Diesel Engine Service and Repair Products Quick Reference Guide

PLEASE NOTE: This is not a diagnostic chart. It can be more accurately described as a products reference chart. It is designed to help diesel owners find fault related solutions by using our SEARCH BOX. If you would like a printed copy of this 10 page chart/guide just add it to your shopping cart with your order of any other item or items and we will send it at no additonal cost.  

Have you been looking for solutions to help troubleshoot and/or repair your diesel engine. Wish there were a quick way to find it? Here is a summary reference chart you may find helpful. The chart is divided into the following 6 sections. Each summarizes the most common problems you may face with your diesel.

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• Section 1-Diesel engine starting problems
• Section 2-Diesel engine performance problems
• Section 3-Diesel engine shut-off problems
• Section 4-Diesel engine leak problems
• Section 5-Diesel engine noise problems
• Section 6-Diesel engine temp problems

Under each section the problem is listed on the left and the reference word or words for the solution are listed on the right. Just click on the highlighted words in the solution to go to resources we offer to help you fix the problem. For a complete explanation of each with illustrations please see my new Advanced Diesel Engine Diagnostics manual

SECTION ONE: RESOURCES TO SOLVE DIESEL ENGINE STARTING PROBLEMS

Engine won't fire - burned out glow plugs........................ Solution: Glow plugs
Engine won't fire - failed glow plug relay......................... Solution: Glow relay
Engine won't fire - old style tired glow system................. Solution: Fast Glow Upgrade / Over ride
Engine won't fire - poor compression............................... Solution: Compression tester
Engine won't fire - internal engine problems.................... Solution: Diesel Performance Tuning
Engine won' run - bad fuel............................................... Solution: Change fuel / diesel purge
Engine won't run - air in fuel system................................ Solution: Fuel line replacement kit
Engine won't run - air in fuel system................................. Solution: Hand primer pump
Engine won't run - weak glow plugs................................. Solution: Glow plug reamer
Engine won't run - weak glow relay................................. Solution: Glow relay upgrade
Engine won't run - weak lift pump.................................... Solution: Engine driven lift pump
Engine won't run - worn out fuel injector nozzles............. Solution: Fuel Injectors
Engine won't run - worn out timing chain......................... Solution: Timing chain
Engine won't run - faulty injection pump.......................... Solution: Diesel Injection Pump
Engine won't run - too cold outside.................................. Solution: Factory block heater
Engine won't run - too cold outside.................................. Solution: Block heater
Engine won’t run - fuel tank screen plugged.................... Solution: Fuel Tank Screen
Engine won’t run - gummed injection system................... Solution: Diesel Purge

SECTION 2: SOLUTIONS FOR POOR PERFORMANCE

Engine runs bad - plugged fuel filters...............................Solution: Fuel filters
Engine runs bad - not getting hot enough........................Solution: Diesel thermostat
Engine runs bad - restricted air exhaust...........................Solution: Air filter / muffler / turbo
Engine runs bad - gummed injection system....................Solution: Diesel Purge
Engine runs bad - excess carbon buildup..........................Solution: EGR valve
Engine runs bad - low fuel flow to injections....................Solution: Diesel Performance Tuning
Engine runs bad - poor compression................................Solution: Valve adjusting wrench
Engine runs bad - poor compression................................Solution: Compression tester
Engine runs bad - poor or incorrect fuel..........................Solution: Change fuel/diesel purge
Engine runs bad - air getting into fuel system...................Solution: Fuel line replacement kit
Engine runs bad - air getting into fuel system...................Solution: Hand primer pump
Engine runs bad - bad fuel injectors.................................Solution: Fuel Injectors
Engine runs bad - internal engine timing.........................Solution: Timing chain
Engine runs bad - incorrect injection pump timing............Solution: Diesel Performance Tuning
Engine runs bad - worn injection pump............................Solution: Injection pump delivery valve
Engine smokes bad - poor engine ventilation...................Solution: Breather upgrade
Engine smokes bad - worn valve stem seals.....................Solution: Valve stem seals
Engine smokes bad - turbo seals gone.............................Solution: Turbo charger
Engine smokes bad - blown head gasket.......................... Solution: Head gasket

SECTION 3: SHUT OFF PROBLEMS

Engine won’t quit - locate vacuum problem....................Solution: Vacuum tester
Engine won’t quit - failed vacuum pump.......................Solution: Vacuum pump rebuild kit
Engine won’t quit - failed check valve..........................Solution: Vacuum pump check valve
Engine won’t quit - leaks in vacuum system...................Solution: Vacuum Troubleshooting
Engine won’t quit - leak in main delivery line.................Solution: Vacuum line / hose
Engine won’t quit - failed shut off valve........................Solution: Vacuum pump shut off valve
Engine won’t quit - vacuum not getting to shut off..........Solution: Vacuum switch (under dash)
Engine won’t quit - leak at brake booster......................Solution: Brake booster o-ring seal
Engine won’t quit - brake booster leaking inside.............Solution: Brake booster

SECTION 4: NOISE PROBLEMS

Engine makes noise - belts loose or worn.....................Solution: V Belts
Engine makes noise - serp belt shock loose..................Solution: Belt shock
Engine makes noise - worn or loose fan clutch...............Solution: Fan Clutch
Engine makes noise - damaged motor mounts...............Solution: Motor mounts
Engine makes noise - loose air cleaner housing..............Solution: Air Cleaner anti rattle kit
Engine makes noise - exhaust leaks.............................Solution: Exhaust
Engine makes noise - injector nailing............................Solution: Diesel Purge
Engine makes noise - injector nailing continues..............Solution: Diesel injectors
Engine makes noise - pump out of time........................Solution: Diesel Performance Tuning
Engine makes noise - valve clearances loose.................Solution: Valve adjusting wrench
Engine makes noise - timing chain/tensioner loose..........Solution: Timing chain
Engine makes noise - cracked or loose flex plate............Solution: Flex plate
Engine makes noise - worn cam and bearings................Solution: Camshaft
Engine makes noise - loose manifolds..........................Solution: Manifold gasket

SECTION 5: FLUID LEAK PROBLEMS

Engine leaks oil: from air cleaner..............................Solution: air cleaner anti rattle kit
Engine leaks oil: from oil filler cap............................Solution: Filler cap gasket
Engine leaks oil: from valve cover.............................Solution: Valve cover gasket
Engine leaks oil: from breather tube...........................Solution: Breather tube
Engine leaks oil: from turbo drain nipple.....................Solution: Anti rattle kit
Engine leaks oil: from oil pressure line.......................Solution: Oil pressure line
Engine leaks oil: from oil pressure gauge....................Solution: Oil pressure gauge
Engine leaks oil: from vacuum pump housing................Solution: Diesel gasket kit
Engine leaks oil: Injection pump to block gasket...........Solution: Diesel gasket kit
Engine leaks oil: from front crank area......................Solution: Front crank seal kit
Engine leaks oil: from rear crank seal 616 617............Solution: Remove engine to replace!
Engine leaks oil: from rear crank seal 60x engines.......Solution: Rear cranks seal kit
Engine leaks oil: from timing chain tensioner..............Solution: Diesel gasket kit
Engine leaks oil: from oil pan...................................Solution: Oil pan gasket
Engine leaks oil: from oil filter housing at block............Solution: Oil filter housing gasket
Engine leaks oil: turbo charger oil feed line..................Solution: Diesel gasket set
Engine leaks oil: from oil cooler lines.........................Solution: Oil cooler line / special tool
Engine leaks oil: from oil cooler................................Solution: Oil cooler
Engine leaks fuel: from fuel cap................................Solution: Fuel cap seal
Engine leaks fuel: from fuel tank..............................Solution: Fuel tank
Engine leaks fuel: from fuel tank hoses......................Solution: Fuel line replacement kit
Engine leaks fuel: from fuel tank outlet screen.............Solution: Fuel tank screen
Engine leaks fuel: from engine hoses.........................Solution: Fuel hose
Engine leaks fuel: from leaking hand pump.................Solution: Primer pump
Engine leaks fuel: from main fuel filter......................Solution: Fuel filter kit
Engine leaks fuel: from fuel injectors.........................Solution: Fuel Injectors
Engine leaks fuel: from injector return hoses................Solution: Fuel injector hard lines
Engine leaks coolant: from water pump......................Solution: Water pump
Engine leaks coolant: from water pump housing...........Solution: Diesel gasket kit
Engine leaks coolant: from coolant short hose..............Solution: Diesel short hose kit
Engine leaks coolant: from coolant hoses....................Solution: Coolant hose
Engine leaks coolant: from radiator cap......................Solution: Radiator cap
Engine leaks coolant: from radiator neck crack.............Solution: Radiator / or neck kit
Engine leaks coolant: from radiator overflow tank.........Solution: Radiator overflow tank
Engine leaks coolant: from heater core.......................Solution: Heater core
Engine leaks coolant: from freeze plugs......................Solution: Freeze plug
Engine leaks coolant: from head gasket.....................Solution: Head gasket
Engine leaks fluid: from transmission pan...................Solution: Transmission service kit
Engine leaks fluid: from transmission cooler lines.........Solution: Transmission cooler lines
Engine leaks fluid: from transmission seals.................Solution: Transmission seal replacement
Engine leaks fluid: from rear axle boots.....................Solution: Rear axle boot kit
Engine leaks fluid: from brake calipers......................Solution: Brake calipers
Engine leaks fluid: from brake hoses.........................Solution: Brake hoses
Engine leaks fluid: from brake master cylinder............Solution: Brake master cylinder
Engine leaks fluid: from power steering hoses.............Solution: Power steering hoses
Engine leaks fluid: from power steering pump.............Solution: Power steering pump
Engine leaks fluid: from steering box seals.................Solution: Steering box