Problem
Engine cranks normally but will not start.
Cause
Incorrect or dirty fuel. No fuel to nozzles or injection pump. Plugged fuel return line. Pump timing off. Inoperative glow plugs, incorrect starting procedure or internal engine problems.
Solution
Flush system and use correct fuel. Check return line clean. Retime pump timing.
Problem
Engine starts but stalls at idle.
Cause
Fuel low in tank. Incorrect or dirty fuel. Limited fuel to nozzles or injection pump. Restricted fuel return line. Idle incorrectly set. Pump timing off. Injection pump trouble. Internal engine problem.
Solution
Fill tank. Flush system and use correct fuel. Check for fuel to nozzles and to pump. Check return line clean. Reset idle. Retime pump timing. Install new pump.
Problem
Rougle idle, no abnormal noise or smoke.
Cause
Low idle incorrect. Injection line leaks. Restricted fuel return line. Nozzle trouble. Fuel supply pump problem. Uneven fuel distribution to nozzles. Incorrect or dirty fuel.
Solution
Adjust low idle. Fix leaks in injection line. Clear fuel return line. Check, repair or replace nozzle. Check, replace if necessary the fuel supply pump. Selective replace of nozzle until condition clears up. Flush system and use correct fuel.
Problem
Rough idle with abnormal noise and smoke.
Cause
Injection pump timing off. Nozzle trouble.
Solution
Retime injection pump timing. Check cylinders in sequence to find defective nozzle.
Problem
Idle is fine but misfires as throttle opens.
Cause
Plugged fuel filter. Injection pump timing off. Incorrect or dirty fuel.
Solution
Replace fuel filter. Retime injection pump timing. Flush system and use correct fuel.
Problem
Loss of power.
Cause
Incorrect or dirty fuel. Restricted fuel return line. Plugged fuel tank vent. Restricted fuel supply. Plugged fuel filter. Plugged nozzle. Internal engine problems or loss of compression and compression leaks.
Solution
Flush system and use correct fuel. Clear fuel return line. Clean fuel tank vent. Check fuel lines, fuel supply pump and injection pump. Replace fuel filter. Selective test nozzles and replace as necessary.
Problem
Noise rap from one or more cylinders.
Cause
Air in fuel system. Gasoline in fuel system. Air in high pressure line. Nozzle sticking open or with low opening pressure. Engine problems.
Solution
Check for cause and correct in fuel system. Replace fuel in fuel system. Bleed system in high pressure line. Replace defective nozzle.
Problem
Combustion noise with excessive black smoke.
Cause
Timing off. Injection pump trouble. Nozzle sticking open. Internal engine problems.
Solution
Rest idle timing. replace pump in injection pump. Clean or replace nozzle.
