TM 5-3895-382-24 Testing and Adjusting Section Troubleshooting Troubleshooting SMCS Code: 1000 NOTE: For a complete description of Type 1 and Type 2 engines,  refer  to  the  Systems  Operation,  Testing and Adjusting Module, "Engine Design" for more information. Troubleshooting can be difficult.  The most common problems are identified in this troubleshooting manual.  The symptoms, causes, and guidance for solving the problems are given. Sometimes additional repair work is required beyond the repair which is recommended.  Frequently, a problem does not exist in isolation.  The problem can be a result of wear or damage to several parts which operate together as part of a system. All   possible   problems   and   the   probable   causes   cannot   be listed.      The   serviceman   must   follow   a   logical   process   of eliminating possible causes and identifying the specific causes of the problems. Troubleshooting  The  Fuel  Injector  Nozzles  On  The Engine NOTE: Be careful when you are handling the fuel injector nozzles in order to prevent damage to the orifices, threads, and other surfaces.  When a fuel injector nozzle is installed, make sure that all surfaces and threads are clean. The procedures which require disassembly or the adjustment of the fuel injector nozzle only relate to the following engines: Type 1 Engines and 9RM Engines Do not disassemble the fuel injector nozzles and do not adjust the fuel injector nozzles on the following engines: Type 2 Engines and 7BJ Engines Replace  the  fuel  injector  nozzle  on  Type  2  engines  and  7BJ engines  if  the  fuel  injector  nozzle  does  not  operate  correctly. These fuel injector nozzles are not serviceable parts. Refer to Specifications, "Fuel Injection Nozzles" for additional information. Problem 1 The  engine  is  difficult  to  start.    If  the  engine  starts,  the engine runs rough. Probable Cause 1. The  fuel  injector  nozzle  does  not  seal  correctly  in  the cylinder head. Make sure that the seals and the mating surface of the cylinder head are clean.  The seal that is formed by the anti-seize compound on the threads of the fuel injector nozzle may be broken.  Make sure that the fuel injector nozzle is tightened to the correct torque in the threaded hole of the cylinder head. 2. Extra seat washers were not removed from the threaded recess in the cylinder head for the fuel injector nozzle. Debris exists on the mating surface of the cylinder head with the seat washer. Remove any extra seat washer or debris. 3. The connections of the high pressure fuel line leak. Tighten the fittings of the high pressure fuel line. 4. The fuel injector nozzle does not operate correctly. NOTE: This  step  does  not  include  Type  2  engines  and 7BJ  engines.    The  fuel  injector  nozzles  for  these engine     serial     numbers     are     not     serviceable. Adjustment  of  these  fuel  injector  nozzles  should not  be  made.    If  any  problems  with  the  internal components  of  these  fuel  injector  nozzles  exist, the fuel injector nozzle should be replaced. Make  sure  that  the  mounting  bolts  for  the  clamp  and  the components  of  the  fuel  injector  nozzle  are  tightened  to  the correct torques.  Make sure that the seal and the spacer are positioned correctly.  Test the fuel injector nozzle on a nozzle tester. 5. The incorrect fuel injector nozzle is installed. Make sure that all fuel injector nozzles have the correct identification code for the engine. Refer to Specifications, "Fuel Injection Nozzles". 6-26