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[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 24, the reader should be able to: Continued
[object Object],[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 24, the reader should be able to:
[object Object],KEY TERMS:
[object Object]
TYPICAL ENGINE-RELATED COMPLAINTS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
ENGINE SMOKE DIAGNOSIS ,[object Object],Continued See this chart on Page 202 of your textbook.
Figure 24–2  White steam is usually an indication of a blown (defective) cylinder head gasket that allows engine coolant to flow into the combustion chamber where it is turned to steam. Figure 24–1  Blowby gases coming out of the crankcase vent hose. Excessive amounts of combustion gases flow past the piston rings and into the crankcase.
THE DRIVER IS YOUR BEST RESOURCE ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],After the nature and scope of the problem are determined, the complaint should be verified before further tests are performed.
VISUAL CHECKS ,[object Object],Continued Oil Level and Condition  The first area for visual inspection is oil level and condition. ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],NOTE:   Check the coolant level in the radiator only if the radiator is cool. If the radiator is hot and the radiator cap is removed, the drop in pressure above the coolant will cause the coolant to boil immediately and can cause severe burns when the coolant explosively expands upward and outward from the radiator opening. ,[object Object],Continued
[object Object],[object Object],Continued ,[object Object],[object Object],[object Object],[object Object],[object Object]
The color of the leaks observed under a vehicle can help the technician determine and correct the cause. Some leaks, such as condensate (water) from the air-conditioning system, are normal, whereas a brake fluid leak is very dangerous. The following are colors of common leaks: What’s Leaking? Sooty black Yellow, green, blue, or orange Red Murky  Clear Engine oil Antifreeze (coolant) Automatic transmission fluid Brake or power steering fluid or very neglected antifreeze (coolant) Air-conditioning condensate (water) (normal)
[object Object],[object Object],Step #1   Clean the engine or area around the suspected leak. Use a high-powered hot-water spray. While the engine is running, spray the entire engine and the engine compartment. Avoid letting water come into direct contact with air inlet, ignition distributor or coil(s). NOTE:   Most oil leaks appear at the bottom of the engine due to gravity. Look for the highest, most forward location for the source of the leak. Continued
NOTE:   If the engine starts to run rough or stalls when the engine gets wet, then the secondary ignition wires (spark plug wires) or distributor cap may be defective or have weak insulation. Be certain to wipe all wires and the distributor cap dry with a soft, dry cloth if the engine stalls. An alternative method is to spray a degreaser on the engine, then start and run the engine until warm. Engine heat helps the degreaser penetrate the grease and dirt. Use a water hose to rinse off the engine and engine compartment. Continued
[object Object],The Foot Powder Spray Trick The source of an oil or other fluid leak is often difficult to determine. A quick and easy method that works is the following. First, clean the entire area. This can best be done by using a commercially available degreaser to spray the entire area. Let it soak to loosen all accumulated oil and greasy dirt. Clean off the degreaser with a water hose. Let the area dry. Start the engine, and using spray foot powder or other aerosol powder product, spray the entire area.  The leak will turn the white powder dark. The exact location of any leak can be quickly located. Continued
Figure 24–3 What looks like an oil pan gasket leak can be a rocker cover gasket leak. Always look up and look for the highest place you see oil leaking; that should be repaired first. Figure 24–4  The transmission and flexplate (flywheel) were removed to check the exact location of this oil leak. The rear main seal and/or the oil pan gasket could be the cause of this leak. Finding  the location of the oil leak can be difficult.   Continued
[object Object],Figure 24–5  Using a black light to spot leaks after adding dye to the oil. A black light will easily show oil leak locations. The dye will show as a bright yellow/ green area. NOTE:   Fluorescent dye works best with clean oil.
ENGINE NOISE DIAGNOSIS ,[object Object],Continued ,[object Object],[object Object],[object Object],[object Object],[object Object]
Figure 24–6 An accessory belt tensioner. Most tensioners have a mark indicating normal operating location. If the belt has stretched, this indicator mark will be outside of the normal range. Anything wrong with the belt or tensioner can cause noise. ,[object Object],Continued
[object Object],[object Object],[object Object],Continued
See the chart on Page 204 of your textbook.   Continued
Figure 24–7 A cracked exhaust manifold on a Ford V-8. ,[object Object]
[object Object],A light ticking noise often heard at one-half engine speed and associated with valve train noise is a less serious problem than many deep-sounding knocking noises. Generally, the deeper the sound of the engine noise, the more the owner will have to pay for repairs. A light “ tick tick tick ,” though often not cheap, is usually far less expensive than a deep “ knock knock knock ” from the engine. Engine Noise and Cost
OIL PRESSURE TESTING ,[object Object],Continued Low oil pressure can cause engine wear, and engine wear can cause low oil pressure . If main thrust or rod bearings are worn, oil pressure is reduced because of leakage around the bearings. Oil pressure testing is usually performed with the following steps: Step #1   Run the engine until operating temperature is achieved. Step #2   With the engine off, remove the oil pressure sending unit or sender, usually located near the oil filter. Thread an oil pressure gauge into the threaded hole.
Figure 24–8 To measure engine oil pressure, remove the oil pressure sending (sender) unit usually located near the oil filter. Screw the pressure gauge into the oil pressure sending unit hole. ,[object Object],Most vehicle manufacturers recommend a minimum oil pressure of 10 psi per 1000 RPM. At 2500 RPM, the oil pressure should be at least 25 psi.  Besides bearing wear, other causes for low oil pressure include: low oil level, diluted oil and stuck oil pressure relief valve.
Engine testing is done to find the cause of an engine problem. All the simple things should be tested first. Remember  KISS —“ K eep  I t  S imple,  S tupid.” A loose alternator belt or loose bolts on a torque converter can sound just like a lifter or rod bearing. A loose spark plug can make the engine perform as if it had a burned valve. Some simple items that can cause serious problems include the following: Use the KISS Test Method - Part 1 ,[object Object],[object Object],[object Object],[object Object],OIL BURNING
Use the KISS Test Method - Part 2 NOISES ,[object Object],[object Object],[object Object]
OIL PRESSURE WARNING LAMP ,[object Object]
A soundly running engine should produce even and steady exhaust at the tailpipe. You can test this with the  paper test . Hold a piece of paper or a “3 x 5” card (even a dollar bill works) within 1 inch (2.5 centimeters) of the tailpipe with the engine running at idle.  The Paper Test - Part 1 Figure 24–9 The paper test involves holding a piece of paper near the tailpipe of an idling engine. A good engine should produce even, outward puffs of exhaust. If the paper is sucked in toward the tailpipe, a burned valve is a possibility.
[object Object],The Paper Test - Part 2 ,[object Object],[object Object],[object Object]
COMPRESSION TEST ,[object Object],Continued ,[object Object],[object Object],[object Object],For best results, the engine should be warmed to normal operating temperature before testing.
[object Object],Continued CAUTION:   Disable the ignition system by disconnecting the primary leads from the ignition coil or module or by grounding the coil wire after removing it from the center of the distributor cap. Also disable the fuel injection system to prevent the squirting of fuel into the cylinder. Step #1   Remove all spark plugs. This allows the engine to be cranked to an even speed. Be sure to label all spark plug wires. Step #2   Block open the throttle. This permits the maximum amount of air to be drawn into the engine. This step also ensures consistent compression test results.
Figure 24–10 A two-piece compression gauge set. The threaded hose is screwed into the spark plug hole after removing the spark plug. The gauge part is then snapped onto the end of the hose. ,[object Object],Step #4   Record the highest readings and compare the results. Most manufacturers specify minimum compression and the allowable variation among cylinders. Most specify a maximum difference of 20% between the highest and the lowest readings.
NOTE:   Note the reading on the compression gauge after the first puff. This reading should be at least one-half the final reading. For example, if the final, highest reading is 150 psi, then the reading after the first puff should be higher than 75 psi. A low first-puff reading indicates possible weak piston rings. Release the pressure on the gauge and repeat for the other cylinders. To make the math quick and easy, think of 10% of 150, which is 15 (move the decimal point to the left one place). Now double it: 15  ×   2 = 30. This represents 20%.
Installing spark plugs can be made easier by using a rubber hose on the end of the spark plug. The hose can be a vacuum hose, fuel line, or even an old spark plug wire end, as shown here. The Hose Trick Figure 24–11 Use a vacuum or fuel line hose over the spark plug to install it without danger of cross-threading the cylinder head. The hose makes it easy to start the threads of the spark plug into the cylinder head. After starting the threads, continue to thread the spark plug for several turns. Using the hose eliminates the chance of cross-threading the plug. This is especially important when installing spark plugs in aluminum cylinder heads.
WET COMPRESSION TEST ,[object Object],Continued NOTE:   During both the dry and wet compression tests, be sure that the battery and starting system are capable of cranking the engine at normal cranking speed. CAUTION:   Do not use more oil than three squirts from a hand-operated oil squirt can. Too much oil can cause a hydrostatic lock, which can damage or break pistons or connecting rods or even crack a cylinder head.
Figure 24–12 Badly burned exhaust valve. A compression test could have detected a problem, and a cylinder leakage test (leak-down test) could have been used to determine the exact problem. ,[object Object],If the compression readings increase only slightly (or not at all), the cause is usually defective valves.
RUNNING (DYNAMIC) COMPRESSION TEST ,[object Object],Continued What is the RPM of a cranking engine? An engine idles at about 600 to 900 RPM, and the starter motor obviously cannot crank the engine as fast as the engine idles. Most specs require the engine to crank at 80 to 250 cranking RPM.  But what should compression of a running engine be?  A  running compression test ,   also called a  dynamic compression test ,   is done with the engine running.
[object Object],[object Object],[object Object],[object Object],Running compression of all cylinders should be equal. A problem is likely to be detected by  variations  in running compression values among the cylinders. Broken valve springs, worn valve guides, bent pushrods, and worn cam lobes are items that would be indicated. For most engines, the value ranges are as follows: The engine is revolving faster, and there is less  time  for air to enter the combustion chamber. With less air to compress, pressure is lower. The higher the RPM, the lower the running compression.
[object Object]
CYLINDER LEAKAGE TEST ,[object Object],Continued Figure 24–13 A typical hand-held cylinder leakage tester. The air is injected into the cylinder through a cylinder leakage gauge into the spark plug hole. To perform the cylinder leakage test, take the steps following.
[object Object],[object Object],Figure 24–14 A whistle stop used to find top dead center. Remove the spark plug and install the whistle stop, then rotate the engine by hand. When the whistle stops making sound, the piston is at the top. Continued NOTE:   The greatest amount of wear occurs at the top of the cylinder because of the heat generated near the top of the cylinders. The piston ring flex also adds to the wear at the top of the cylinder. Step #3   Calibrate the cylinder leakage unit per manufacturer’s instructions.
[object Object],[object Object],[object Object],[object Object],[object Object],NOTE:   If leakage seems unacceptably high, repeat the test, being certain that it is being performed correctly and that the cylinder being tested is at TDC on the compression stroke. Step #4   Inject air into the cylinders one at a time, rotating the engine as necessitated by firing order to test each cylinder at TDC on the compression stroke. Continued
[object Object],[object Object],[object Object],[object Object],[object Object]
CYLINDER POWER BALANCE TEST ,[object Object],NOTE:   Most automotive test equipment uses automatic means for testing cylinder balance. Be certain to correctly identify the offending cylinder. Cylinder #3 as identified by the equipment may be the third cylinder in the firing order instead of the actual cylinder #3. See the power balance chart on Page 208 of your textbook.
POWER BALANCE TEST PROCEDURE ,[object Object],Continued This method is not recommended on any vehicle with any type of electronic ignition. If any of the plug wires are removed from a spark plug with the engine running, the ignition coil tries to supply increasing levels of voltage attempting to jump the increasing gap as the plug wires are removed.  This high voltage could easily track the ignition coil, damage the ignition module, or both. The acceptable method, which will work on all types of ignition systems, including distributorless, is to  ground  the secondary current for each cylinder.
Figure 24–15 Using a vacuum hose and a test light to ground one cylinder at a time on a distributorless ignition system. This works on all types of ignition systems and provides a method for grounding out one cylinder at a time without fear of damaging any component. ,[object Object]
VACUUM TESTS ,[object Object],Continued Manifold vacuum is developed by the pistons as they move down on the intake stroke to draw the charge from the throttle body and intake manifold. Air to refill the manifold comes past the throttle plate into the manifold.  Vacuum will increase any time the engine turns faster or has better cylinder sealing while the throttle plate remains in a fixed position. Manifold vacuum will decrease when the engine turns more slowly or when the cylinders no longer do an efficient job of pumping.  Vacuum tests  include testing the engine for  cranking vacuum ,  idle vacuum ,   and vacuum at 2500 RPM.
[object Object],[object Object],[object Object],Continued Cranking Vacuum Test  Measuring manifold vacuum during cranking is a quick and easy test to determine if piston rings and valves are properly sealing. The engine should be warm and the throttle closed. To perform the cranking vacuum test, take the following steps: Cranking vacuum should be higher than 2.5 inches of mercury. (Normal is 3 to 6.) If lower than 2.5 look for the following: ,[object Object],[object Object],[object Object],[object Object]
Figure 24–16  An engine in good mechanical condition should produce 17 to 21 in. Hg of vacuum at idle at sea level. ,[object Object],NOTE:   Engine vacuum readings vary with altitude. A reduction of 1 inch Hg per 1,000 feet (300 meters) of altitude should be subtracted from the expected values if testing a vehicle above 1,000 feet (300 meters). Continued
Figure 24–17 A steady but low reading could indicate retarded valve or ignition timing. ,[object Object],[object Object],Low and Steady Vacuum  If the vacuum is lower than normal, yet the gauge reading is steady, common causes include: Continued
[object Object],Figure 24–18  A gauge reading with the needle fluctuating 3 to 9 in. Hg below normal often indicates a vacuum leak in the intake system. A common cause of sticking valves is lack of lubrication of the valve stems.  See Figures 24–19 through 24–26. If the vacuum gauge fluctuates above and below a center point, burned valves or weak valve springs may be indicated. Continued If the fluctuation is slow and steady, unequal fuel mixture could be the cause.
Figure 24–20  An oscillating needle 1 or 2 in. Hg below normal could indicate an incorrect air–fuel mixture (either too rich or too lean). Continued Figure 24–19  A leaking head gasket can cause the needle to vibrate as it moves through a range from below to above normal.
Figure 24–22  If the needle drops 1 or 2 in. Hg from the normal reading, one of the engine valves is burned or not seating properly. Continued Figure 24–21  A rapidly vibrating needle at idle that becomes steady as engine speed is increased indicates worn valve guides.
Figure 24–24 A steady needle reading that drops 2 or 3 in. Hg when the engine speed is increased slightly above idle indicates that the ignition timing is retarded. Figure 24–23 Weak valve springs will produce  a normal reading at idle, but as engine speed increases, the needle will fluctuate rapidly between 12 and 24 in. Hg. Continued
Figure 24–26 A needle that drops to near zero when the engine is accelerated rapidly and then rises slightly to a reading below normal indicates an exhaust restriction. Figure 24–25 A steady needle reading that rises 2 or 3 in. Hg when engine speed is increased slightly above idle indicates the ignition timing is advanced. Continued
NOTE:   A common trick that some technicians use is to squirt some automatic transmission fluid (ATF) down the throttle body or into the air inlet of a warm engine. Often the idle quality improves and normal vacuum gauge readings are restored. The use of ATF does create excessive exhaust smoke for a short time, but it should not harm oxygen sensors or catalytic converters.
EXHAUST RESTRICTION TEST ,[object Object],[object Object],[object Object],[object Object]
[object Object],TESTING BACK PRESSURE WITH A VACUUM GAUGE Manifold vacuum will drop gradually if the engine is kept at a constant speed with the exhaust restricted. After a short time the exhaust tends to “pile up” above the restriction and eventually remains in the cylinder at the end of the exhaust stroke.  At the beginning of the intake stroke, when the piston traveling downward should be lowering pressure (raising vacuum) in the intake manifold, the extra exhaust in the cylinder  lowers  the vacuum. If the restriction is severe enough, the vehicle can become undriveable because cylinder filling cannot occur except at idle.
[object Object],TESTING BACK PRESSURE WITH A PRESSURE GAUGE ,[object Object],[object Object],[object Object],Continued
[object Object],NOTE:   An adapter can be easily made by inserting a metal tube or pipe. A short section of brake line works great. The pipe can be brazed to the oxygen sensor housing or it can be glued in with epoxy. An 18-millimeter compression gauge adapter can also be adapted to fit into the oxygen sensor opening. Figure 24–27 A technician- made adapter used to test exhaust system backpressure.
DIAGNOSING HEAD GASKET FAILURE ,[object Object],Continued ,[object Object],[object Object]
[object Object],[object Object],Figure 24–28 A tester that uses a blue liquid to check for exhaust gases in the exhaust, which indicate a head gasket leak problem. The liquid turns yellow if combustion gases are present in the coolant.  Continued
[object Object],[object Object],[object Object],[object Object],NOTE:   A leaking thermal vacuum valve can cause symptoms similar to those of a defective head gasket. Most thermal vacuum valves thread into a coolant passage, and they often leak only after they get hot.
DASH WARNING LIGHTS ,[object Object],Continued A summary of typical dash warning lights and their meanings: Oil (Engine) Light  Indicates engine oil pressure is too low. When this light comes on, the driver should shut off the engine and check the oil level and condition for possible dilution with gasoline caused by a fuel system fault.  If the oil level is okay, there is a possible serious engine problem or a possible defective oil pressure sending (sender) unit. The tech should always check oil pressure using a reliable mechanical oil pressure gauge if low oil pressure is suspected.
[object Object],Continued Follow these steps to prevent possible engine damage: ,[object Object],[object Object],[object Object],[object Object]
If a misfire goes away with propane added to the air inlet, suspect a lean injector. Misfire Diagnosis NOTE:   Some automobile manufacturers combine the dash warning lights for oil pressure and coolant temperature into one light, usually labeled “engine.” Therefore, when the engine light comes on, the technician should check for possible coolant temperature and/or oil pressure problems. If the engine does not feel or smell hot, it is possible the problem is a faulty coolant temperature sensor or gauge.
[object Object],Continued Continued
[object Object],( cont. )
SUMMARY ,[object Object],[object Object],[object Object],[object Object],Continued
SUMMARY ,[object Object],[object Object],[object Object],[object Object],[object Object],( cont. )
end

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Chap24

  • 2.
  • 3.
  • 4.
  • 5.
  • 6.
  • 7.
  • 8. Figure 24–2 White steam is usually an indication of a blown (defective) cylinder head gasket that allows engine coolant to flow into the combustion chamber where it is turned to steam. Figure 24–1 Blowby gases coming out of the crankcase vent hose. Excessive amounts of combustion gases flow past the piston rings and into the crankcase.
  • 9.
  • 10.
  • 11.
  • 12.
  • 13. The color of the leaks observed under a vehicle can help the technician determine and correct the cause. Some leaks, such as condensate (water) from the air-conditioning system, are normal, whereas a brake fluid leak is very dangerous. The following are colors of common leaks: What’s Leaking? Sooty black Yellow, green, blue, or orange Red Murky Clear Engine oil Antifreeze (coolant) Automatic transmission fluid Brake or power steering fluid or very neglected antifreeze (coolant) Air-conditioning condensate (water) (normal)
  • 14.
  • 15. NOTE: If the engine starts to run rough or stalls when the engine gets wet, then the secondary ignition wires (spark plug wires) or distributor cap may be defective or have weak insulation. Be certain to wipe all wires and the distributor cap dry with a soft, dry cloth if the engine stalls. An alternative method is to spray a degreaser on the engine, then start and run the engine until warm. Engine heat helps the degreaser penetrate the grease and dirt. Use a water hose to rinse off the engine and engine compartment. Continued
  • 16.
  • 17. Figure 24–3 What looks like an oil pan gasket leak can be a rocker cover gasket leak. Always look up and look for the highest place you see oil leaking; that should be repaired first. Figure 24–4 The transmission and flexplate (flywheel) were removed to check the exact location of this oil leak. The rear main seal and/or the oil pan gasket could be the cause of this leak. Finding the location of the oil leak can be difficult. Continued
  • 18.
  • 19.
  • 20.
  • 21.
  • 22. See the chart on Page 204 of your textbook. Continued
  • 23.
  • 24.
  • 25.
  • 26.
  • 27.
  • 28.
  • 29.
  • 30. A soundly running engine should produce even and steady exhaust at the tailpipe. You can test this with the paper test . Hold a piece of paper or a “3 x 5” card (even a dollar bill works) within 1 inch (2.5 centimeters) of the tailpipe with the engine running at idle. The Paper Test - Part 1 Figure 24–9 The paper test involves holding a piece of paper near the tailpipe of an idling engine. A good engine should produce even, outward puffs of exhaust. If the paper is sucked in toward the tailpipe, a burned valve is a possibility.
  • 31.
  • 32.
  • 33.
  • 34.
  • 35. NOTE: Note the reading on the compression gauge after the first puff. This reading should be at least one-half the final reading. For example, if the final, highest reading is 150 psi, then the reading after the first puff should be higher than 75 psi. A low first-puff reading indicates possible weak piston rings. Release the pressure on the gauge and repeat for the other cylinders. To make the math quick and easy, think of 10% of 150, which is 15 (move the decimal point to the left one place). Now double it: 15 × 2 = 30. This represents 20%.
  • 36. Installing spark plugs can be made easier by using a rubber hose on the end of the spark plug. The hose can be a vacuum hose, fuel line, or even an old spark plug wire end, as shown here. The Hose Trick Figure 24–11 Use a vacuum or fuel line hose over the spark plug to install it without danger of cross-threading the cylinder head. The hose makes it easy to start the threads of the spark plug into the cylinder head. After starting the threads, continue to thread the spark plug for several turns. Using the hose eliminates the chance of cross-threading the plug. This is especially important when installing spark plugs in aluminum cylinder heads.
  • 37.
  • 38.
  • 39.
  • 40.
  • 41.
  • 42.
  • 43.
  • 44.
  • 45.
  • 46.
  • 47.
  • 48.
  • 49.
  • 50.
  • 51.
  • 52.
  • 53.
  • 54. Figure 24–20 An oscillating needle 1 or 2 in. Hg below normal could indicate an incorrect air–fuel mixture (either too rich or too lean). Continued Figure 24–19 A leaking head gasket can cause the needle to vibrate as it moves through a range from below to above normal.
  • 55. Figure 24–22 If the needle drops 1 or 2 in. Hg from the normal reading, one of the engine valves is burned or not seating properly. Continued Figure 24–21 A rapidly vibrating needle at idle that becomes steady as engine speed is increased indicates worn valve guides.
  • 56. Figure 24–24 A steady needle reading that drops 2 or 3 in. Hg when the engine speed is increased slightly above idle indicates that the ignition timing is retarded. Figure 24–23 Weak valve springs will produce a normal reading at idle, but as engine speed increases, the needle will fluctuate rapidly between 12 and 24 in. Hg. Continued
  • 57. Figure 24–26 A needle that drops to near zero when the engine is accelerated rapidly and then rises slightly to a reading below normal indicates an exhaust restriction. Figure 24–25 A steady needle reading that rises 2 or 3 in. Hg when engine speed is increased slightly above idle indicates the ignition timing is advanced. Continued
  • 58. NOTE: A common trick that some technicians use is to squirt some automatic transmission fluid (ATF) down the throttle body or into the air inlet of a warm engine. Often the idle quality improves and normal vacuum gauge readings are restored. The use of ATF does create excessive exhaust smoke for a short time, but it should not harm oxygen sensors or catalytic converters.
  • 59.
  • 60.
  • 61.
  • 62.
  • 63.
  • 64.
  • 65.
  • 66.
  • 67.
  • 68. If a misfire goes away with propane added to the air inlet, suspect a lean injector. Misfire Diagnosis NOTE: Some automobile manufacturers combine the dash warning lights for oil pressure and coolant temperature into one light, usually labeled “engine.” Therefore, when the engine light comes on, the technician should check for possible coolant temperature and/or oil pressure problems. If the engine does not feel or smell hot, it is possible the problem is a faulty coolant temperature sensor or gauge.
  • 69.
  • 70.
  • 71.
  • 72.
  • 73. end