COMMON RAIL SYSTEM
07-CR-E5,07-CR-TE5,07-CR-TIE5, DM
1-S5
[3] LIST OF MALFUNCTION SYMPTOM
Malfunctions and corresponding symptoms resulting from the CRS may also be generated from other sources,
such as the engine (mechanical parts), the fuel system, etc. When performing CRS troubleshooting, the aim is not to
quickly determine that the CRS is the cause of a malfunction. Rather, the cause should be exhaustively considered
while verifying the causes listed below.
9Y3200007CRS0007US0
Malfunction
symptom
Area of Fault Cause Action
Engine overheat
Fuel system Poor fuel Switch to the correct fuel (No.2-D diesel fuel).
Lubrication system
Engine oil deterioration. Change engine oil.
Inappropriate engine oil.
Replace with the appropriate engine oil (API
Service Classification CJ-4 grade or higher).
Faulty oil pump. Replace oil pump.
Insufficient engine oil level Add engine oil.
Insufficient
output
Intake system Clogged air cleaner element. Clean or replace air cleaner element.
Fuel system
Air mixed with the fuel system. Perform fuel system air bleeding.
Faulty fuel filter. Replace fuel filter.
Poor or inappropriate fuel. Switch to the correct fuel (No.2-D diesel fuel).
Engine
Worn cylinder liner and the piston ring
of the piston. (Low compression
pressure)
Overhaul engine.
Other Overheat Refer to "Engine Overheat" items.
Faulty starting
Intake system Clogged air cleaner element. Clean or replace air cleaner element.
Fuel system
Insufficient fuel. Add fuel and perform fuel system air bleeding.
Fuel system clogged. Clean the fuel system.
Large amount of intermixing water to
the water separator, element clogging
and deformation.
Clean or replace.
Air being introduced through fuel
system connection points.
Tighten connections.
Clogged fuel filter Replace fuel filter.
Fuel feed pump operation fault. Replace fuel feed pump.
Injection pipe connection loose. Tighten connecting nut.
Electrical system
Battery fault Inspect battery.
Faulty starter wiring. Replace starter wiring.
Loose battery cable.
Tighten battery terminal connections, or replace
cables.
Faulty starter operation. Replace starter assembly.
Starting assist device (glow plug) fault. Replace starting assist device (glow plug).
Lubrication system Excessive engine oil viscosity. Replace with oil of appropriate viscosity.
Engine
Burnt pistons. Replace piston, piston ring and crankcase.
Burnt main bearing. Replace main bearing and crankshaft.
Low compression pressure. Overhaul engine.
Other Ring gear damage. Flywheel / starter replacement.
Idle fault Engine
Poor valve clearance Adjust valve clearance.
Poor valve seat contact. Break in valve and valve seat, or replace.
Low coolant temperature. Perform warm-up operation.
Large difference in cylinder to cylinder
compression pressure.
Overhaul engine.
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