 3.7.7 Check engine oil level

Refill with oil to the correct level

• 3.7.8 Determine turbocharger health status
• 3.7.9 Check cylinder compression

Make necessary repairs

• 3.7.10 Control block test
• - check the reliability of fastening of the control unit connectors

Fix connectors

3.8 Over-revving the engine when releasing the pedal or changing gear

• 3.8.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 3.8.2 Check harness condition (open or shorted)

Make necessary repairs

• 3.8.3 Check clutch adjustment

Make necessary repairs

• 3.8.4 Determine the health status of the turbocharger

See "Manual" appendix E

• 3.8.5 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 3.8.6 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

3.9 Engine stalls during acceleration

3.9.1 Check diesel parameters

• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 3.9.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 3.9.3 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 3.9.4 Check clutch adjustment

Make necessary repairs

• 3.9.5 Check harness condition (open or shorted)

Make necessary repairs

• 3.9.6 Checking the control block

- check the reliability of fastening of the control unit connectors

Fix connectors

3.10 Engine does not stop

• 3.10.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

4 Noise, smell or smoke

• 4.1 Engine knock or noise
• 4.1.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the condition of the electrical consumers of the CRS system

Perform diagnostics and necessary repairs

• 4.1.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 4.1.3 Check cylinder compression

Make necessary repairs

• 4.1.4 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 4.1.5 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

4.2 Intermittent noise

• 4.2.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 4.2.2 Check Check the condition of the wiring harness (broken or pinched)

Make necessary repairs

• 4.2.3Control block test
• - check the reliability of fastening of the control unit connectors

Fix connectors

• 4.3 Various mechanical noises
• 4.3.1Check that the nozzles do not rattle (discharge through the nozzles)

Make necessary repairs

• 4.3.2 Fuel pipe holders broken or missing

Make necessary repairs

• 4.3.3 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 4.3.4 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 4.3.5 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 4.3.6 Check clutch adjustment

Make necessary repairs

• 4.3.7 Determine the health status of the turbocharger

See "Manual" appendix E

• 4.3.8 Check valve clearances

Adjust valve clearances

4.4 Exhaust smell

• 4.4.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• - use the diagnostic tool to check the status of electrical consumers

Perform diagnostics and necessary repairs

• 4.4.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 4.4.3 Check oil consumption (engine overload)

In case of increased oil consumption, make the necessary repairs

• 4.4.4 Determine the health status of the turbocharger

See "Manual" appendix E

• 4.4.5 Check engine oil level

Refill with oil to the correct level

• 4.4.6 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 4.4.7 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

4.5 Smell of diesel fuel

• 4.5.1 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 4.5.2 There are leaks in the diesel fuel temperature sensor

Replace diesel fuel temperature sensor or rubber o-ring

• 4.5.3 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 4.5.4 Check for leaks in the high pressure circuit

Make necessary repairs

4.6 Blue, white or black smoke

• 4.6.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• 4.6.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 4.6.3 Check engine oil level

Bring the oil level up to the top of the dipstick

• 4.6.4 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 4.6.5 Check oil consumption (engine overload)

In case of increased oil consumption, make the necessary repairs

• 4.6.6 Check cylinder compression

Make necessary repairs

• 4.6.7 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

4.7 Blue, white or black smoke when accelerating

• 4.7.1 Check diesel parameters
• - use the diagnostic tool to check for malfunctions in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• 4.7.2 Check the intake system
• - check for leaks/air leaks

Make necessary repairs

• - check the condition of the air filter

Replace the air filter with a new one

• - check for clogging of the intake manifold

Clean intake manifold

• 4.7.3 Check the low pressure circuit
• - check the correct connections in the low pressure circuit

Make necessary repairs

• - check for leaks in hoses and fittings
• - check the serviceability and compliance of the fuel filter

Replace the filter with the one required by the specification

• - make sure there is no water in the diesel fuel in the glass on the coarse fuel filter

Clean the fuel filter from water by draining it by opening the cock

• - make sure there is no air in the fuel

Bleed the low pressure circuit

• 4.7.4 Check engine oil level

Bring the oil level up to the top of the dipstick

• 4.7.5 Determine the health status of the turbocharger

See "Manual" appendix E

• 4.7.6 Check oil consumption (engine overload)

In case of increased oil consumption, make the necessary repairs

• 4.7.7 Check cylinder compression

Make necessary repairs

• 4.7.8 Check for leaks in the high pressure circuit

Make necessary repairs

• 4.7.9 Check the condition of the wiring harness (broken or pinched)

Make necessary repairs

• 4.7.10 Check the injectors
• - start the injector test cycle with the corresponding command of the standard test program of the KTS-Bosch diagnostic tool

Follow the diagnostic program of the KTS-Bosch device.

• 4.7.11 Checking the control block
• - check the reliability of fastening of the control unit connectors

Fix connectors

• 5 Diesel overheats
• 5.1 Insufficient amount of coolant in the cooling system

Top up the coolant to the correct level

• 5.2 Radiator dirty on the outside

Clean the radiator

• 5.3 Thermostat valve does not open fully

Replace thermostat

• 5.4 Insufficient fan belt tension

Tighten the belt

5.5 Oiling the fan drive belt and pulleys

Remove the drive belt, remove traces of oil from the surface of the belt and pulleys

• 6 The oil pressure on a warm diesel engine is below the allowable
• 6.1.1 Use the diagnostic tool to check for faults in the COMMON RAIL injection system, carry out the standard test program "KTS - Bosch"

Follow the diagnostic program of the KTS-Bosch device.

• 6.1.2 Faulty pressure sensor or indicator (redundant instruments)

Replace the pressure gauge or gauge, if necessary, after checking the oil pressure with the control instrument kit

• 6.2 Leakage of oil line connections

Find the leak and repair it

• 6.3 Faulty oil pump

Troubleshoot and fix

• 6.4 The oil level in the diesel crankcase is below the permissible level

Add oil up to the upper mark on the oil dipstick

• 6.5 Wear limit in mates: crankshaft journals - main (connecting rod) liners

Troubleshoot

• 6.6 Stuck safety valve in oil filter housing

Rinse the valve and the valve channel in the filter housing.

Adjust the pressure in the lubrication system (section 3.2.3)

• 6.7 Clogged oil filter

Change the oil filter

8 Starter

• 8.1 When the starter is turned on, the diesel crankshaft does not turn or rotates very slowly
• 8.1.1 Loose battery terminals or oxidized wire ends

Clean the lugs and tighten the terminals

• 8.1.2 Low battery

Charge or replace battery

• 8.1.3 Collector and brushes dirty

Clean commutator and brushes

• 8.1.4 Poor contact of the brushes with the commutator. Brush wear

Remove the starter from the diesel, clean the manifold, remove the stuck brushes or replace them if they are worn out

• 8.1.5 In the starter relay, the surfaces of the contact bolts and the contact plate that contact when turned on are burnt

Clean the starter relay contacts or install the contact bolts in the sockets of the cover, turning around the axis by 180 °, and install the contact plate with the reverse side

• 8.1.6 Starter drive failed

Replace starter motor

8.2 After starting the diesel engine, the starter remains on

• 8.2.1 The contact plate is welded to the starter relay contact bolts or the contacts in the starter control circuit relay are welded

Stop the diesel, disconnect the battery and perform the work according to 8.1.5 or replace the relay in the starter control circuit

• 8.3 The starter armature rotates at a high frequency without turning the diesel crankshaft
• 8.3.1 Broken flywheel teeth

Replace flywheel ring

• 8.3.2 Starter drive failed

Replace starter motor

8.4 The starter relay is intermittent (turns the starter on and off immediately)

• 8.4.1 Break in the holding coil of the relay

Replace the relay

• 8.4.2 Low battery

Charge or replace battery

• 8.5 The drive gear does not systematically engage with the flywheel ring during normal relay operation
• 8.5.1 Face wear of the backed part of the flywheel ring gear

Ground the ring teeth or replace the flywheel ring

• 8.5.2 Stuck drive gear on armature shaft due to lack of or poor quality lubrication

Clean the drive and shaft from old grease; apply lubricant CIATIM-201/203/221

• 8.5.3 Face wear of the backed part of the teeth of the drive gear

Refill teeth or replace drive

9 Generator

• 9.1 The ammeter (voltmeter) does not show charging after starting the diesel engine and then during the entire operation time
• 9.1.1 Opening of the positive terminal or shorting it to the generator case;

Disconnect the rectifier, solder and isolate the break. Isolate the damaged insulation (Repair at a specialist workshop)erskoy)

• 9.1.2 Drive coil open circuit

Disassemble the generator, solder and isolate the damage site, and if it is impossible to eliminate this defect, replace the excitation coil

• 9.1.3 Short circuit to the generator case of one of the stator phases

Replace the stator

• 9.1.4 Short circuit of the power rectifier outputs or breakdown of diodes of direct and reverse polarity

Replace rectifier

• 9.1.5 Faulty voltage regulator

Replace voltage regulator

• 9.1.6 Poor contact of brushes with the commutator, stuck or worn brushes

Clean the commutator, remove the hang or replace the brushes

9.2 The generator does not produce full power

• 9.2.1 Broken wires to the regulator

Solder and isolate the damage

• 9.2.2 Opening of one of the stator phases

Replace the stator (Repair at a specialist workshop)

• 9.2.3 Turn-to-turn stator winding

Replace the stator

• 9.2.4 Turn-to-turn short circuit of the field coil winding

Replace exciter coil

• 9.2.5 One of the power rectifier diodes is faulty

Replace rectifier

• 9.3 The battery is systematically recharged
• 9.3.1 Faulty voltage regulator

Replace voltage regulator

• 9.3.2 Short circuit to the ground of the output "Ш" of the voltage regulator

Isolate the insulation failure

• 9.4 Generator noise
• 9.4.1 Drive belt slip or over tension

Adjust the drive belt tension