Troubleshooting - Ezgo 1600xd Repair Manual

4. TROUBLESHOOTING

Symptom
Engine does not • No fuel
start
• Air in fuel system
• Water in fuel system
• Clogged fuel pipe
• Clogged fuel fi lter
• Excessively high viscosity of fuel or engine
oil at low temperature
• Fuel with low cetane number
• Fuel leak due to loose injection pipe mount-
ing nut
• Incorrect injection timing
• Clogged injection nozzle
• Defective fuel injection pump
• Defective fuel transfer pump
• Defective piston, cylinder bore or bearing
• Compression leak from cylinder
• Improper valve seating, damaged valve
spring, valve seized
• Improper valve timing
• Worn piston ring and bore
• Excessive valve clearance
Start motor does • Discharged battery
not run
• Defective start motor
• Defective key switch
• Disconnected wiring
Engine running is • Clogged or dirty fuel fi lter
not smooth
• Clogged air cleaner
• Fuel leak due to loose injection pipe mount-
ing nut
• Defective fuel injection pump
• Incorrect nozzle opening pressure
• Seized or clogged nozzle
• Clogged fuel overfl ow pipe
• Defective governor
Either white or blue • Excessive engine oil
exhaust smoke is
• Worn piston ring and bore or seized piston
produced
ring
• Incorrect injection timing
• Insuffi cient compression pressure
3
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ENGINE - TROUBLESHOOTING
Cause Solution
• Add fuel
• Bleed air
• Change fuel and repair or fl ush fuel system
• Clean
• Clean or replace
• Use the specifi ed fuel or engine oil
• Use the specifi ed fuel
• Tighten nut
• Adjust
• Clean or replace
• Repair or replace
• Repair or replace
• Repair or replace
• Replace head gasket, tighten cylinder head
bolts, glow plug and nozzle holder
• Repair or replace
• Correct or replace timing gear
• Repair or replace
• Adjust
• Charge
• Repair or replace
• Repair or replace
• Connect
• Clean or replace
• Clean or replace
• Tighten nut
• Repair or replace
• Adjust or replace
• Repair or replace
• Clean or replace
• Repair or replace
• Reduce to the specifi ed level
• Repair or replace
• Adjust
• Adjust valve clearance
SUUV-W00 Apr. 2011