List of Figure

Page
Figure 1 ........................................................................................................................ 2
Figure 2 ........................................................................................................................ 3
Figure 3 ........................................................................................................................ 3
Figure 4 ........................................................................................................................ 3
Figure 5 ........................................................................................................................ 3
Figure 6 ........................................................................................................................ 4
Figure 7 ........................................................................................................................ 4
Figure 8 ........................................................................................................................ 4
Figure 9 ........................................................................................................................ 5
Figure 10 ...................................................................................................................... 5
Figure 11 ...................................................................................................................... 5
Figure 12 ...................................................................................................................... 5
Figure 13 ...................................................................................................................... 6
Figure 14 ...................................................................................................................... 7

List of Table
Table 1 ........................................................................................................................ 2
 Task 1
1. Identify maintenance types and maintenance schedules of vehicle engine
systems.
maintenance types
Planned Maintenance Un planned Maintenance
 Preventive Maintenance  Breakdown Maintenance
 Periodic Maintenance
 Corrective Maintenance
Preventive Maintenance breakdown Corrective Maintenance
Maintenance
It is a group of us fares and This type of aintenance The set of tasks is aimed at
operations that ensure the occurs if you wait until the correcting the defects that
continuation of the car machine has stopped can be found in the car
running Without the working before epairing it. - occurs when an issue
occurrence of any problems is noticed.
that lead to its suspension, Examples of corrective
including: maintenance include:
detection and examination Repairing a broken -
1. Measure the fluid level in HVAC unit rather than
the car .maintaining it
2. Check and adjust engine Figure 1
clearances
Periodic Maintenance
It is a periodic maintenance related to the number of kilometers
It is limited to a time of gratitude manufactured
It consists of periodic inspection of maintenance and cleaning equipment
Replace parts to prevent sudden failure
 maintenance schedules :
the process of making sure planned work is carried out. It involves bringing all the
necessary resources together to make sure tasks are completed correctly and on time
EX : show in table 1
Periodic maintenance schedule
80000km 75000km 60000km 40000km 30000 10000 5000km maintenance
km km
engine

Engine oil and

* * * * * * * filter change
Check and clean
* * the air filter
Air filter change
* *
2. Explain the preliminary inspections to save engine from sudden faults,
select and use appropriate test equipment to diagnose the fault
  First Visul inspection
Oil Level and Condition
• Thin & dark oil with burned smell indicate
engine internal problem
• Thick & dark oil usually indicates dirt or
contaminants
• Milky, foamy, or cream-colored oil can be
indicative water contamination.

Figure 2
Coolant Level and Condition:
 The coolant level should only be
checked when the engine is cool
 When the engine is cold the level of
the liquid in the expansion bottle is
higher than when the engine is hot.
The coolant level must be between
the maximum and minimum mark to
confirm that the coolant level is OK
Figure 3
 Secondly, with the use of the kit
Cooling Circuit Sealing Check:
The refrigerant circuit leak test is
implemented using a manually operated
pressure tester
 Remove the expansion bottle cap
while the engine is cold
 The tester is attached in place of the
cover.
 The piston is actuated on the pump Figure 4
 The cooling system is pressurized.
The process that consists of pressing
the system to 0.1 bar less than the
pressure setting value for
refrigeration circuit or 0.9 bar max.

Figure 5

Cylinder Power Balance Test

The purpose of a cylinder power balance
test is to determine whether all cylinders
contribute power equally. to test the engine
 We remove the spark plug wire from
One spark plug at a time while
watching the tachometer (engine
RPM value).

Figur
e6

Dry Compression Test

Before measuring the engine compressions,
you must carry out the following
preliminary checks:
1. Check the oil level and quantity.
2. Check the intake system from any
clogging.
3. Check the battery and starter motor
speed.
 properly disable the ignition system
and fuel system,
1. Remove all spark plugs.
2. Thread the compression tester into
one spark plug hole and crank the
engine.
3. Apply full accelerator pedal to open Figure 7
the throttle valve to the maximum
limit
4. Apply continues engine cranking
until the pressure gage needle stop
increasing, repeat this step for the all
cylinders and note the pressure
reading for each cylinder
5. Record the highest readings and
compare the results. Manufacturers
specify a maximum difference of
20% between the highest reading
and lowest reading. Figure 8

Wet Compression Test

 If the pressure test reading indicates low
Compression of one or more cylinders
 Add three squirts oil to the cylinder
and re-test.
 Oil is used to help seal around the
piston rings
 If the readings improve significantly
the cause of the low pressure is wear
of the piston rings.
 If the pressure readings increase
only slightly cause the drop The Figure 9
pressure is usually faulty in the
valves.

Engine Vacuum Test

 First, the vacuum hose for the brake
booster
 Place the vacuum tester into the
brake booster slot in the intake
manifold show in figure 10
 the vacuum gauge reading should be figure 10
steady and give a reading of at least
17 to 20 inches of mercury (in. Hg)
show in figure 11
 If it looks like the needle stays at 17
most time but goes down to 10 and
goes up quickly probably Because of a
problem in one cylinder

figure 11
- Fluctuating or low readings can indicate many different problems :show in figure 12

Cylinder Leakage Test

 -This test is done by injecting air under
pressure into its cylinders one by one. An
air leak test helps determine the condition of
the engine.
-Air is injected into the cylinder through the
spark plug hole
Follow the following steps:
1. The engine should be at normal
operating temperature.
2. The cylinder being tested must be at
top dead center (TDC) of the
compression stroke
3. Calibrate the cylinder leak unit
according to the manufacturer's
instructions (between 5 to 7 bar),
inject air in cylinders one by one
4. Evaluate the results: Less than 10%
leakage: good More than 30%
leakage: definite problem
5. Check the source of the air leak:
A. If air is heard coming out of the oil
filler cap, the piston rings are
damaged or broken.
B. If air bubbles are seen coming out of
the radiator or reservoir, a blown
head gasket or a cracked cylinder
head is likely.
C. If air is heard coming from the
throttle body or air inlet on fuel-
injection-equipped engines, there is
a defective intake valve(s).
D. If air is heard coming from the
tailpipe, there is a defective exhaust Figure 13
valve(s)

Engine Oil Pressure Test

Corrosion can cause low oil pressure due to
corrosion of the rod bearings, resulting in
oil leakage around the bearings
 Follow the following steps:
1. Operate the engine until normal
operating temperature is achieved.
2. With the engine off, remove the oil
pressure switch or sensor, usually
located near the oil filter. Thread an
oil pressure gauge into the threaded
hole. Figure 14
3. Start the engine and observe the
gauge. Record the oil pressure at idle
and at 2500 RPM. Most vehicle
manufacturers recommend a
minimum oil pressure of 0.4 bar per
1000 RPM. Therefore, at 2500
RPM, the oil pressure should be at
least 1.6 bar. Always compare your
test results with the manufacturer’s
recommended oil pressure.

Task 2
Suggest different inspection methods to diagnose the problem of three
engines from the previous problems; Use at least two tests to check the
problem and record the results in table form; Then compare the results to
assess engine performance.
 engine has a noticeable decrease in the level of oil.
inspection methods
Visul inspection Engine Oil Pressure Test
Check the oil level and quantity
Results
 Oil Condition ( good )  oil pressure at idle and at 1000
 Oil Level ( low ) RPM was 0.2 bar
 oil pressure at 2500 RPM was
1.4 bar
manufacturer’s recommended oil pressure.
 Oil Condition ( good )  oil pressure at idle and at 1000
 Oil Level ( good ) RPM should be minimum oil
pressure of 0.4 bar
 oil pressure at 2500 RPM should
be at least 1.6 bar.

 engine has low power performance.

inspection methods
Visul inspection Dry Compression Test
Coolant Level and Condition Wet Compression Test
Oil Level and Condition
 Oil Condition ( good ) Dry : c1 = 150psi / c2 =150psi
 Oil Level ( good ) C3 =150psi / c4 = 150 psi
 Coolant Condition ( good ) Wet : c1 = 150psi / c2 = 150psi
 Coolant Level ( low ) C3 = 150 psi / c4 = 140 psi

manufacturer’s recommended
 Oil Condition ( good ) Compression ratio = 150 psi
 Oil Level ( good )
 Coolant Condition ( good )
 Coolant Level ( low )
Task 3
Evaluate and justify the results of engine selection in terms of its operation
and performance compared to the specification manual
  In engine engine has a noticeable decrease in the level of oil.
Lack of oil pump pressure comes as a result
 Low oil level
 Diluted oil
 Stuck oil pressure relief valve
After examining it, check the bearings, and if the defect is one of them, replace
them
 Proper oil pressure is very important for the operation of any engine. Low oil
pressure can cause engine wear

 engine has low power performance.

A compression test reveals the condition of your engine's valves, its valve seats, and
piston rings and whether these parts are wearing evenly. Healthy engines should
have compression over 100 psi per cylinder, with no more than 10 percent variation
between the highest and lowest readings
 And compare the results of the presence of corrosion and valve leakage in the
exhaust
 The cause of internal oil consumption is often worn valve guides or defective
valve guide seals. There might be exhaust smoke during deceleration because
of oil leaking into the combustion chamber through the intake valve guides.
Deceleration causes very high engine vacuum, which pulls oil into the
combustion chamber.