1. ENGINE MECHANICAL DIAGNOSIS

2. Diagnostic Strategies
Insolating the System
Tools
Screening Tests
Pinpoint Tests

3. Engine Performance Problems
No-start
Hard starting
Stalling
Misfire
Hesitation
Surging
Lack of power
Ping (spark knock)
Rod Knock
Backfire
Induction Backfire
Excessive Oil Consumption
Over Heating
Tip-in
WOT
Vapor Lock
Run-On
Intermittent

4. Other Annoying Problems
Oil leaks
Excessive oil consumption
Coolant leaks
Coolant in oil
Over heating
Engine noises

5. Misfiring Ignition system problem Fuel system problem
Engine mechanical problem
Air induction problem

6. Other Related Terminology
Seized engine
Hydro-static lock
Blown engine
Threw a rod
Spun bearing
Burnt piston
Burnt valve
Sucked a valve

7. Abnormal Combustion This problem causes a knocking type sound that
occurs upon acceleration.

8. Diagnostic Tools Vacuum gauge Compression tester
Cylinder leakage tester
Stethoscope
Crankcase pressure tester
Oil pressure gauge
Cooling inspection tools
Spark plug condition

9. Vacuum, Pressure & Atmospheric Pressure
Vacuum is any pressure lower than atmospheric pressure.
Measure in inches of mercury (“ Hg) or centimeters of mercury (Cm Hg).
Pressure is any pressure that is greater than atmospheric pressure.
Measured in pounds per square inch (PSI) or Kilograms per square centimeter (Kg/cm2)

10. Types of Engine Vacuum
Venturi vacuum is found in the venturi on carbureted engines only.
Ported vacuum is just above the throttle plate.
Manifold vacuum is always below the throttle plate.

11. Vacuum Gauge Used to measure manifold vacuum
Measured in inches of mercury (“Hg)
Great screening tool for engine problems
Must be connected to the intake manifold

12. Vacuum Diagnosis Chart

13. Compression Test
Allows technician to pumps air out of the cylinder through the spark plug hole.
Engine is cranked through at least four compression strokes.
The cylinders are measured and compared to determine leakage.

14. How to Perform a Compression Test
Remove the spark plugs.
Screw the appropriate adapter into the spark plug hole and connect the gauge.
Disable the engine so it will not start.
Connect the remote starter button to the engine’s starting system.
Crank the engine through at least 4 compression strokes.
Do this for all the cylinders.

15. Common Leakage Points
Intake Valve
Exhaust valve
Head Gasket
Rings

16. Interpreting the Results
All cylinders should be with 25% of each other from the highest to the lowest reading. This indicates a mechanically sound engine.
To determine this take the highest reading times 75% this will give you the lowest acceptable reading. 1 2 3 4
175
160
165
155
175 x .75% = _____ lowest OK

17. What to do About a Low Cylinder
1. You need to determines if your problem is the piston rings or the valves. Do a wet test or a cylinder leakage test. There’s a big difference in cost between a valve job and a complete overhaul.
2. If adjacent cylinders low: head gasket or warped head.
3. Coolant in cylinder.

18. Cylinder Leakage Tester
Use this tester to pin-point specific malfunctions in the cylinder.
This tester pumps air into the cylinder.
You listen to where it leaks out.

19. Cylinder Leakage Set-up
Connect air supply to the tester and calibrate the tester.
Remove the spark plug, attach the adapter and get the cylinder at TDC between the compression and power strokes.
Connect the air supply to the cylinder and listen for where the air escapes.

20. Evaluating the Results
If the leakage is 20% or less the cylinder is OK.
If the leakage is greater than 20% check the following:
Air escaping from the tail pipe.
Burnt exhaust valve.
Air escaping from the throttle body.
Burnt intake valve.
Air Escaping from the oil filler.
Bad piston rings.

21. Cylinder Power Balance
Locates a misfiring cylinder.
Manually
Scopes have built-in power balance test.
Car’s computer will run it’s own cylinder balance test. Need a scan tool.

22. Methods of Performing a Power Balance Test
1) Remove each plug wire one at a time listen for drop in engine RPM. If there in no drop the misfiring cylinder is located. This test is tough in the catalytic converter.
2) Remove the fuel injector wire to each cylinder one at a time. This way the converter won’t be over loaded with fuel.
3) This test is built in on many engine analyzers. All 3 of our analyzers have it.
4) With many new cars, this test can be run with the scan tool.

23. Camshaft Verification
Refer to manufacturers service information.
OHC
SOHC
DOHC

24. Overhead Valve

25. Single Overhead Cam

26. Dual Overhead Cam

27. Exhaust Color Normal exhaust is clear.
White smoke (steam) indicates coolant entering the combustion chamber.
Black smoke indicates excessive gasoline (rich mixture) entering the combustion chamber.
Blue smoke indicates oil entering the combustion chamber.

28. Diagnosing Engine Noises
Ticking, clicking or clatter.
Usually indicates valve train problems:
Camshaft
Lifters
Pushrods
Rocker arms
Timing chain or gears
Knocking
Usually indicates lower end noises:
Rod bearing worn (rod knock)
Main bearing worn (main bearing knock)
Loose piston (piston slap)
Loose wrist pin (double knock)
p. 146

29. Diagnosing Engine Noises
Stethoscope helpful in isolating noises but a big screwdriver, dowel rod or heater hose can also work.
Sort out bearing noises such as alternators and water pumps.

30. Mechanical Damage

31. Crankcase Pressure Test
This test checks the amount of gases passing the piston rings (also called a blow-by test).
The tester connects in place of the PCV valve.
The engine is run and the amount of blow-by it measured.
This test is weird, but it really shows if an engine has bad rings.

32. Measuring Oil Pressure
This test accurately measures engine oil pressure.
Remove the car’s sender unit and attach the shop pressure gauge.
Can indicate a variety of engine problems.
This is where the oil pressure sender is removed from.

33. Interpreting the Results
Causes of low oil pressure.
Worn engine bearings.
Worn or defective oil pump.
Defective pressure sender.
Low oil level.
Diluted oil.

34. Checking for Oil Consumption
Only two ways to lose oil: leak or burn.
Burning oil.
Look for blue smoke and check oil consumption.
Leaking oil.
Perform a oil leak inspection.
Visual
Dyes

35. Cooling System Inspection
Check the following:
Coolant level.
Coolant condition.
Anti-freeze protection.
Hoses and belts.
Check the water pump.
Radiator fins.
Pressure test for leaks.
Test cap.
Determine thermostat condition.
Check fan for proper operation.

36. Loss of Coolant
Leaks
Loss to combustion chamber

37. Block Test
This test is used to determine a cracked head, block or head gasket.
This test is performed by taking vapor from the top of the cooling system and running it through a blue liquid.
If the fluid stays blue the engine is OK.
If the fluid turns yellow the coolant is leaking into the combustion chamber.

38. Damaged Cylinder Head

39. Maintenance Oil change Oil filter Coolant flushing Manual Flush & Fill
Coolant recycler