Diesel Engine

Diagnosis

Prof. Dr. Walid Abdelghaffar

 Diesel Engine
PARTS SYSTEMS
• Fixed Parts • Cooling Water System
✓ Bed plate
✓ Cylinder block • Lubricating Oil System
✓
✓
Cylinder liner
Cylinder head
• Air System
• Moving Parts • Fuel System
✓ Crank shaft
✓ Connecting rod
✓ Piston
✓ Cam shaft
✓ Push Rod
✓ Rocker arm
✓ Intake & Exhaust valves
 Electronic diesel Control (EDC)

• EDC enables precise and differentiated

modulation of fuel-injection parameters
• EDC is important for lowering fuel consumption
and harmful exhaust gas emissions (NOx, CO,
HC, Particulates)
• The fuel consumption of DI engines is 10-15%
lower than IDI engines
• In EDC the driver has no direct control over the
injected fuel quantity through the accelerator
pedal and cable
 The variables control the injected fuel
quantity in EDC system:

• The vehicle response desired by the driver

(accelerator pedal position)
• The engine operating status
• The engine temperature
• Intervention by other systems (e.g..
Traction control)
• The effect on exhaust-gas emission levels
 EDC system structure
EDC subdivided
into :
• The sensors
• The control
unit
• The actuators
• Diagnosis
interface
Electronical Unit Injector
(EUI) FUEL SYSTEM

• Fuel System
• Electronic System
Types of EUI

1. MEUI
Mechanically Actuated Electronically
Controlled Unit Injector
2. HEUI
Hydraulically Actuated Electronically
Controlled Unit Injector
MEUI Fuel System
1. Mechanic
• FEATURES • BENEFITS
Injection pressures up Improved fuel economy
to 30000 psi Low exhaust emissions
Precise control of fuel
delivery
2. Electronic
• FEATURES • BENEFITS
- Electronic speed - Precise engine speed
governing control
- Cold start up mode - Low smoke and
strategy emissions
- Automatic altitude - Built-in engine
compensation protection
- Variable injection timing
- Oil pressure and cooling
warnings derate
Fuel System Components
Electronic System
Diesel engine diagnosis
Diesel engine malfunctions
• Engine overheated.
• Oil pressure lowered.
• Excessive Oil consumption.
• Engine starting impossible.
• Output insufficient.
• Fuel consumption excessive.
• Engine smoking.
• Engine knock.
 Engine overheated

Cooling unit Air compressor cylinder

head gasket

Check coolant

normal Too low / rusted

Check fan belt / wear /

replenish Inspect cooling water leakage
damage
Repair /
normal external internal
replace
Check fresh radiator Engine
Retighten / replace
cap disassembly

normal replace

Check thermostat

normal replace

Inspect
radiator
Repair /
normal
replace
Check cooling water
pump
Repair /
normal
replace
Engine disassembly (clean cooling
passages)
 Oil pressure lowered

Check oil
amount

normal Too low

Check cooling
replenish
temperature

normal Too high

Inspect oil Refer to engine

quality overheat

Water mixed in Fuel mixed in

normal
oil oil

Check oil relief Fuel supply

valve Oil cooler
pump

Cylinder head
normal Adjust / replace Engine blow by
gasket

Inspect oil
Air compressor
pump

Cracked block
Oil consumption excessive

Oil leakage

external internal

Check injector
Replace /
sleeve
retighten

Check cylinder
head gasket

Check valve
guide and seal

Inspect
turbocharger
oil seal

Check air
compressor

Oil filter
 Engine starting impossible
Fuel
Electrical system Others
system

inspection of battery electrolytic liquid Inspect fuel Inspect air

& amount amount cleaner

Clean /
normal too low normal none Normal
replace

Inspect
Inspection of loose electric wiring Adjustment / recharging Check valve clearance
fuel filter

Retighten
normal normal replace normal adjust
/ replace

Inspection of Inspect Check cylinder head

magnetic switch overflow valve gasket

Repair / Air
normal normal normal
replace removal

Inspect injection nozzle and

Inspection of starting relay Engine disassembly
pipe or loose connections

Retighten
normal replace normal
/ replace

Inspect injection
Inspection of starting switch
timing

Repair /
normal Advance injection timing normal
replace

Supply & injection pump

Starting motor disassembly
disassembly
Engine starting impossible (cont.)

• For vehicles that use electronic system :-

❖Crankshaft speed sensor.
❖Coolant level sensor.
 Output insufficient

Fuel system others

Inspect fuel Inspect air Inspect air leakage of pipe

filter cleaner line and intercooler

Clean / Retighten /
normal replace normal normal
replace replace

Inspect Inspect chock Inspect turbo

overflow valve brake gate charger

Repair /
normal Air removal Normal
replace

Inspect injection nozzle and check valve

pipe or loose connections clearance

Retighten /
normal Normal adjust
replace

Inspect injection Check cylinder

timing head gasket

normal advance normal replace

Supply & injection Engine

pump disassembly disassembly
 Excessive fuel consumption

Inspect Fuel
leakage
Due to Too low tire
inflation pressure Retighten /
Normal
replace

Inspect injection
nozzle

Adjust /
normal
replace

Check injection
timing

normal advance

Check valve
clearance

normal adjust

Check cylinder head

gasket

Engine
disassembly
Engine smoking

• Black smoke
❖Air cleaner element clogged.
❖Restriction in air duct.
❖Leakage in intake manifold.
❖Turbocharger seized up and not rotating.
❖Exhaust piping deformed or clogged.
❖Bad atomization of the injectors.
Engine smoking (Cont.)

• Blue smoke
❖Oil leak into combustion chamber.

• White smoke
❖valves out of adjustment.
❖retarded injection timing
❖Water enters combustion chamber.
❖Head gasket sealing problem.
Engine knock

• Due to too

❖advanced injection timing.

❖Excessive air/ fuel charge.

Diesel Injector Diagnosis
The basic components of a
computer system
The basic components of a
computer system
Diesel injection
• The diesel injection system together with heat generated
by compression provides the ignition system in a diesel
engine.

• The pipes that convey the fuel from the pump to the
injectors operate at very high pressures of several
hundred bars. This causes the pipes to expand with each
injection pulse.

• By clamping a piezoelectric pick-up to the injection pipe,

this expansion of the fuel injection pipe is converted into
an electrical signal which is displayed on an oscilloscope
screen.
Using the piezoelectric pick-up and the oscilloscope to
examine diesel injection details.
Adaptor Adjustment
• For best results, the pipes should be
thoroughly cleaned and the piezo-adaptor
placed as close as possible to the injector,
on a straight section of pipe.

• It will not work if it is placed on a bend in

the pipe.
At Idle Speed

• When the instrument is set up correctly

the engine should be started and allowed
to idle.

• A pattern of the type shown in Fig should

then be seen.

Dr. Walid Abdelghaffar

Diesel injection pressure pattern at idle speed
Diesel injection pressure pattern at idle speed
Diesel injection pressure pattern at idle speed
Diesel injection pressure pattern at idle speed
Diesel injection pressure pattern at idle speed
Diesel Engine
Diagnosis

Prof. Dr. Walid Abdelghaffar