B

Tool mark

Tool mark

• Fuel leakage into engine oil, increase engine oil level
• Error code (fuel leakage code)

Fault

• Unauthorised disassembly

Possible cause

• Attempted of Unauthorised rework

Warranty decision

•  No warranty claim
  - Liability of current / privious repaier

C

Crack (C)

Symptom

• Rough running
• Noisy

Fault

• Crack of nozzle

Possible cause

• Damage due to poor handling

Warranty decision

• No warranty claim

D

Sealing surface is damaged

Symptom

• External fuel leakage from HP pipe connection

Fault

• Damaged to HP pipe seal face
• Large particle contamination on sealing face

Possible cause

• Damaged caused by handling on previous repair

Warranty decision

• No warranty claim

A

Heavy Contact (A)

Symptom

• No injection
• Misfire
• Rough idle
• Lack of power

Fault

• Restricted injector fuction due to nozzle distortion

Possibile causa

• Injector bending
  - HP Injector bending
  - Unbalanced clamping force

B

Collision (B)

C

Carbon deposit on nozzle retaining nut

Symptom

• Lack of power
• Hard knocking noise
• No injection
• Combustion soot in the engine oil
• Combustion soot in the Fuel system

Fault

• Damaged Injector gasket and carbon deposit on nozzle retaining nut due to injector bouncing on seat
• Combustion gas passing through the copper gasket

Possible cause

• Loose injector clamp
• Copper gasket not replaced after previous removal of injector
• Contamination on the seal surface

Combustion gas

Symptom

• Lack of power
• Knocking noise
• Combustion soot in the engine oil
• Combustion soot in the Fuel system

Fault

• Carbon passing though cooper gasket

Possible cause

• Cooper gasket not replace of previous removal of inijector
• Obstruction on the cooper gasket surface

Warranty decision

• No warranty claim

Carbon passing gasket

C

 Deformation of nozzle hole

Symptom

• Rough idle
• Lack of power

Fault

• Nozzle injector holes are formed / concave

Possible cause

• Use of wires wire brush or wire strand to clean injector

Warranty decision

• No warranty claim
  - Liability of current / privious repaier

C

Carbon coking

Symptom

• Lack power
• No injector

Fault

• Hard carbon build up on injector nozzle

Possible cause

• Engine oil burning
• High temperature combustion
• Poor quality fuel

Warranty decision

• No warranty claim
  - Liability of owner for use off poor quality fuel or storage
  - Liability of other components causing oil burning
  - Liability of other components causing high temperature compustion

Symptom

• Lack power
• No injector

Fault

• Rusty deposit on injector noozle

Possible cause

• High water content in the fuel or water entering cylinders

Warranty decision

• No warranty claim
  - Liability of owner for use off poor quality fuel or storage

C

Carbon coking (Oil burning)

Symptom

• Lack of power
• No injector

Fault

• Carbon build up on injector nozzle

Possible cause

• Engine oil burning
• Poor quality fuel
• Wrong injection timing

Warandy decision

• No warranty claim
  - Liability of owner for use of poor quality fuel
  - Liability of owner components causing oil burning
  - Liability of owner components causing injector timing issue

Nozzle corrosion

          Corrosion

Symptom

• Rough running

Fault

• Corrosion of nozzle stem

Possible cause

• Corrosion by sulfate acid

Warandy decision

• No warranty claim
  - Liability of owner for use of poor quality fuel

C

Temper colored

Tempered discolouration

No carbon buildup

Symptom

• Rough idle
• Lack of power

Fault

• High temperature combustion

Possible cause

• Turbo malfunction

Warranty decision

• No warranty claim
  - Liability of other components causing high temperature combustion 

Nozzle melt

Carbon buildup expended

In extreme cases could result in melted injector nozzles

Symptom

• Lack of power
• Hard knocking noise
• No injector

Fault

• Abnormal high temperature combustion and carbon deposit

Possible cause

• Engine oil burning
• Poor quality fuel
• Wrong injection timing

Warranty decision

• No warranty claim

Carbon coking

Symptom

• Rough idle
• Lack of power

Fault

• Nozzle injector holes are clogged

Possible cause

• Thermal overload
• Bio diesel above specification requirements
• Metal intrusion (copper, zinc in contact with fuel)

Warranty decision

• No warranty claim
  - Liability of owner for use of unauthorised fuel or storage materials

Melt aluminum adhesion

Symptom

• Lack of power
• Knocking noise
• No injector

Fault

• Melted aluminium deposit due to high temperature combustion causing other engine components to melt

Possible cause

• Turbo malfunction
• Icorrect combustion timing

Warranty decision

• No warranty claim
  - Liability of orther components high temperature combustion

D

Debris inlet clogging

Metal debris

Sand

Symptom

• Lack of power
• Rough idling
• No injector

Fault

• Debris seen in the inlet filter
  - Very high risk that smaller debris parts have entering injector causing damages or malfunction of injector

Note: Inlet filter is protection for large particles only. Not serviceable

Possible cause

• Contamination entered system during replacement of parts in the HP system
• Damaged or wrong fuel filter fitted
• Contamination entered system during fuel filter replacement

Warranty decision

• No warranty claim