S-5
03-M-DI Series, WSM
DIESEL ENGINE
[4] TROUBLESHOOTING
W1014322
Symptom
Probable Cause
Solution
Reference
Page
Engine Does Not
Start
(Starter Does Not
Run)
• No fuel
• Air in the fuel system
• Water in the fuel system
• Fuel pipe clogged
• Fuel filter clogged
• Excessively high viscosity of fuel or engine oil
at low temperature
• Fuel with low cetane number
• Fuel leak due to loose injection pipe retaining
nut
• Incorrect injection timing
• Fuel camshaft worn
• Injection nozzle clogged
• Injection pump malfunctioning
• Seizure of crankshaft, camshaft, piston,
cylinder or bearing
• Compression leak from cylinder
• Improper valve timing
• Piston ring and cylinder worn
• Excessive valve clearance
• Battery discharged
• Starter malfunctioning
• Key switch malfunctioning
• Starter auto reduction unit defective
• Wiring disconnected
Replenish fuel
Vent air
Change fuel and
repair or replace fuel
system
Clean
Clean or change
Use specified fuel or
engine oil
Use specified fuel
Tighten retaining nut
Adjust
Replace
Replace
Replace
Repair or replace
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
Correct or replace
timing gear
Replace
Adjust
Charge
Repair or replace
Repair or replace
Replace
Connect
–
S-20
S-20, 21,
25
S-20
S-21, 25
–
–
S-44
S-86
S-54
S-88
S-49
–
–
S-53
S-42, 56,
57, 71, 72,
79
S-31
S-29
S-89, 93,
96
–
S-92, 100
S-100
Engine Revolution Is
Not Smooth
• Fuel filter clogged or dirty
• Air cleaner clogged
• Fuel leak due to loose injection pipe retaining
nut
• Injection pump malfunctioning
• Incorrect nozzle injection pressure
• Injection nozzle stuck or clogged
• Governor malfunctioning
• Bearing worn out
• Shaft bent
• Fin or other part damaged due to foreign
matters
Clean or change
Clean or change
Tighten retaining nut
Replace
Replace
Replace
Repair
Replace the
turbocharger
assembly
Replace the
turbocharger
assembly
Replace the
turbocharger
assembly
S-21, 25
S-21
S-44
S-49
S-88
S-88
S-50, 54
S-101
S-101
S-101
KiSC issued 10, 2009 A
