Chapter- 4

Engine diagnosis and Tune up

 Diagnosis: - is a method of finding out the troubles within an engine by
visual examination, by the sound produced, by the smoke of the exhaust
and/or with the help of instruments.
 Tune-up:- is a process of correcting or adjusting the troubles or
problems of an engine
 Engine servicing - is a method of keeping the engine in a state of
better performance, lower fuel consumption and lower emission.
 Servicing Diesel Fuel System

 Injection pump
 It is one of the most important component parts of diesel fuel injection
system.
 Function of the injection pump

 It supplies fuel precisely at the right point in the diesel cycle for the
pressure build-up resulting from ignition that occurs after TDC.
 The pump meters the quantity delivered per cycle to match the torque-
speed relationship demanded by the engine.
For automobile applications there are most commonly used types of fuel
injection pumps, these are:
1. In- line pump system
2. Distributor type pump system
1. In- line pump system
– Has a plunger as a number of cylinders
– It is most commonly used in diesel engine for heavy commercial vehicle
 2. The distributor type pump system
• Uses a single plunger for all cylinders
• Distributor pumps are generally lighter and more
compact,
• Less costly than in-line counter parts
• Their governors and injection advanced devices are
simpler and smaller.
 4.1 Installing injection pump to engine

PROCEDURE:
• Step1. Install a new O-ring to the pump.
• Step2. Align the set key on the drive shaft and groove of the injection
pump drive gear.
• Step3. Align the period lines (or match marks) of the injection pump and
timing belt case.
• Step4. Install the two nuts holding the injection pump to the timing gear
case.
• Step5. Install the pump stay mount bolt.
• Step6. Check injection timing
• Step7. Install injection pipes
• Step8. Connect fuel hoses to injection pump
• Step9. Connect accelerator connecting rod
• Step10. Install timing belt
• Step11. Start engine and check for fuel leaks
• Step12. Check idle speed and maximum speed
 4.2 Inspecting Injection Timing

Injection Timing:
• The simplest way to check valve timing is to
bring the number 1 cylinder to TDC on the
compression stroke and align the timing marks on
the crankshaft with the pointer used to time the
ignition.
Fig. Identification of injection timing mark
Now check:
 If injection timing marks placed on crankshaft pulley
and engine casting are in alignment example (180
BTDC)
 If this is not the case, the injection timing has to be
corrected (adjusted)
 In order to adjust, loosen the injection pump
fastening nuts slightly
 Adjust injection timing according to manufacturer’s
specification
• If injection timing is retarded -- Slowly move pump towards
the crankcase.
• If injection timing is advanced-- Slowly move pumps away
from the crankcase.
• Tighten the injection pump and recheck the
injection timing adjustment-
• If the injection timing adjustment is correct,
install the delivery valve components and tighten
the delivery valve holder to the specified torque.
• Fit the injection pipe to the delivery valve holder
and test run the engine.
 4. 3 Bleeding injection system

Bleeding is a process of removing air from the fuel

system
Air enters the fuel system when:
• components had been removed,
• repairing or replacing takes place
• the vehicle runs out of fuel, and the tank
becomes completely empty.
 Method for air bleeding
(a) Bleed the air out of the system by operating the
priming pump.

Fig. Actuating the priming pump for bleeding

 A. System with In-Line Injection pump:

• Step1. Loosen the priming pump by turning it

counterclockwise
• Step2. Loosen the air vent screw positioned nearest to the
priming pump in the system (usually found on the fuel filter
unit)
• Step3. Operate the priming pump by hand until pure diesel
fuel, free from air bubbles, comes out of the air vent screw
• Step4. Tighten the air vent screw
• Step5. Now, open the air vent plug on the fuel injection
pump
• Step6. Close the air vent screw when air bubbles
disappears from fuel coming out of the plug
• Step7. Tighten the priming pump by pushing it downwards
and turning it clockwise at the same time
 B. System with Distributor (VE) Injection pump:

• In this case no priming pump and pre-delivery feed

pump is found in these fuel systems
• The injection pump is “self venting” when the engine
operates
Valve Clearance:
• There must be a certain clearance between the top of
the valve stem and the operating mechanism to allow
the valve to seat correctly under all working conditions.
• With some engines it may be necessary to check
and adjust the valve clearances at intervals of
10,000km (6,000miles) or even 19,000km
(12,000miles).
• The actual clearance may vary from engine to
engine; in some designs the exhaust valve
clearance will be greater than the inlet valve
clearance.
 VALVE CLEARANCE CHECK-UP & ADJUSTMENT

What is valve timing?

• Valve timing - is the opening and closing of the
inlet and exhaust valves at the correct time in
relation to piston position.
• We know that valves are opened and closed by
the camshaft(s) which are driven by chain,
toothed belt or gear train from the crankshaft.
Valve Timing Diagram
Valve timing diagram shows the opening and closing degrees of intake and exhaust
valves with relates to crank shaft and piston position in each strokes.
 How to adjust valve timings?
Incorrectly adjusted valves can cause the engine to
stall. That is:
• If too tight, and they don't seal/seat down properly,
so that cylinder isn't working hard enough and will
eventually burn that valve.
• If too loose and the valve timing changes, so the
engine sounds rattle and runs rough.
 Excessive valve clearances have an effect of:-

1. Presence of a regular taking sound

– The noise can become more of a general clatter
emanating from the top of the engine, if more than
one valve clearance is excessive.
2. The valve is not fully open
– (The valve opens too let & closes two early)
3. The valve is returned to its seat mach faster than
it would normally do.
– In severe cases this can result in the head of the valve
breaking off causing extensive engine damage.
4. With some arrangements, an indentation may
being created in the rocker (tinge pad)
 Insufficient valve clearance

• The valve do not close completely, resulting in loss of

compression & power
• Due to incomplete closing the valve face and its seat will
be burnt & may have to be renewed
• If the valve concerned happened to be intake valve, it
could be possible back fairing (burning gasses could find
their way back into the intake manifold) with a
consequent risk of fire.
• Valve opens early & close late
•

Rocker arm & shims Valve clearance adjustment

Rocker arm adjustment:
Used for Over head valves(OHV)
Shims adjustment:
Used for Over head Cams(OHC)
 E.g. adjustment procedure (for z method)
1. Warm-up the engine, then stop it.
2. Set No. 1 cylinder to TDC/compression.
3. Adjust the valve clearance. The valve clearance is measured between the
valve stem and rocker arm adjusting screw.
Adjust only the valves indicated by arrows.
Valve clearance: Intake 0.20 mm (0.008 in.)
Exhaust 0.30 mm (0.012 in.)

4. Rotate the crankshaft 3600.

5. Adjust the remaining valves indicated by arrows.
Second rounds to adjust the left valves
 For shims adjustment
PROCEDURE:
• Step1. Remove intake pipe.
• step2. Remove cylinder head cover.
• step3. Set no.1 cylinder at TDC mark/at the end of
compression stroke.
• step4. Identify intake and exhaust valves
• Step5. Adjust the closed valves turn by turn by rotating
the crankshaft.
• Step6. If it is shim type, install new shim by choosing the
proper sizes.
Fig. shim type valve clearance adjustment
a. Using a thickness gauge, measure the clearance between the
valve lifter and camshaft.
b. Record the valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance (Cold):
Intake = 0.15-0.25mm (0.006-0.010in.)
Exhaust = 0.35-0.45 mm (0.014-0.018in.)
c. Turn the crankshaft one revolution (360°), and align the mark
d. Check only the closed valves indicated in the illustration above.
Measure the valve clearance
e. Remove the used shims by pressing down the valve lifter using
SST/ two flat screwdrivers.
f. Determine the replacement adjusting shim size by using
following (Formula or Charts) refer manual.
 g. Using a micrometer, measure the thickness of the
removed/used shim(s).
h. Calculate the thickness of the new shim so the valve
clearance comes within specified value
T… Thickness of used shim
A… Measured valve clearance
N… Thickness of new shim
Intake N = T + (A-0.20 mm (0.008 in.))
Exhaust N = T + (A-0.40 mm (0.016 in.))
i. Select a new shim with a thickness as close as possible to
the calculated values.
j. Install a new adjusting shim
k. Recheck the valve clearance.
l. Reinstall cylinder head cover
m. Reinstall intake pipe
 Spark plug cleaning

 Spark plugs should be cleaned about every 250

hours of use.
Measuring and adjusting Spark Plug Gap
• The spark plug gap is one of the most important
engine service specifications.
• It is the distance between the center and side
electrodes.
• A narrow gap requires less voltage to create a
spark but increases current flow, which can burn
the electrodes.
• A wide gap develops higher ignition voltage, but if
the gap is too wide, enough voltage may not be
available to create a spark.
• Spark plug gaps for breaker-point ignitions range
from 0.60-1.0 mm.
• Some electronic ignitions require plug gaps of 1.0 to
2.0 mm.
• Plug gaps must always be checked and adjusted by
using of feeler gauge.
 PROCEDURE:
Step 1:
• Disconnecting each spark plug wire one at a time
while the engine is running.
• If the engine speed drops or starts running rough
when one is disconnected, you know that spark plug is
good.
• If you disconnect a spark plug and no significant
change happens in the engine, you have found a bad
spark plug.
 Step 2: Test the spark plug ignition by disconnecting
the spark plug wire from the spark plug.
• Hold the end of the spark plug wire close to a metal
surface.
• If the spark plug is good, you will see a spark or you'll
hear a crackling noise.
• This means that voltage is getting through the wire
to the spark plug.
Step 3: See if there is a spark on each spark plug
wires when the engine is cranked.
• If compression is good, you will have spark on each
one of your spark plug cylinders.
• No spark would mean that a spark plug wire is dead.
Step 4: Remember that each link connected to the spark
plugs needs to be hooked up securely. Links include
battery cable, ignition wires and coil wires, not just the
spark plug wires.
Step5: Wiggle the link connections from your spark plugs.
Then test again. Sometimes it's just a matter of a line
connection being loose.
Step6: Check to make sure that the end of each of the
spark plugs is clean and free of any dirt, oil or grease
deposits.
Step7: Measure the gap with a round (wire-type) feeler
gauge, figure below.
Step8: Bend the side electrode to adjust the gap using a
bending tool
Step9: Re- check the gap
 Replacing or repairing air cleaner
• Air cleaners are employed in the intake system to
purify the air drawn in for combustion effectively
without impeding the incoming airflow rate.
• The dust entering with the intake air is trapped by
either:
– Oil-wetted type or

– Dry(paper)type of air cleaner – the most often used

 Air cleaners also perform the following functions:-

• It captures moisture and carbon soot that are

present in the atmospheric air.
• It acts as a silencer and reduces the noise caused
by the intake air as the intake valves open and
close.
• It acts as a flame arrestor if the engine backfires
through the air-intake systems.
 Procedure of cleaning:
• Remove the air cleaner element.
• Clean the element by blowing compressed air
from inside if it is dry-paper type; otherwise
refer to the repair manual.
• If the element is torn or excessively dirty,
replace it with a new one.
• Check the carburetor mountings and gaskets for
leakage.
• Check the intake manifold mountings and
gaskets for leakage.
Fig. How to clean air Cleaner
Fig. Oil Bath Type of Air Cleaner
 Fuel filter:

• The fuel filter, which is installed between

the pump and the fuel rail,
• Removes dirt and contaminants from the
fuel before it is delivered to the injectors
 Check Or Replace Contact Point
• Point closing: - during this time a voltage from storage
battery passes to primary ignition coil winding and
energizes it.
• Point opening: - during this time the flow of current
from storage battery gets stop, voltage in primary
winding gets collapse and the secondary winding gets
energized, then high voltage will develops up.
Dwell angle:

This is the period during which the contact breaker

points are remain closed.
 Checking and Adjusting Engine Idle Speed
• Idle speed means the operation of an engine while the vehicle is
parking or without selecting the gear and the gear shifting lever
is on the neutral position.
• In other words the throttle valve is fully closed, but it gets the air
through the idle system or idle circuit.
 Idle speed can be adjusted by two techniques:

• Through experience by using the sound of the engine, it must

have smooth vibration while tightening and loosening the idle
adjusting screw.
• By using a special instrument that is called a tachometer.
 PROCEDURE:

• Check that the adjusting lever touches the idle speed

adjusting screw when the accelerator pedal is released.
• If not, adjust the accelerator linkage.

• Start the engine.

• Check the idle speed.

• Adjust the idle speed by turning the idle speed adjusting
screw.
Example of Idle speed:
• 1PZ…………… 600-700 rpm
• 1HZ M/T…… 600-700 rpm
• 1HZ A/T……. 660-760 rpm
 Adjusting ignition timing

• ignition timing – is the measurement of the

degrees of crankshaft rotation at which the spark

plugs fire in each of the cylinders.

PROCEDURE OF SETTING IGNITION TIMING STATICALLY
1. Identify an advanced and TDC mark
2. Identify direction of distributor shaft rotation
3. Know engine firing order
4. Align the moving ignition timing mark on the flywheel or
crankshaft with the fixed mark on the engine block.
5. Mount distributor shaft while cylinder number one is at
the end of compression stroke and advance mark aligned
with timing mark.
6. Push the distributor housing gently to turn it in the
opposite direction to distributor rotor rotation, until the
contact breaker points open and the test lamp lights up.
In this setting, tighten the distributor firmly into position.
7. Then, crank the engine to start it.
Timing by the ignition test lamp
SETTING IGNITION TIMING DYNAMICALLY:

1. Hook up power timing light. Attach the red lead to the positive
battery terminal and the black lead to the negative terminal.
2. A third lead has a special connector that attaches to the number
one cylinder plug wire. (The service manual will show the location
of the number one cylinder pickup at the distributor cap.)
3. Consult the service manual for the location of the timing marks.
Rotate the engine by hand or Tap the ignition switch until the
marks are visible.
4. Clean the dirt off the timing marks with solvent to see them
better.
5. Very carefully make a neat line with white chalk or white enamel
paint over the correct timing mark. This will help you see the
mark when the engine is running
6. Start the engine and let it warm. The engine must
be fully warmed and idling at the proper speed to
set the timing
7. While the engine warms, check the service
manual if there are any special timing procedures.
Most engines with contact ignition systems must
be timed with the vacuum advance line removed
at the distributor and plugged. The best way to do
this is by attaching a vacuum gauge in the end of
the line.
8. If it is too advance or too retard, retimed by
turning the distributor housing until the two
marks are aligned.
 Engine Cylinder Compression Test
PROCEDURE:
• Run the engine to the warm up temperature
• Connect necessary tools and equipments
• Disconnect ignition line +ve ignition coil terminal/disconnect fuel
shutoff line from fuel shutoff solenoid.
• Remove all spark plugs/injectors or glow plugs
• Adapt the tester through spark plug hole/glow plug hole or injector
hole.
• Open the throttle valve fully
• Crank the engine and measure all cylinder compression holding
ability
• Relate the result with manufacturer’s specification
• To pin point the problem add 3 – 4 droplet of engine oil through
the spark plug hole and perform again steps
• Draw the conclusion
Engine cylinder compression tester
 The cylinder leakage test:
• The cylinder leakage tester has an advantage
over the compression tester because it allows for
precise identification of the problem area.
• The biggest disadvantage of this test is that its
test requires more time to conduct than does
the compression test.
 Purpose of cylinder leakage test

• To determine the cause of low compression.

• It helps to pinpoint places where air escapes or
leakage occurs.
• It is an additional test executed when the
compression test has given a bad result for one
or more cylinders.
 PROCEDURE:

1. Run the engine to the warm up temperature

2. Connect necessary tools and equipments.
3. Connect the tester with the compressed air source
4. Remove air cleaner duct from the intake manifold, radiator cup
and dipstick
5. Set cylinders to be tested at the end of compression stroke. Use
whistle if necessary in order to inform you cylinder number one is
at TDC position.
6. Adapt the tester through spark plug hole/glow plug hole and apply
compressed air to all cylinders turn by turn.
7. Open throttle valve fully.
8. Observe the leakage of air through radiator cup, intake air duct,
dipstick hole, exhaust pipe
9. Read the leakage percentage shown on the tester gauge.
Interpret the reading as follows:
• Less than 10% = good compression
• 10% to 20% = fair compression
• 20% to 30% = poor compression
• More than 30% = a leakage problem

10. If cylinder leakage is more than 20 percent,

listen for air leakage at the following sources to
isolate the problem.
• Air escaping through the crankcase indicates worn or broken
rings, a cracked or burned piston, or worn cylinder walls.

• Air escaping through the exhaust pipe indicates a leaking

exhaust valve.

• Air escaping through the carburetor indicates a leaking intake

valve.

• Air bubbles in the radiator indicate a leaking head gasket or a

cracked head or block.

• Two cylinders next to each other with high leakage indicate a

leaking head gasket or an engine crack between the cylinders.
11.Turn off the compressed air and disconnect the air
source from the cylinder adapter.

12.Using a wrench on the crankshaft pulley, rotate the

engine until the distributor rotor points at the next
cylinder tower location in firing order sequence. This
places that cylinder at TDC on the compression stroke.

13.Install the test adapter in the spark/glow plug hole on

the next cylinder.

14.Repeat steps for all remaining cylinders

15.Draw conclusion
Fig. Cylinder leakage tester
 Cylinder Power Balances Test
• A cylinder power balance test measures the amount of
power that a particular cylinder contributes to the total
power output of the engine.
• The total output of an engine is the sum of all the power
produced by the individual cylinders.
• The cylinder power balance test is quick and easy to
perform.
• It is valuable in identifying the exact cylinders that have
problems.
Testing Engine Power Balance

• Use tachometer (for both gasoline diesel engines)

• Idle speed-drop test- for diesel engine

• Glow plug resistance test - for diesel engine( low

temperature and resistance indicate low injection)

 Engine knock/Noise test
• The cause of noise when the engine is operating
is due to the sliding friction and slapping or
knocking.
• The noise of each moving parts when the engine
is operating optimally is said to be normal noise.
• But when the clearance b/n the moving parts are
beyond the limit, abnormal noise is created.
The noise of the moving parts is high during the
following conditions.

• When the engine is cold

• When the engine oil is not viscous

• When accelerating

• When the engine is highly loaded

• When the engine ignition timing gets more advanced.

Procedure to test engine knock :
a) Check the water level in the radiator
b) Check the oil and refill if necessary
c) Run the engine up to normal operating T0c
d) Check the noise as follows

Fig. Using a sound scope for engine knock test

 Analyzing Engine Exhaust Gases

 Sometimes called a combustion efficiency meter

 The main purpose of the emission controls is to
reduce the amounts of CO, HC, NOx in the
exhaust gas.
 Federal and state laws set the maximum legal
limits on the amount of HC and CO permitted in
the exhaust gas.
 Procedure to Analyze Engine Exhaust Gases :

• Check that the analyzer is probably calibrated.

• Run the engine for 30-60 seconds at about 2000rpm before
measuring the concentration.
• Wait at least one minute before measuring to allow the
concentration to stabilize, but complete the measuring within
three minutes.
• Insert a testing probe at least 40 cm in to the tail pipe, one probe
in place of dipstick gauge and measure the concentration within
a short time [0.5 – 1.5 %] for CO.
• If the concentration exceeds the specified value, tighten the idle
mixture adjusting screw little by little until the concentration is
within the specified value.
• Print the result if you want
• Draw the conclusion by referring the manual.
•