International DT402 Troubleshooting
| Engine Model: International Harvester DT402 |
| Engine Type: 4-stroke in-line 6-cylinder turbocharged liquid-cooled diesel |
| Total Displacement: 402 cu.in (6.58 L) |
| Rated Engine Power: 145 Hp (108.2 kW) at 2200 rpm |
| Fuel System Type: Direct injection |
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| Engine starts up hard or doesn't start |
Fuel filter element clogging - Service the filter.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles fault - If necessary, replace with a new nozzle.
Defective fuel injection pump - Replace injection pump or repair it.
Wrong valve timing - Use correct valve timing adjustment.
Fuel pipes clogging - Clean fuel pipes.
Injection timing is wrong - Set up as recommended.
Cylinder or piston rings are worn - Replace defective components.
| Engine starts but stalls immediately |
Clogged fuel filter - Change filter element.
Fuel injection pump damage - Repair or install new pump.
Air cleaner is dirty - Clean air cleaner element.
Unadjusted nozzle opening pressure - Adjust as recommended.
| Engine shuts off while running |
Fuel injection timing is not adjusted - Adjust as recommended.
Fuel filter element clogging - Replace the filter element.
Engine has not warmed up to the recommended temperature - Warm up engine as required.
Injection nozzles are jammed or clogged - Clean or change injection nozzles.
| Engine stops at low idle speed |
Low idle speed setting is incorrect - Need to adjust idle speed.
Incorrect valve clearance - Adjust valve clearance.
Damaged fuel injection pump - Change pump or rebuild it.
Faulty or dirty injection nozzles - Service or change injection nozzles.
Dirt in the fuel hoses or lines - Clean fuel lines and hoses.
Air filter is dirty - Clean or replace element.
Cylinder head gasket is defective - Cylinder-head gasket replacement required.
Unadjusted injection timing - Adjust injection timing as required.
Fuel injection pump failure - Rebuild or replace pump.
One of moving engine parts has broken - Repair or replace defective components.
Dirty radiator fins or defective radiator cap - Install new cap or clean radiator.
Engine has a lack of coolant - The cooling system needs to be refilled and checked for faults.
Fan belt is loose or defective - If necessary, replace the belt.
Lack of engine oil - Check and refill engine oil.
Cylinder head gasket is blown - Gasket should be replaced.
Injection timing is wrong - Adjust as recommended.
| Insufficient oil pressure |
Oil level is low - Fill the crankcase with oil.
Oil pump malfunction - Inspect and change as required.
Oil filter clogging - Change or clean engine oil filter element.
Worn or dirty relief valve - Change or service relief valve.
Crankshaft bearing clearance is excessive - Test and replace or repair worn components.
Excessive crankpin bearing clearance - Check and change or repair defective parts.
| Diesel engine consuming too much oil |
Oil leaking: Seals or gaskets are wearing excessively - To repair leaks, replace worn parts.
Crankcase oil too light - Use oil of correct viscosity.
Damaged or seized piston rings - Change the piston rings as required.
Worn valve guides and valve stems - Valves need to be changed.
Cylinder liners or pistons are worn - Inspect liners and pistons, change as necessary.
Engine is cold - Warm up engine as required.
Engine oil level is low - Check oil level and add oil as required.
Fuel injection pump timing is not adjusted - Set it up as required.
Broken or worn pistons - Replace the pistons.
Connecting rod is worn or misaligned - Need to change or align the connecting rod.
Low battery output - Battery is drained, recharge it.
Battery runs out quickly - Battery needs to be serviced or replaced.
Disconnected battery cables or bad terminals - Connect wires correctly or change terminals.
Battery is drained or defective - Battery needs to be recharged or replaced.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery capacity is low - Charge the battery.
Starter motor is damaged - Repair or change starter.
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