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Engine Systems Inspection
Engine Systems Inspection
1/15/2019 2
• After removing the air cleaner, if the
element is full of dirt and dust, replace it.
• A filter element impregnated with water
or oil should be replaced, as trapped dust
and sand cannot be removed with
compressed air.
• Using an air gun, blow the dust and sand
particles out from the lower surface.
• Next, clean the upper surface and once
again blow evenly from the lower surface.
• Clean Air Cleaner Case: First use a
rag to wipe out the dust from inside the
case, then blow with compressed air.
• Install the element correctly in the air
cleaner case and assemble the case cover.
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• When the oil has become thick and dark, it
must be renewed and the air cleaner body
cleaned-out.
• The procedure for servicing this type of air
cleaners as follows:
1. Remove Air Cleaner Assembly from a
vehicle
2. Disassemble Air Cleaner (Fig. A)
3. Clean Filter Element & Air Cleaner
case (Fig. B) A
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To prevent contaminants from reaching the fuel system components,
fuel filters must be changed or serviced at specific intervals.
Fuel filters and elements are serviced by replacement only.
Some vehicle manufacturers recommend fuel filter replacement at
48,000km.
If dirty or contaminated fuel is placed in the fuel tank, it may be
necessary to replace the filter before the recommended mileage.
A plugged fuel filter may cause the engine to surge and cut out at high
speed, or hesitate on acceleration.
• When servicing a series filter,
the first-stage filter is generally changed more
often than the second-stage filter.
The second-stage filter is often replaced with
every third first-stage filter replacement.
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• Adjust accelerator pedal lever to maximum fuel
injection position.
• Without altering any of the adjustments, check
that the fuel delivery at 800 rpm is according to
specified volume per 200 shots or injection.
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2. LEAKAGE TEST
• While maintaining pressure at about 10-20kg/cm2 below
opening pressure (adjust by tester handle), check that there
is no dripping for 10 seconds from the injection hole or
around the retaining nut.
• If the nozzle drips with in 10 seconds, replace or clean and
overhaul the nozzle assembly.
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3. SPRAY PATTERN TEST
• The injection nozzle should shudder at a certain
pumping speed between 15-60 times (old nozzle) or 30-
60 times (new nozzle) per minute.
• Check the spray pattern during shuddering.
• If the spray pattern is not correct during shuddering,
the nozzle must be replaced or cleaned.
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A. Disassemble injector nozzle (follow manufacturer procedure).
B. Wash parts in clean diesel fuel.
Do not touch the nozzle mating surfaces with your fingers.
C. Tilt the nozzle body about 60 degrees and pull the needle out
about one third of its length.
D. When released, the needle should sink down into the body
vent smoothly by its own weight.
E. Repeat this test, rotating the needle slightly each time.
– If the needle does not sink freely, replace the nozzle
assembly.
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Perform a visual inspection for:
Coolant leaks
Loose or missing fan belts
Low coolant level
Water pump noises
Plugged radiator fins
Coolant in the oil (oil looks milky)
Combustion leakage into coolant
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A bad pump may leak, fail to circulate
coolant, or produce a grinding sound.
Causes:
Rust in the cooling system
Lack of coolant
Over tightened belts
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• Remove the cap from the radiator and visually inspect the condition of
the cap’s pressure valve and upper and lower sealing gaskets.
– If the gaskets are hard, brittle, or deteriorated, the cap may leak
when exposed to hot, pressurized coolant.
• Over time the spring in the cap can weaken and will lower the
coolant’s boiling point.
Testing radiator cap
– The opening pressure of the cap is measured by pressure tester.
Procedures:
1. Remove radiator cap from radiator.
2. Install the correct cap adapter and radiator
pressure cap to the tester head.
3. Pump the tester until the gauge reads the
pressure rating of the cap.
The cap should hold that pressure for at least 1 minute. If it does
not, replace it.
Apply a pressure greater than the cap’s rating. A good cap will
1/15/2019vent the excess pressure. 24
I. INSPECT RELIEF VALVE
• Coat the valve with engine oil and check
that it falls smoothly into the valve hole
by its own weight.
– If it does not, replace the relief valve.
If necessary, replace the oil pump
assembly.
II. INSPECT DRIVE AND DRIVEN ROTORS
A. Inspect rotor body clearance
• Using a thickness gauge, measure the
clearance between the driven rotor and body.
If the body clearance is greater than
maximum, replace the oil pump
assembly.
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B. Inspect rotor side clearance
• Using a thickness gauge and precision
straight edge, measure the clearance
between the rotors and precision straight
edge.
– If the side clearance is greater than
maximum, replace the oil pump
assembly.
A B C E
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• Oil is the life-blood of an engine, it is critical that the oil and
filter are changed on a regular basis.
• To replace engine oil and filter follow the following procedure:
1. PREPARE A VEHICLE
i. Park a vehicle in level place.
ii. Allow the engine to run awhile. After it is warmed, turn off the
engine.
2. DRAIN ENGINE OIL
a) Remove the oil filler cap.
b) Remove the oil drain plug, and drain the oil into a container.
3. REPLACE OIL FILTER
4. FILL WITH ENGINE OIL
a. Clean and install the oil drain plug with a new gasket.
b. Fill engine with new engine oil of a recommended viscosity
number and API.
c. Reinstall the oil filler cap.
5. START ENGINE AND CHECK FOR LEAKS
6. RECHECK ENGINE OIL LEVEL
A. Stop the engine and wait until it cool down
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B. Check engine oil level using a dipstick
• When ever a manifolds are removed from cylinder head inspect
it for crack, bad gasket, and warpage.
• If the manifold is cracked or the sealing surfaces are severely
damaged, it should be replaced.
• A leaking manifold gasket is a common causes of internal
coolant leaks.
• A bad manifold gasket in intake can also cause vacuum leaks
and exhaust gas leaks if exhaust manifold gasket is defective.
• When installing a manifold, use new gaskets and seals.
• When the manifold is removed or there is evidence of a leak
between the manifold and the cylinder head, the sealing
surfaces should be checked for flatness (warpage).
• Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head for warpage.
– If warpage is greater than maximum, replace the manifold.
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