C2.4 Tier 4 Final Engines for Caterpillar Built Machines Caterpillar

Cylinder Is Noisy

Usage:

Probable Causes

Active codes and logged codes
Low quality fuel
Injectors
Lack of lubrication
Valve train components
Gear train and components of the lower end
Piston and connecting rods

Recommended Actions

Note: The procedures have been listed in order of probability. Complete the procedures in order.

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Table 1
Troubleshooting Test Steps	Values	Results
1. Active Codes and Logged Codes A. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM). B. Download the "Product Status Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.	Codes	Result: A diagnostic trouble code is not active or logged. Proceed to Test Step 2. Result: A diagnostic trouble code is active or logged. Troubleshoot the active or logged codes.
2. Check the Engine Oil Level and Obtain an Oil Sample A. Check oil level. B. If the oil level is high, then take an oil sample to check for fuel dilution. Refer to Troubleshooting, Oil Contains Fuel.	Oil	Result: The engine oil sample shows action required. Make necessary repairs. Result: The engine oil sample and engine oil level are OK. Proceed to Test Step 3. Result: The engine oil is not at the correct level. Determine root cause of why the oil level was high or low.
3. Low Quality Fuel A. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. If necessary, obtain a fuel analysis in order to confirm that the correct fuel is being used for the engine. Refer to Systems Operation/Testing and Adjusting, "Fuel System Quality Test" for the proper procedure.	Fuel	Result: The fuel quality is OK. Proceed to Test Step 4. Result: The fuel quality is not OK. Replace the fuel. Verify that the repair eliminated the problem.
4. Fuel Injectors A. If service has been performed on the engine fuel system recently, verify that the injector trim codes in the Engine ECM match the injector for each cylinder. If injectors were moved between cylinders or if an injector was replaced and the injector trim codes were not updated in the Engine ECM, this can cause an engine miss. B. Access the "Cylinder Cutout Test" in the "Diagnostic Tests" under the "Diagnostics" menu. Cut out each cylinder one at a time to listen for improvements in the engine. If engine sound improves while cutting out a specific cylinder or cylinders, then check that the injector(s) are working properly by using 440-6907 Injector Kit. Note: The injector deliver quantity is not a reliable indicator of a failed injector. It is not recommended to use that test in determining if an injectors is failed.	Fuel Injector	Result: If injector(s) trim codes for each cylinder do not match what is in the Engine ECM, then refer to Special Instruction, REHS9707 for the procedure to install the new injector QR codes within the Engine ECM and on-line. Confirm that this resolves the issue. Result: If injector(s) are found to be defective, then replace the injector(s). Refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Install. Refer to Special Instruction, REHS9707 for the procedure to install the new injector QR codes within the Engine ECM and online. Confirm that this resolves the issue. Note: If two or more injectors are not working properly, this is likely a result of water in the fuel, bad fuel, or contaminated fuel. Contaminated fuel can occur by pre-filling the fuel filter or contamination during a previous repair of the fuel system. The root cause needs tobedetermine to prevent a repeat occurrence. Result: There are no previous known services on fuel system and there was no noticeable improvement during the cylinder cut out test. The customer could have ordered injectors through parts and did not change the injector trim codes in the Engine ECM. Visually confirm that the injector trim code for each cylinder matches what is in the Engine ECM. Refer to Special Instruction, REHS9707 for the procedure to install the new injector QR codes within the Engine ECM and online.
5. Low Compression A. Perform a compression test. Refer to Systems Operation, Testing and Adjusting, Compression Test. B. Possible causes of low compression: • Faulty piston • Faulty piston rings • Worn cylinder bores • Worn valves • Faulty cylinder head • Damaged cylinder head	Compression	Result: Low compression is present. Make the necessary repairs, Verify that the repair eliminated the problem. Result: Low compression is not present. Proceed to Test Step 6.
6. Valve Train Components A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive". B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage: 1.Camshaft 2. Valve springs 3. Camshaft followers 4. Rocker shaft 5. Bridges 6. Pushrods 7. Injectors Refer to the Disassembly and Assembly for additional information. C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves. Refer to the Disassembly and Assembly for additional information.	Valve train	Result: The valve train components are not damaged. Proceed to Test Step 7. Result: The valve train components are damaged. Make the necessary repairs, Verify that the repair eliminated the problem.
7. Pistons and Connecting Rods A. Inspect the pistons and connecting rods for damage or wear.	Pistons and connecting rods	Result: The pistons or the connecting rods are worn or damaged. Replace any damaged parts. Verify that the repair has eliminated the noise.

If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).