9.1.

INTRODUCTION
9 TROUBLES
ENGINE

This chapter deals with the various engine troubles and their causes. The remedies of these
not given because they are self-understood according to the causes. Some of the major
troubles are
scooters, cars and tractors are also elaborated with their causes.
troubles of
S.No. Troubles Possible causes
1. Engine does not turn over when starting 1. Discharged battery.
is attempted. 2. Open starting circuit.
3. Jammed bendix drive.
4. Jammed cranking drive.
5. Jammed engine.
6. Also causes listed under item 3.
2. Engine turns over slowly but does not 1. Discharged battery.
start. 2. Defective cranking motor.
3. Bad connection in starting circuit.
4. Undersized battery cables.
5. Also, causes listed under item 3.
3. Engine turns over at normal speed but 1. Defective ignition system.
does not start. 2. Defective or over-chocking fuel system.
3. Air leakage in intake manifold or carburettor.
4. Defective engine.
4.Engine runs but misses one cylinder. 1. Defective spark plug.
2. Defective distributor lead or cap.
3. Stuck valve.
4. Defective piston or rings.
5. Defective head gasket.
5 Engine runs but misses different cylinders. 1. Defective ignition.
2. Defective fuel system.
3. Loss of compression.
4. Defective valve action.
5. Defective rings.
6. Overheated engine.
7. Sticking manifold heat control valve.
8. Clogged exhaust.
6 Engine lacks power, acceleration or high 1. Defective ignition.
speed performance at hot or cold. 2. Defective fuel system.
3. Clogged exhaust.
4. Throttle valve not opening fully.
5. Loss of
compression.
O GROUP 2: POWER GENERATION SYSTEMS )
9-2 Automobile Engneerina
S.No. Troubles Possible causes
6. Excessive carbon in engine.
7. Defective valve action
8. Excessive rolling resistance from
pressure, dragging brakes, wheel low type
9. Heavy oil.
10. Wrong or bad fuel.
misalignment!
7 Engine lacks power, acceleration or high 1. Engine overheats.
2. Defective choke.
speed performance at hot only.
3. Sticking manifold heat control valve.
4. Vapour lock.
1. Stuck automatic choke.
Engine lacks power, acceleration or
2. Stuck manifold heat control valve.
|high speed performance at cold only.
3. Struck cooling system thermostat.
4. Struck engine valves.
Engine overheats. 1. Lack of water.
2. Late ignition timing.
3. Loose or broken fan belt.
4. Defective thermostat.
5. Clogged water jackets.
6. Defective radiator hose.
7. Defective water pump.
8. Insufficient engine oil.
9. High altitude, hot climate operation.
10. Late valve timing.
10. Rough idle. 1. Incorrect carburettor idle adjustment.
2. Malfunctioning crankcase ventilator valve
on closed crankcase ventilating system.
3. Also, causes listed under items 6, 7 and 8.
11 Engine stalls cold or as it warms up. 1. Closed choke valve.
2. Fuel not getting to or through carburettor.
3. Manifold heat control valve stuck.
4. Engine overheats.
5. Too low setting of idling speed.
12 Engine stalls after idling or speed 1. Defective fuel pump.
driving slow. 2. Overheating.
3. High carburettor float level.
4. Incorrect idling adjustment.
13. Engine stalls after high speed driving. 1. Vapour lock.
2. Defective carburettor venting or idle
compensator valve.
3. Engine overheats.
14. Engine backfires. 1. Ignition timing off.
2. Spark plug of wrong heat range.
3. Excessive rich or lean mixture.
4. Overheating of engine.
5. Carbon in engine.
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EngineTroubles
93
S.No. Troubles
Possible causes
6. Valves hot or sticking.
7. Cracked distributor cap.
15.Smoky exhaust: 1. Excessive oil
(a) Blue smoke. (b)Black smoke. consumption.
2. Excessive rich mixture.
16. Excessive oil consumption. 1. Extemal leaks.
2. Burning oil in combustion chamber.
17. Low oil pressure. 1. Worn engine bearing.
2. Engine overheating.
3. Oil dilution or foaming.
4. Defective lubrication'system.
18. Excessive fuel consumption. 1. Nervous driver.
2. High speed.
3. Short run operation.
4. Excessive fuel pump pressure or pump leakage.
5. Choke partly closed after warm-up.
6. Clogged air cleaner.
7. High carburettor float level.
8. Stuck or dirty float needle valve.
9. Worn carburettor jet.
10. Stuck metering rod or full power piston
11. Idle too rich or too fast
12. Stuck accelerator pump check valve
13. Carburettor leaks
14. Faulty ignition
15. Loss of engine compression
16. Defective valve action
17. Clutch slippage
18. Excessive rolling resistance from low tyre
pressure,dragging brakes, wheel mis
alignment, etc.
19. Engine is noisy : 1. Valve and tappet noise.
(a) Regular clicking. 2. Spark knock due to low octane fuel, carbon,
(b) Ping or chatter on load or acceleration. advance ignition timing. Also, causes listed
(c) Light knock or pound with engine under time 14.
floating. 3. Worn connecting rod bearing or crank pin,
(d) Light metallic double knock usually mis-aligned rod, lack of oil.
most audible during idle. 4. Worn or loose piston pin or lack of oil.
(e) Chattering or ratting during acceleration 5. Worn rings, cylinder walls, low ring tension,
Hollow muffled, belt-like sound, engine broken rings.
cold. 6. Piston slap due to worm pistons, walls,
() Dull, heavy, metallic knock under load collapsed piston skirts, eXcessive clearance,
or acceleration, especially, when cold. lack of oil, mis-aligned connecting rods.
(h) Miscellaneous noises. 7. Regular noise, worn main bearings, irregular,
worn end thrust bearings.
8. Rattles, etc. from loosely mounted accessories,
generator horn, oil pan, etc.
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94

9.2. WNHEN YOUR VEHICLE LACKS POWER, WHAT SHOULD YOU

DO ? Automobile Engine rima
a 2-wheeler or a
1f your vehicle has a 2-stroke engine, it does not matter whether it is 3-wheelmoster, you wil
The 13
have to face the facts that there could be 13 or more causes leading to lack of power.
causes are listed below starting withthe most minor possible cause
and ending with the most
2. Clogged air passage or filter.
frequent
major:
1. Low tyre pressure.
3. Wet cables. 4. Heavy petrol mixture ratio.
5. Binding brakes. 6. Metering rod at lowest position.
7. Unsuitable jet size. 8. Improper carburettor setting.
9. Unsatisfactory performance of spark plugs, coil, condenser at highest temperature and Speed.
10. Clogged port. 11. Low crank case compression.
12. Iniproper assembly of pistons. 13. Worn out bores, pistons and rings.
9.3. WHEN YOUR CAR SUDDENLY STOPS, HOW MANY THINGS COULD BE WRONG
dead halt. Note all ofthe
There are not less than 18 reasons why your car should suddenly come to a
cors
due to engine malfunctions. In fact, none of them are due to serious piston assembly problems. But
certain order-from dhe
can lead to these problems. All the 18 possible causes are listed below. There is a
simplest problem to the most complex-in which you should check them out to identify what is wrong wih
your car and decide what you should do about it.
2. No fuel in tank.
1. No spark.
3. Fuel not reaching carburettor. 4. Fuel filter blocked.
6. Loose low tension or high tension leads.
5. Loose battery terminal.
7. Sudden failure of contact breaker points, coil or condenser.
8. Contact breaker points joined or welded together or no gap.
9. Noengine on or pump failure. 10. No coolant or water pump failure.
11. Radiator hose burst. 12. Broken fan belt.
13. Thermostat stuck in closed position. 14. Excessive overheating.
15. Dynamo not charging. 16. Carburettor jet blocked.
17. Fuel pump failure. 18.Water splash into ignition system.
SMOKY EXHAUST CAN COST YOU?
9.4. WHAT A
Black smoke means excess fuel-it affects the purse on the daily run. Also, it can lead to indigestion anu
unhealthy for the long run. It reduces engine life and makes your car uncomfortable. thelife of
shortens
Blue smokeindicates that excess oil is burning. It promotes heavy carbon deposits and
your engine. Atmospheric pollution due to carbon monoxide emission is another great hazard.
bills later. The
Both types of smoke can cost you a lot of money on adaily run and also in terms of1repair
accordingto
their
causes of black smoke and blue smoke in 2-wheelers and 3-wheelers are given below
degree of severity, from the most minor to the most serious.
Causes of black smoke:
satisfactorily.
1. Choke in operation. 2. Spark plugs not functioning carburettorfloat.
3. Clogged air filter. 4. Punctured or incorrectly set
5. Worn out or wrong size jets. 6. Needle valve stuck open.
7. Ignition system erratic. 8. Incorrect ignition timing.
9. Worn out, stuck or broken piston rings.
Causes of blue smoke:
1. Excessive petrol mixture ratio. 2. Excessive oil in clutch chamber. rings.
piston
3 Crank case oil seals worn out or damaged. 4. Worn out, stuck or broken
5. Worn out cyl1ndcr bore.
) GROUP 2 : POWER GENERATION SYSTEMS O
Fngine Tubles 95
os HoW TO COOL OFF AN OVERHEATED TWO-STROKE ENGINE ?
Life becomes distinctly unconfortable when your engine begins to overheat. Especially if youdon't know
why.
There are 8 possible causes of overheating. But allshould not get you burn up, because some are quite
minor and easily rectified.
To find out which is the cause in your case, you will have to check out the possibilities one by one. The
most sensible way is to start with minorcommon problems and end with those requiring expert attention.
All 8 possible causes of engine overheating are listed below in this order:
1. Low tyre pressure. 2. Overspeeding.
3. Binding brakes. 4. Wrong type of spark plug.
5. Rich fuel mixture. 6. Incorrect timing.
7. Restricted exhaust. 8. Tight pistons and rings.

9.6. IF YOUR TRACTOR BEGINS TO OVERHEAT, WHAT YOUWILL DO ?

If your engine begins to overheat, you should not fall water upon the engine to cool it but you should find
the causes of overheating. There are 17possible causes of overheating, as listed below starting with the
most minor possible cause and ending with the most major:
1. Insufficient cooling. 2. Leakage in hose pipe or radiator.
3. Loose or broken fan belt. 4. Low tyre pressure.
5. Rubbing brakes. 6. Shrinkage in hose pipe.
7. Overloading and overspeed. 8. Resistance in exhaust.
9. Insufficient oil pressure, 1low oil level. 10. Incorrect functioning of thermostat.
11. Incorrect water pump. 12. More scale deposits in water jackets.
13. Slipping clutch. 14. Wrong valve timing.
15. Incorrect atomizer. 16. Wrong injection timing.
17. Tight piston and rings in cylinder bore.
9.7. TROUBLE SHOoTING OF COMPONENTS OFMARUTI- MG 410
Complaint Possible causes Remedy
1. ENGINE :
Poor starting Starter willnot run:
1 Main fuse is blown off. Replace.
2. Contact is not closing in main switch
or this switch is open circuited. Repair or replace.
3. Run-down battery. Recharge.
4. Defective starting relay. Repair or replace.
5 Loose terminalconnection on the battery. Clean and retighten.
6. Defective brushes in starter. Replace.
7. Loose battery cord connection. Retighten.
8. Open in field or armature circuit of starter. Repair or replace.
No sparking :
1. Defective spark plug. Adjust the gap or replace.
2. Short circuit (grounded) fault in Repair or replace defective
high tension cords. cords.
3 Cracked rotor or cap in distributor. Replace.
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96
Automobile Engimeering
Complaint Possible causes
Remedy
4. Burnt breaker contact points. Replace.
5. Breaker contact gap out of adjustment. Adjust as prescribed.
6. Defective condenser. Replace.
7. Contact is not closing positively in main Replace.
switch or this switch is open circuited.
8. Loose or blown fuse. Set right or replace.
9. Ignition timing out of adjustment. Adjust as prescribed.
10. Defective ignition coil Replace
Faulty intake and exhaust systems :
1. Carburettor needs readjustment. Adjust as prescribed.
2. Fuel pump is not discharging adequately. Replace.
3. Clogged fuel filter. Clean or replace.
4. Defective choke mechanism. Repair or replace.
5. Loose intake manifold. Retighten.
6. Carburettor is dirty and clogged. Disassemble and clean.
7. Float level out of adjustment. Adjust as prescribed.
8. Clogged fuel hose. Clean or replace.
9. Not enough fuel in the tank. Refill.
10. Clogged exhaust ports. Clean.
Abnormal internal condition in engine:
1. Ruptured cylinder head gasket. Replace.
2. Valve clearance out of adjustment. Adjust as prescribed.
3. Weakened or broken valve spring. Replace.
4. Loose manifold, permitting air to be drawn Retighten and, as
in.
necessary, replace the
gasket.
5. Worn pistons, rings or cylinders. Replace worn rings and
pistons and, as
necessary rebore.
6. Broken valve timing belt. Replace.
7. Poor valve seating. Repair or replace.
8. Wrong kind of enginc oil. Replace.
9. Burnt valves. Replace.
Not enough power. Inadequate compression : Adjust as prescribed.
1. Valve clearance out of adjustment.
2. Valves not seating tight. Repair.
3. Valve stems tending to seize. Replace.
4 Broken or weakened valve spring. Replace.
S. Piston rings seized in grooves or broken. Replace.
6. Worn pistons, rings or cylinders. Replace wornpartsand.
as necessary, rebore.

7. Leaky cylinder head gasket. Replace.

Improperly timed ignition : |Adjust as prescribed.
1. lgnition timing out of adjustment.
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EngineTroubles 97

Complaint Possible causes Remedy

2. Defective spark plug. Adjust the gap or replace.
3. Breaker point gap out of adjustmnent. Adjust or replace.
4. Leaky high tension cords for some Replace.
cylinders.
5. Distributor governor is not working Repair.
correctly.
Fuel system out of order :
1. Clogged carburetto. Disassemble and clean.
2. Defective fuel pump. Repair or replace.
3. Clogged fuelfilter. Replace.
4 Choke wire working erratically. |Adjust.
5. Float level out of adjustment. Adjust.
6. Clogged fuel pipe. Clean or replace.
7. Clogged fuel tank outlet. Clean.
8 Loose joint in fuel system. Retighten.
Abnormal condition in air intake system :
1 Air cleaner dirty and clogged. Clean or replace.
2. Poor returning motion of choke valve. Repair, adjust or replace.
Clogged exhaust system :
1. Muffler is clogged with carbon. Clean.
Overheating tendency of engine:
1. (Refer to the section entitled
"over-heating").
Others :
1. Dragging brakes. Adjust as prescribed.
2. Slipping clutch. Adjust or replace.
Sudden drop of Abnormal condition in electricalsystems:
speed in high speed 1. Breaker contact point gap too large. Adjust as prescribed.
cruise. 2. Spark plug gap too large. Adjust as prescribed.
3. Cracked rotor or cap in distributor, Replace.
resulting in leakage.
4 Defective condenser. Replace.
5. Deteriorated ignition coil or crack resulting Replace.
in leakage.
6. Leaky high tension cords. Replace.
7. Ignition timing out of adjustment. Adjust as prescribed.
Abnormal conditionin fuel system:
1. Float level set too low.
Adjust as prescribed.
2. Clogged condition of main, jet circuit Clean.
in carburettor.
3. Inadequately discharging fuel pump. Replace.

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98

Possible causes
Automdbile Engineering
Complaint Remedy
Abnormal condition in engine :
1. Loss of compression pressure Replace.
due to leaky cylinder head gasket.
2. Compression pressure too low because Replace and, as
of wornpistons, rings, cylinders or necessary, rebore.
burnt valves.
Abnormal condition in electrical
Engine not responding
quickly to pedal control system :
in picking up speed. 1. Ignition timing out of adjustment. Adjust as prescribed.
2. Defective spark plug or plug gap Replace or adjust as
out of adjustment. prescribed.
3. Leaky high tension cords for some Replace.
cylinders.
4. Breaker contact points out of Adjust or replace.
adjustment or defective.
5. Defective condenser. Replace.
Abnormalcondition in fuel system:
1 Float level too low or too high. Adjust as prescribed.
2. Clogged jets in carburettor. Clean.
3. Air cleaner is dirty and clogged Clean or replace.
Abnormal condition in engine :
1. Exhaust ports dirty with carbon. Clean.
2. Muffler clogged with carbon. Clean.
3. Compression pressure too low. Replace worn running
parts or rebore.
4. Poorly seating valves. Repair.
5. Valve clearance out of adjustment. |Adjust as prescribed.
6. Pistons tending to seize. Replace and, as
necessary, rebore.
7. Bearings tending to seize. Replace.
Erratic idling. Abnormal condition in ignition system :
1. Ignition timing out of adjustment. Adjust as prescribed.
2. Defective spark plug or plug gap too large Replace or adjust.
3. Cracked cap in distributor, there being Replace.
leakage inside.
4. Leaky high tension cords. Replace.
5. Cracked rotor in distributor, there being Replace.
leakage inside.
Abnormal condition in fuel system : prescribed.
1. Carburettor idling adjustment is disturbed. Adjust as
2. Clogged pilot jet in carburettor. Clean.
3. Float level out of adjustment. |Adjust as prescribed.
4 Air cleaner is dirty
and clogged. Clean or replace.

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EngineTroubls 99

Complaint Possible causes Remedy

5. Air is being sucked in due to loose joints Retighten or replace.
or broken parts.
6. Broken carburettor packings. Replace.
Abnormal condition in engine:
1. Exhaust ports clogged with carbon. Clean.
2. Valve clearance out of adjustment. Adjust as prescribed.
3. Poorly seating valves. Repair.
4. Blown cylinder head gasket. Replace.
Abnormal detonation. Abnormal condition in ignition system:
1. Spark plugs are tending to overheat. Change plug heat value.
2. Ignition timing out of adjustment. Adjust as prescribed.
3. Defective breaker contact point. Replace.
4. Loose connection in high tension or Retighten.
low tension circuit.
Abnormal condition in fuel system:
1. Air-fuel mixture too lean. Clean and adjust.
2. Carburettor is dirty inside. Clean.
3. Float level out of adjustment. Adjust as prescribed.
4. Water inside arburettor. Clean.
5. Air is leaking in through inlet Retighten.
manifold joint.
Abnormal condition in engine :
1. Excessive carbon deposit on piston Clean.
crowns or cylinder head.
2. Blown cylinder head gasket, resulting Replace.
in low compression pressure.
3. Valve clearance out of adjustrment. Adjust as prescribed.
4. Valves tending to size. Replace.
5. Weakened valve springs. Replace.
Overheating. Abnormal condition in ignition system:
1. Ignition timing out of adjustment. Adjust as prescribed.
2. Wrong heat value of spark plugs. Change heat value.
3. Breaker point gap out of Adjust as prescribe.
adjustment in distributor.
Abnormalcondition in fuel and exhaust
systems :
1. Float level set too low. Adjust as prescribed.
2. Clogged jets in carburettor. Clean.
3. Loose inlet manifold. Retighten.
4. Clogged exhaust ports. Clean.
Abnormal condition in cooling system:
1. Not enough coolant. Refill.
2. Loose or broken fan belt. Adjust or replace.
O GROUP 2 POWER GENERATION SYSTEMS CO
9-10
Awtomobile Engineering
Corplaint Possible causes Remedy
3. Erratically working thermostat. Replace.
4. Poor water pump performance. Replace.
5. Leaky radiator cores. Repair or replace.
Abnormal condition in lubrication
system :
1. Clogged oil filter. Replace.
Clean.
2. Clogged oil strainer.
3. Deteriorated oil pump performance. Replace.
4. Oilleakage from oil pan or pump. Repair.
5. Wrong kind of lubrication oil. Change.
6. Not enough oil in oil pan. Replenish.
Others:
1. Dragging brakes. Adjust.
2. Slipping clutch. Adjust or replace.
3. Blown cylinder head gasket. Replace.
Abnormal engine Crankshaft noise :
noise. 1 Worn down bearings, resulting in Replace.
excessively large running clearances.
2. Worn connecting rod bearings. Replace.
3. Distorted connecting rods. Repair or replace.
4. Worn crankshaft journals. Repair by grinding or
replace crankshaft.
5. Worn crankpins. Repair by grinding or
replace crankshaft.
Noise due to pistons, rings, pins or
cylinders
1. Abnormally worn bores of cylinders. Rebore to next oversize or
replace.
2. Worn pistons, rings or pins. Replace and as necessary,
rebore to next oversize.
3. Pistons tending to seize. Replace.
4. Broken piston rings. Replace.
Others :
1. Excessively large camshaft thrust play. Replace.
2. Excessively large crankshaft Adjust as prescribed.
thrust clearance.
3. Valve clearance too large. Adjust as prescribed.
4. Not enough engine oil. Replenish.
High fuel Abnormal condition in ignition system: Adjust as prescribed.
consumption. 1. Ignition timing out of adjustment.
2 Leaky high tension cords. Replace.
3. Breaker point gap Adjust or replace.
4. Wrong heat value maladjusted.
of spark
Change heat value.
5. Cracked distributor cap or plugs. Replace.
rotor.
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EngineTroubles 9-11

Complaint Possible causes Remedy

Abnormalcondition in fuel system:
1. Float level set too high. Adjust as prescribed.
2. Fuel leakage from tank, pipe Repair or replace.
or carburettor.
3. Erratic returning action of choke valve. Repair and adjust.
4. Pilot screw set incorrectly. Adjust as prescribed.
5. Clogged breather in carburettor. Clean.
6 Air cleaner is dirty and clogged. Clean or replace.
Abnormal condition in engine:
1. Leakage of combustion gases Retighten or replace head
from cylinder head. gasket.
2 Valve seating poorly. Repair.
3. Valve clearance out of adjustment. Adjust as prescribed.
Others :
1. Dragging brakes. Adjust as prescribed.
2. Slipping clutch. Adjust or replace.
Excessiveengine oil Oil leakage :
consumption. 1. Oil drain plugs loose. Retighten.
2. Loose oil pan securing bolts. Retighten.
3. Broken oil pan gasket. Replace.
4. Leaky oil seals. Replace.
5. Blowm cylinder head gasket. Replace.
6. Oilfilter malpositioned or loose. Set the pump right or
re-tighten mounting bolts.
"Oil pumping" (Oil finding its way
into combustion chambers) :
1. Oil rings are wom or broken. Replace.
2. Piston ring end gaps are not Reposition rings.
staggered as prescribed.
3. Badly worn ring grooves. Replace pistons.
4. Worn pistons or cylinders. Replace pistons and,
as necessary, rebore.
Oil leakage along valve stems:
1 Defective valve stem oil seals. Replace.
2. Badly worn valves or valve guide bushes. Replace.
|2. CARBURETTOR:
Fuel overflow from 1. Float valve is worn or dirty Clean or replace.
carburettor. with foreign matter.
2. Float is ruptured and Replace.
contains some fuel.
3. Broken or otherwise defective gasket. Replace.
4. Loose float chamber securing screws. Retighten.
5. Fuel pump discharge pressure too high. Adjust.
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9-12
AutOIdbile Engineering
Complaint Possible causes
Remedy
3. EXHAUST AND MUFFLER:
Poor muffling 1. Lose exhaust pipe connection. Retighten.
performance. 2. Broken muffler gasket. Replace.
3. Broken manifold, pipeor muftler. Repair or replace.
4 Exhaust manifold loose in place. Retighten.
5. Interference between body and nmuffler. Repair eliminating any
contact.

4. CLUTCH:
Slipping clutch. 1. Loss of clearance at the tip of release fork. Adjust as prescribed
2. Clutch facings dirty with oil. Replace.
3. Clutch facings excessively worn. Replace.
4. Weakened diaphragm spring. Replace.
5. Distorted pressure plate or flywheel Replace.
surface.
6. Not enough play of clutch pedal. Adjust and, as necessary,
replace clutch facings.
Dragging clutch. 1. Excessive clutch pedal play. Adjust as prescribe.
2. Weakened diaphragm spring or worm Replace.
spring tip.
3. Damaged or worn splines of transmission Replace.
input shaft.
4. Front input shaft bearing worn or broken. Replace.
5. Excessively wobbly clutch disc. Replace.
6. Clutch facings broken or dirty with oil.
Replace.
Clutch vibration. Glazed (glass like) clutch facings.
2. Clutch facings dirty with oil.
Repair or replace.
3. Replace.
Wobbly clutch disc or poor Replace.
facing contact.
4. Weakened torsion spring
(in clutch disc). Replace.
5. Clutch disc rivets
loose. Replace the disc.
6. Distorted pressure plate or flywheel
surface. Replace.
7. Weakened engine mounts (cushion
pads).
Retighten or replace.
Noisy clutch. Worn or broken release
(throw out) Replace.
2.
bearing.
Front input shaft bearing worn
3
Excessive rattle of down. Replace.
4. Cracked clutch disc.clutch disc hub. Replace the disc.
5. Pressure plate Replace.
and diaphragm spring are Replace.
rattling.
Grabb1ng clutch. 1. Clutch facings are soaked with
2. Clutch facings are oil. Replace.
O GROUP 2
POWER
excessively worn. Replace.
GENERATION SYSTEMS O
EngineTroubles 9-13

Complaint Possible causes Remedy

3. Rivet heads are showing out of the facing. Replace.
4. Torsion springs are weakened. Replace.
5. TRANSMISSION:
Gears slipping out 1. Distorted shift rod. Repair or replace.
of mesh. 2 Worn shift fork shaft. Replace.
3. Worn locating steel balls. Replac.
4. Weakened springs for locating steel balls. Replace.
Worn shift fork. Replace.
6. Excessive rattle in thrust direction of gears. Replace.
7. Worn ring or hub in synchronizers. Replace.
8. Worn bearings of input shaft, Replace.
main shaft or countershaft.
Gears refusing to 1. Weakened or broken synchronizer springs. Replace.
disengage. 2. Worn inner groove of synchronizer ring. Replace.
3. Synchronizer ring is seized on the cone. Replace the ring.
4. Distorted shift fork shaft or shaft fork. Replace.
5. Worn shift fork. Replace.
Excessive gear noise. 1. Not enough oil in transmission. Replenish.
2. Defective synchronizer. Replace.
3. Gears rattling in thrust direction. Replace.
4. Broken or worn bearings. Replace.
Hard shifting. 1. Clutch pedal play too large, resulting in a Adjust as prescribed.
"dragging clutch".
2. Clutch disc facings are worn. Replace.
3. Clutch disc facings are dirty with oil. Replace.
4 Distorted or unevenly worn shift fork shaft. Replace.
5. Broken locating balls. Replace.
Worn synchronizer sleeve. Replace.
7. Worn synchronizer hub. Replace.
6. DIFFERENTIALS:
Breakage (case, gears, 1. Insufficient or wrong kind of gear oil. Replenish or change.
bearings, etc.). 2. Improperly shimmed side bearings Adjust as prescribed.
or pinion bearings.
3. Improper mesh of drive pinion Adjust or replace.
with ring gear.
4. Excessive backlash due to worn side Adjust or replace.
gear thrust washer and pinion thrust
washer.
5. Distorted rear axle housing. Replace.
6 Loose bolts securing ring gear. Replace.
Gear no1se. 1. Maladjusted back lash between drive Adjust as prescribed.
pinion and ring gear.
2. Damaged gear teeth or improper Replace or adjust.
mesh of drive pinion and ring gear.
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9-14
Automobile Engineerina
Complaint Possible causes
Remedy
3. Improper tooth contact in
the mesh Adjust as prescribed.
between drive pinion and ring gear.
4. Insufficient or wrong kind of gear oil. Replenish or replace.
5. Ring gear wobbles when turning or
ring Replace or retighten.
loose.
gear securing bolts are
6. Broken or otherwise damaged teeth of Replace.
side gears or differential pinion gearS.
Bearing noise. 1. (Constant noise) Insufficient or Replenish or change.
wrong kind of gear oil.
2. (Constant noise) Damaged or worn Replace.
bearings or borne parts.
3. (Noise during coasting) Damaged Replace.
bearings of rear drive pinion.
4. (Noise during turning) Broken Replace.
bearings on axle shafts.
7. PROPELLER SHAFT:
Vibration and noise. 1. Broken or worn bearings of Replace.
universal joint spider.
2. Distorted propeller shaft. Replace.
3. Unbalanced propeller shaft. Replace.
4. Loose propeller shaft. Retighten.
Noise occurring at 1 Won or damaged universal joint. Replace.
standing start or 2. Worn propeller shaft splines, due Replace.
during coasting. to lack of lubrication.
3. Loose propeller shaft. Retighten.
4. Loose flanged yoke of universal joint. Retighten
8. BRAKES :
Not enough 1. Brake oil leakage from brake Locate the leaking point
braking force. lines. and repair.
2. Drum-to-shoe clearance out of adjustment. Adjust as prescribed.
3. Overheated brakes. Determnine the cause or
overheating and repair.
4. Poor contact of shoes on brake drum. Adjust for proper contact.
5. Brake shoes stained with oil or wet with Replace.
water.
6. Badly worn brake shoe linings. Replace.
Uneven braking 1. Shoe linings are wet with water or Clean or replace.
(Brakes not working stained with oil in some brakes.
in unison). 2. Drum-to-shoe clearance out Adjust as prescribed.
of adjustment in some brakes.
3. Drum is out of round in some brakes. Replace.
4 Wheel tires are inflated unequally. Inflate equally.
5. Defective wheel cylinders. Repair or replace.
6. Disturbed front wheel Adjust as prescribed.
alignment.
) GROUP 2 POWER GENERATION SYSTEMS O
EnjineToubles 9-15

Complaint Possible causes Remedy

Padal stroke too large. Drum to shoe clearance out Adjust as prescribed.
of adjustment.
2. Air trapped in the brake oilcircuit. Bleed air out as prescribed.
3. Brake pedal improperly adjusted. Adjust as prescribed.
4. Brake oil leakage. Locate the leaking point
and repair.
5. Not enough oil in the brake Replenish.
fluid reservoir.
6. Excessively worn brake drums. Replac.
7. Distorted or poorly contacting Repair or replace.
brake shoes.
8. Defective cup in master cylinder. Replace.
9. Worn brake shoes. Replace.
Dragging brake. 1. Clogged return port in master cylinder. Clean.
2. Brake shoes improperly mounted on Repair.
backing plate.
3. Weakened or broken return springs in the Replace.
brake.
4. Defective wheelcylinders. Repair or replace.
5. Sluggish parking brake cables or linkage. Repair or replaces.
6. Brake shoes improperly adjusted. Adjust as prescribe.
Pedal pulsation 1. Damaged or out of round brake drums. Replace.
(Pedal pulsates when 2. Damaged wheel bearings. Replace.
depressed for braking) 3. Distorted steering knuckle or Replace.
real axle shafts.
Braking noise. 1 Glazed shoe linings, or foreign Repair or replace.
matters stuck to linings.
2. Wornor loose shoe linings. Replace.
3. Broken front wheel bearings. Replace.
4. Distorted to loose backing plates. Replace or retighten
securing bolts.
|9. FRONT SUSPENSION AND STEERING SYSTEM :
Hard steering. 1. Wheel tyres not adequately inflated. Adjust the pressure.
2. The road ends tending to seize. Replace.
3. Linkage connections tending to seize. Repair or replace.
4. Steering gearbox out of adjustment. Adjust as preseribed.
5. Unevenly worn steering shaft bush. Replace.
Poorly lubricated or worn joints in linkage. Lubricate or replace.
7. Disturbed front wheel alignment. Adjust as prescribed.
Wobbly steering 1. Wheel tyres inflated unequally. Adjust the pressure.
wheel. 2. Wobbly wheels. Repair or replace.
3. Large difference in tire diameter between Replace.
rightand left wheels.
4. Loose hub nuts., Retighten.
O GROUP 2 POWER GENERATION SYSTEMS O
9-16 Autowobile Engineering
Complaint Possible causes Remedy
5. Damaged or worn wheel bearings. Replace.
6. Worn or loose tie rod ends. Replace or retighten.
7. Steering gearbox out of adjustment. Adjust as prescribed.
8. Steering gearbox mounted loose. Retighten.
9. Worn steering centre lever. Replace.
10. Worn steering knuckle oil seal. Replace.
Steering wheel pulling 1. Unevenly wom wheeltyres. Replace.
to one side. 2 Brake dragging in one road wheel. Repair.
3. Wheel tyres unequally inflated. Adjust the pressure.
4. Worn or distorted link rods. Replace.
5. Disturbed front wheel alignment. Adjust as prescribed.
Shocks coming to 1. Tyre inflating pressure too high. Reduce to the
steering wheel. specification.
2. Poor shock absorber performance. Replace.
3. Differences in tyres diameter amount Adjust.
the four road wheels.
4 Worn steering linkage connections. Replace.
5. Worn or broken front wheel bearings. Replace.
6 Loose front wheel. Retighten.
7. Steering wheel loose in place. Retighten the nut.
Rapid wear or uneven 1. Wheel tyres improperly inflated. Adjust the pressure.
wear of wheel tyTes. 2. Differences in diameter among four tyres. Adjust or replace.
3. Worn or loose road wheel bearings. Replace.
4. Wobbly wheel tyres. Repair or replace.
5. Wheel tyres improperly "rotated" to Adjust.
result in unbalance.
6. Disturbed front wheel alignment. Adjust as prescribed.
Steering noise. 1 Loose bolts and nuts. Retighten.
2. Loose leaf spring seats. Retighten.
3. Broken or otherwise damaged Replace.
wheel bearings.
4. Worn or sticky tie rod ends. Replace.
5. Linkage joints needing grease. Lubricate or replace.
10. STARTING MOTOR:
Starter runs but pinion 1. Worn pinion of starter clutch. Replace.
will not mesh into ring 2. Defective splines resulting in sticky pinion Repair or replace.
gear. plunging motion.
3. Worn bush. Replace.
4. Wrong pinion plunging position. Adjust.
5. Worn teeth of ring gear. Replace.
Starter will not run at Battery trouble :
all, or runs but too 1. Poor contact in battery terminal connection Repair or retighten.
2.
slowto crank with full Loose grounding cable connection. Retighten.
force 3. Battery run down. Recharge.
) GROUP 2 : POWER GENERATION SYSTEMS O
PyjineTronbles 9-17

Complaint Possible causes Remedy

4. Battery voltage too low due to battery Replace.
deterioration.
Ignition switch trouble :
1 Poor contacting action. Replace.
2 Lead wire socket loose in place. Retighten.
3. Open-circuit between ignition switch Repair.
and magnet switch.
Magnet switch trouble:
1. Lead wire socket loose in place. Retighten.
2. Burnt contact plate, or poor Replace or repair.
contacting action.
3. Open-circuit in pull-in coil. Replace.
4. Open-circuit in holding coil. Replace.
Starter proper trouble :
1. Brushes are seating poorly Repair or replace.
or worn down.
Burnt commutator. Repair or replace.
3. Open-circuit in armature winding. Replace.
4. Worn down starter. Replace.
Starter does not 1 Fused contact points of magnet Repair or replace.
stop running. switch contact plate.
2. Short-circuit between turns of magnet Replace.
switch contact plate.
3. Failure of returning action in ignition switch Replace.
11. ALTERNATOR :
Battery quickly 1 Loose or broken "y" belt. Adjust or replace.
becomes over 2. Open circuit in stator winding. Repair or replace.
discharged. 3. Open circuit in rotor winding. Repair or replace.
4. Excessively worn slip ring brushes. Replace.
5. Weakened brush springs. Replace.
6. Regulator setting too low Adjust as prescribed.
(Regulated voltage too low).
7. Poor contacting action of low speed point Repair.
in regulator.
8. Fused high speed contact point in Repair or replace.
regulator.
9. Improper acid concentration in or low level Replace, or replenish.
of battery electrolyte.
10. Defective battery cell plates. Replace the batiery.
11. Insufficient contact in battery terminal Clean and retighten.
connection.
12. Open circuit between two "F" terminals Repair.
(one on regulator and theother on
alternator) or high resistance.
) GROUP 2 POWER GENERATION SYSTtMS )
9-18
Automobile Engineerinq
Complaint Possible causes Remedy
13. Excessive electrical load. Advise the user to
economize.

Battery tends to 1. Regulated voltage set too high. Adjust as prescribed.

become overcharged. 2. Poorly grounded "E" terminal of regulator. Repair.
3. Open circuit in voltage regulat or pressure Replace.
coil.
4. Fused low speed point of regulator. Repair or replace.
5. Poor contacting action of high speed Repair or replace.
point of regulator.
6. Open circuit or high resistance between Repair.
two "N" terminals (one on alternator and
the other on regulator).
Alternator noise. 1. Worn, loose or otherwise defective Replace.
bearings.
12. WIPER MOTOR:
Wiper will not run. 1. Fuse is set loose or blown off. Tighten or replaces.
2. Incomplete metal-to-metal contact in Repair.
connector.
3. Worn or floating brushes. Replace or repair.
4. Dirty or burnt commutator. Repair or replace.
5. Short circuited or fused field coil. Replace.
6. Loose terminal connection on wiper switch. Repair.
Wiper will not stop 1. Defective wiper switch. Repair or replace.
running.
Wiper stops at wTOng 1. Improper wiper arm setting. Repair.
positions. 2. Cover plate incorrectly positioned in place.
Repair.
Poor wiping action. 1. Insufficient pressure of wiper arm.
2.
Replace.
Deteriorated or hardened blade. Replace.
3. Blade improperly set. Repair or replace.
4. Windshield dirty with oil. Clean.
13. FUEL METER:
Faulty mneter 1. Incomplete metal to metalcontact in
indication. terminal connections. Retighten.
2. Defective receiver gauge due to
point or deformed bimetal element.burnt Replace.
3. Erratic float movement.
4. Defective grounding (for float and gauge). Repair or replace.
Noindication. 1. Open circuit. Repar.
2. Open circuited heat wire. Repair.
3. Burnt point. Replace.
4. Defomed bimetal Replace.
5. Open circuited element. Replace.
resistor. Replace.

) GROUP 2
POWER GENERAION SYSIEMS O
EngineTronbles 9-19
Complaint Possible causes Remedy
J4. TURN SIGNAL LAMPS:
Flashing frequency is 1. Lamps are imperfectly grounded. Repair.
higher on one side, or 2. Lamps of wrong watt ratings are used.
Replace.
flashing occurs only 3. One of the lamp bulbs is blown on right
on one side, right or or left side or on front or rear side.
Replace.
left. 4. Defective turn signal relay. Replace.
5. Open circuit or high resistance between Repair.
switch and lamps.
No flashing occurs on 1. Blown fuse in turn signal circuit. Replace.
both sides, right and 2. Open circuit or high resistance between Repair.
left. battery and switch.
3. Defective turn signal relay. Replace.
Flashing frequency is 1. Lamps of a smaller watt rating than the Replace.
too low, or no flashing specification rating are used.
occurs on both sides. 2. One of the lamps on right or left side or on Repair.
front or rear side is poorly grounded.
3. Supply voltage is too low. Recharge the battery.
4. Fuse set loose in place, resulting in poor Repair or replace.
contact.
5. Incomplete metal-to-metal contact in Repair.
connector.
6. Defective turn signal relay. Replace.
Flashing frequency is 1. Lamps of a larger wattage than the Replace.
too high. specification are used.
2. Defective flasher. Replace.
15. SPEEDOMETER :
Faulty indication. 1. Damaged speedometer drive or driven gear. Replace.
2. Defective drive cable. Replace.
3. Drive cable incompletely or improperly Set right.
tied into the meter.
4. Defectivespeedometer. Replace.
Speedometer noise. 1. Inadequately lubricated or defective cable. Lubricate or replace.
2. Not enough oil in transfer. Replenish.
l6. WATER TEMPERATURE METER:
Faulty indication. 1. Incomplete metal-to-metal contact in Repair and tighten.
terminal connections.
2. Receiver gauge defective (due to burnt Replace.
point or deformed bimetal element).
3. Defective temperature gauge. Replace.
No indication. 1. Open circuit.
2.
Repair.
Defective receiver gauge Replace.
(open circuited heat wire, deformed
bimetal element or pointer).
3. Defective temperature gauge. Replace.
o GROUP 2 : POWER GENERAION SYSTEMS O
9-20
Autowobile Engineering
Complaint Possible causes Remedy
17. OIL PRESSURE WARNING LAMP :
Turning ignition 1. Lamp bulb is blown. Replace.
switch on (for engine 2. Blown-off fuse. Replace
starting) does not 3 Defective oil pressure switch. Replace.
light this la1p. 4. Open circuit between lamp and ignition Repair.
switch.
5. Open circuit between lamp and pressure Repair.
switch.
Lamp remains burning 1. Not enough oil in engine oil pan Replenish.
even after engine 2. Oil pressure toolow. Repair or replace the pump
starts up. 3. Defective oil pressure switch. Replace.
18. CHARGE WARNING LAMP :
Turning ignition 1. Lamp bulb is blown. Replace.
switch on (for engine 2. Blown-off fuse. Replace.
starting) does not light 3. Open-circuit. Replace.
this lamp. 4. High resistance in circuit wire due to loose Retighten.
connection.
Lamp remains burning 1. Alternator is not producing full output. Repair.
even after engine 2. Defective voltage regulator. Repair or replace.
starts up. 3. Ground-circuit formed between lamp and Repair.
the battery.
19. HORN:
Horn will not sound 1. Blown-off fuse.
off. 2. Broken circuit wire. Replace.
3. Defective horn. Repair.
Poor sound quality. 1. Incomplete contacting action inside horn
Replace.
switch. Repair.
2. Improper point gap or burnt point inside
the horn. Repair or replace.
3. Cracked diaphragm.
Replace.
EXERCISES-9
1. If engine does not turn over when
If engine backfires, what may be starting attempted, what may be
is
2
possible causes ? possible causes
3. What may be poss1ble causes of low oil
4 Whal may be possible causes of pressure ?
excessive
1f engine is noisy, what may be possible fuel consumption?
5.
6 When your vehicle lacks power, causes ?
7 When your car what should you do ?
suddenly stops, how many
8 What arc thc causes of black smoke ? things could be wrong ?
9 How will you cool an
overheated two-stroke engine ?
0 What utc poSsible causes ofpoor starting of acar ?

) GKOUP 2
POWIK
GENERAIION SYSIEMS )