Engine does not start

Cranking speed too low

Repair starting system or charge or replace battery so that engine cranks at a minimum of 150 rpm.

No voltage at glo plug bus

If test light shows no voltage at bus with key at "ON" position, test relay and wiring.

Glow plug faulty

Test and, if necessary, replace glow plug.

Air in fuel system

Bleed fuel system.

Injection pump not delivering fuel

If no fuel emerges from a loosenes injection pipe during cranking, check timing belt and fuel supply from filter.

Injection pipes misconnected

Connect pipes in correct location

Injection timing incorrect

Adjust injection timing.

Faulty injection

Check and, if necessary, replace injectors.

Engine mechanical faults, as described earlier under this heading

Test compression and, if necessary, repair engine.

Faulty injection pump

Try to start engine with new pump installed. If necessary, replace pump permanently. Check and, if necessary, adjust the idle speed.

Idle speed incorrect of idle rough or irregular

Loose fuel hose between filter and injection pump

Tighten, if necessary, and repair.

Air in fuel system

Bleed fuel system.

Inadequate fuel supply owing to clogged fuel filter, or fuel return line and injection pipes leaking, dirty, kinked, or squeezed at connections

Inspect and, if necessary, replace lines and hoses or replace fuel filter

Faulty injection

Check and, if necessary, repair or replace injection injectors.

Injection timing incorrect

Adjust injection timing.

Engine mechanical faults, as described earlier under this heading

Test compression and, if necessary, repair engine.

Faulty injection pump

Try engine at idle with new pump installed. If necessary, replace pump permanently.

Engine lugging in too high a gear

Observe correct shift speeds.

Smoky exhaust (black, blue or white)

Engine not reaching correct operating temperature

Check and, if necessary, replace cooling system thermostat.

Maximum rpm incorrect

Check and, if necessary, replace injection pump.

Faulty injection nozzles

Check and, if necessary, repair or replace injection nozzles.

Injection timing incorrect

Adjust injection timing.

Restricted exhaust system

Check exhaust system for dents and obstructions

Engine mechanical faults, as described earlier under this heading

Test compression and, if necessary, repair engine.

Faulty injection pump

Observe exhaust with new pump installed if necessary, replace pump permanently.

Poor power output, slow acceleration (speedometer accurate, clutch not slipping)

Maximum rpm incorrect

Check and, if necessary, replace injection pump.

Air cleaner filter dirty

Clean or replace air cleaner filter.

Inadequate fuel supply owing to clogged fuel filter, or fuel return line and injection pipes leaking, dirty, kinked, or squeezed at connections

Inspect and, if necessary, replace lines and hoses, replaced fuel filter.

Air in fuel system

Bleed fuel system.

Faulty injection nozzles

Check and, if necessary, repair or replace injection nozzles.

Injection timing incorrect

Adjust injection timing.

Engine mechanical faults, as described earlier under this heading

Test compression and, if necessary, repair engine.

Faulty injection pump

Check acceleration and speed with new pump installed. If necessary, replace pump permanently.

Excessive fuel consumption

Air cleaner filter dirty

Clean or replace air cleaner filter

Fuel leaks

Check and, if necessary, replace or tighten all pipes, hoses and connections.

Return pipe and hose blocked

Check return line for kinks and dents. Replace faulty lines. If line is clogged, blow it out with compressed air, then bleed fuel system.

Faulty injection nozzles

Check and, if necessary, repair or replace injection nozzles.

Engine mechanical faults, as described earlier under this heading

Test compression and, if necessary, repair engine.

Faulty injection pump

Check fuel consumption with new pump installed, if unnecessary, replace pump permanently.

Symptom

Probable cause

Remedy

Engine does not stop

Faulty starting switch operation

Correct or replace part

Broken harness between starting switch and fuel cut solenoid

Replace harness

Trouble condition

Probable cause

Remedy

Engine will not crank

Battery charge low

Charge or replace battery

Battery cables loose, corroded or worn

Repair or replace cables

Transaxle range switch faulty

(Vehicle with automatic transaxle only)

Adjust or replace switch

Fusible link blown

Replace fusible link

Starter motor faulty

Repair starter motor

Injector faulty

Replace Injectors

Engine cranks slowly

Battery charge low

Charge or replace battery

Battery cables loose, corroded or worn

Repair or replace cables

Starter motor faulty

Repair starter motor

Starter keeps running

Starter motor faulty

Repair starter motor

Starter switch faulty

Replace ignition switch

Starter spins but engine will not crank

Starter spins but engine will not crank

Ring gear teeth broken

Pinion gear teeth broken or starter motor faulty

Repair starter motor

Ring gear teeth broken

Replace flywheel ring gear or torque converter

Symptom

Probable cause

Remedy

Engine malfunctions due to insufficient fuel supply

Bent or kinked fuel pipe or hose

Repair or replace

Clogged fuel pipe or hose

Clean or replace

Clogged fuel filter of in-tank fuel filter

Replace

Water in fuel filter

Replace the fuel filter or clean the fuel tank and fuel lines

Dirty or rusted fuel tank interior

Clean or replace

Malfunctioning fuel pump

Malfunctioning fuel pump

Replace

When the fuel filter warning lamp illuminates

Water has accumulated in the fuel filter

Remove the water accumulated in the fuel filter as below

Comment

Probable cause

One of the following causes may be suspected.