Table 3-2. Troubleshooting - Continued

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TABLE 3-2 Troubleshooting

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TM-9-2815-254-24 Diesel Engine Model DN4M 4 Cylinder 1.2 Liter Manual

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Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 8. Check for low engine compression. a. Perform engine compression check. Refer to paragraph 3-27.7. b. If engine defective, repair or replace engine. ENGINE DOES NOT DEVELOP FULL POWER. Step 1. Check for blocked air intake system. Remove blockage as found. lf no blockage is found, do step 2. Step 2. Check for air in fuel system lines. Step 3. Engine overheated. Refer to Engine Overheating, Malfunction 7. lf not a problem, refer to Malfunction 5. ENGINE OVERHEATING. Step 1. Step 2. Step 3. Step 4. Inspect coolant level. a. Check engine for coolant leaks. lf engine has no leaks, do step 2. b. Repair coolant leaks. Check for defective thermostat. a. If thermostat is suspected of being defective, replace thermostat. Refer to paragraph 3-6. b. If engine continues to overheat, do step 3. Check for defective water pump. a. Remove and check water pump for damage. If not defective, do step 4. b. Replace defective water pump. Refer to paragraph 3-7. Check improper fuel pump injection timing. Adjust fuel injection pump timing. Refer to paragraph 3-13.2. 8. EXCESSIVE OIL CONSUMPTION. Step 1. Check for oil leakage. a. Inspect engine for oil leaks. lf no leaks, do step 2. b. Repair or replace defective components. Step 2. Check for blocked air intake system. Remove blockage as found. lf no blockage, do step 3. Step 3. Check for defective intake or exhaust valve seals or valve guides. a. Repair or replace defective components. Refer to paragraph 3-27.4. b. Disassemble and inspect valve seals and guides. Refer to paragraph 3-27.2. If not defective, replace engine. 3-6

ARMY TM 9-2815-254-24 AIR FORCE TO 38G1-94-2 Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4. ENGINE HARD TO START OR WILL NOT START IN COLD WEATHER. step 1. Check for faulty glow plugs. a. Test glow plugs. Refer to paragraph 3-22.3. If glow plugs not defective, do step 2. b. Replace defective glow plugs. Refer to paragraph 3-22. Step 2. Refer to Malfunction 3 and perform steps 1 through 5. 5. ENGINE MISFIRES OR RUNS IRREGULARLY OR STALLS FREQUENTLY. Step 1. Step 2. Step 3. Step 4. step 5. Step 6. step 7. Check for fuel being supplied to fuel injection pump. a. Test feed pump capacity. Refer to paragraph 3-11.5 step aj. If feed pump not defective, do step 2. b. Repair or replace fuel feed pump. Refer to paragraph 3-11. Check for air in fuel system lines. Bleed fuel system at fuel fitter. Refer to paragraph 3-12. If no air, do step 3. Check for tow coolant temperature. a. If coolant temperature not low, do step 4. b. Replace defective thermostat. Refer to paragraph 3-6. Check for fuel injector nozzle dirty, defective or leaking. a. Clean and test fuel injector. Refer to paragraph 3-10. If not defective, do step 5. b. Replace fuel injector nozzle. Refer to paragraph 3-10. Check for improper fuel injection timing. a. Check fuel injection timing. Refer to paragraph 3-13.1. If fuel injection timing is correct, do step 6. b. Adjust fuel injection timing. Refer to paragraph 3-13.2. Check for defective fuel injection pump. a. Remove and test fuel injection pump. Refer to paragraph 3-11.5. If not defective, do step 7. b. Replace fuel injection pump. Refer to paragraph 3-11. Check for valves improperly adjusted. a. Adjust valves. Refer to paragraph 3-26.6. if properly adjusted, do step 8. 3-5