09100-10217 Suzuki Bolt

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Misreading Oil Level
A. Accurately measure the consumption of oil and fuel over a period of 50 engine hours.
Oil level
Result: The oil consumption is less than 0.08% of the fuel consumption.
Oil consumption is within specification. Return the unit to service
Result: The oil consumption is greater than 0.08% of the fuel consumption.
Proceed to Test Step 2.
2. Oil Level
A. Check for a high oil level in the engine.
Oil level
Result: The oil level in the engine is high.
Repair: Make sure that the oil is not contaminated with fuel. Refer to Troubleshooting, "Oil Contains Fuel".
Make sure that the oil is not contaminated with coolant. Refer to Troubleshooting, "Oil Contains Coolant".
Remove the excess oil.
Proceed to Test Step 8.
Result: The oil level is OK.
Proceed to Test Step 3.
3. Oil Leaks
A. Check for evidence of oil leaks on the engine.
B. Check for evidence of oil in the coolant.
Oil leaks
Result: An oil leak is identified.
Repair: Rectify the cause of the oil leak.
Result: Oil is present in the coolant.
Repair: Refer to Troubleshooting, "Coolant Contains Oil".
No oil leaks are identified
Proceed to Test Step 4.
4. Engine Crankcase Breather
A. Check the engine crankcase breather for blockage or restrictions.
B. Check for excessive oil from the outlet of the breather.
C. Check that the application has not been operated above the recommended gradient.
D. Check if the Oil Mist Separator drain hose is fitted using correct orientation (white mark facing OMS drain spigot).
E. Check to see whether an OMS filter is fitted.
Breather
Result: The engine crankcase breather is blocked or restricted.
Repair: Clear the blockage or restriction.
Result: Excessive oil is ejected from the outlet of the breather.
Repair: Investigate the cause of the excessive oil content in the breather flow. Check that the engine has been serviced in line with the recommended maintenance intervals. Refer to Operation and Maintenance Manual, if above 1500 hours, change the crankcase breather filter. Refer to Operation and Maintenance Manual, Crankcase Breather (Canister) - Replace.
Note: Some oil presence from the breather is normal.
Proceed to Test Step 8
Result: Little or no oil is ejected through the breather.
Repair: Clean oil from hoses and re-test.
Proceed to Test Step 5.
5. Air Intake and Exhaust System
A. Check the air filter restriction indicator, if equipped.
B. Check the air intake and the exhaust system for the following defects:
Signs of dirt ingress
Blockages
Restrictions
Damage to the air intake and exhaust lines and hose
C. Check for ECM codes for inlet air restriction:
107-15: Engine Air Filter 1 Differential Pressure high - least severe (1)
107-16: Engine Air Filter 1 Differential Pressure high - moderate severity (2)
D. Check the engine has not exceeded the service interval for the air cleaner element. Refer to Operation and Maintenance Manual.
Air intake and exhaust system
Result: The air filter restriction indicator has operated or the air filter is blocked.
Repair: Make sure that the air filter is clean and serviceable. If necessary, replace the air filter.
Result: The air intake or the exhaust system is blocked, restricted, or damaged.
Repair: Repair the air intake or the exhaust system, as required.
Result: A 107-15 or 107-16 code is active
Repair: Refer to Troubleshooting, Inlet Air is Restricted.
Result: The service interval for the air cleaner element has been exceeded.
Repair: Replace the air cleaner element. Refer to Operation and Maintenance Manual, Engine Air Cleaner Element - Replace.
Result: The air intake or the exhaust system is OK.
Proceed to Test Step 6.
6. Turbocharger
Note: The turbocharger that is installed on this engine is a non-serviceable item. If any mechanical fault exists, then the turbocharger must be replaced.
A. Check that the oil drain for the turbocharger is not blocked or restricted.
Note: Wetted walls are considered to be a normal level of oil. Pooled oil is considered excessive.
Turbocharger
Result: The oil drain for the turbocharger is blocked or restricted.
Repair: Remove the blockage or restriction. If necessary, replace the oil drain line.
Check that the repairs have eliminated the faults.
Proceed to Test Step 8.
Result: The turbocharger is OK.
Proceed to Test Step 7.
7. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing and Adjusting, "Compression - Test".
Cylinder compression
Result: The results of the compression test are outside the specifications.
Repair: Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the following list:
Loose glow plugs
Worn piston
Worn piston rings
Worn cylinder bores
Worn valves
Worn seals
Faulty cylinder head gasket
Damaged cylinder head
Result: The results of the compression test are OK.
Contact the Dealer Solutions Network (DSN).
8. Clean the Fuel System
A. Following the instructions on the bottle, add Cat Fuel System Cleaner (343-6210) to the fuel tank.
Electronic Unit Injectors
Return the unit to service, the fuel system will be cleaned during operation.