Scribd
Upload
67 views

Gasoline Engine Basic

This document provides procedures for basic inspection and adjustment of various engine components, including: 1) Compression pressure test to check piston rings and valves 2) Ignition timing check to ensure proper ignition system function 3) Idle speed adjustment to set engine idle RPM 4) Checks of throttle position sensor output, fuel pressure, valve clearances, and timing belt alignment. Step-by-step check procedures are provided for each item along with purposes, check conditions, and suspected faulty components if tests reveal issues.

Uploaded by

Ammar Rayyan
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
67 views

Gasoline Engine Basic

This document provides procedures for basic inspection and adjustment of various engine components, including: 1) Compression pressure test to check piston rings and valves 2) Ignition timing check to ensure proper ignition system function 3) Idle speed adjustment to set engine idle RPM 4) Checks of throttle position sensor output, fuel pressure, valve clearances, and timing belt alignment. Step-by-step check procedures are provided for each item along with purposes, check conditions, and suspected faulty components if tests reveal issues.

Uploaded by

Ammar Rayyan
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 48

BASIC BASIC INSPECTION INSPECTION & & ADJUSTMENT ADJUSTMENT

Compression Pressure Test Ignition Timing Idle Speed Adjustment TP Sensor Adjustment Fuel Pressure Test Valve Clearance Adjustment(MLA) Timing Belt Alignment

COMPRESSION PRESSURE TEST


PURPOSE
To check the condition of piston rings, cylinder head gasket, valve seat, valves and valve springs.

COMPRESSION PRESSURE TEST


CHECK CONDITION
ENGINE OIL LEVEL, STARTER MOTOR AND BATTERY ARE NORMAL

CHECK PROCEDURE
1. REMOVE THE SPARK PLUGS 2. ATTACH THE COMPRESSION GAUGE TO THE SPARK PLUG HOLE

COMPRESSION PRESSURE TEST


3. DEPRESS THE ACCELERATOR PEDAL TO FULLY OPEN THE THROTTLE VALVE 4. CRANK THE ENGINE AND READ THE GAUGE 5. REPEAT STEP 2 THROUGH 4 ON ALL CYLINDERS AND CHECK THE PRESSURE DIFFERENTIAL FOR EACH CYLINDERS LIMIT MAX. 1.0/ BETWEEN CYLINDERS

COMPRESSION PRESSURE TEST


PROCEDURE
6. IF A CYLINDER PRESSURE OR PRESSURE DIFFERENTIAL IS BELOW SPECIFICATION, ADD A SMALL AMOUNT ENGINE OIL THROUGH SPARK PLUG HOLE. IF THE ADDITION OF OIL BRINGS THE COMPRESSION UP
SUSPECTED ITEMS : WORN CYLINDER AND PISTON RINGS, PISTON OR RING BROKEN

IF SAME COMPRESSION PRESSURE AFTER ADDING OIL


SUSPECTED ITEMS : VALVE, VALVE SPRING, VALVE SEAT, CYLINDER HEAD GASKET

IGNITION TIMING
PURPOSE
The fuel system and ignition system should be correctly functioning for the engine to run smoothly. Hence, proper operation of the fuel system and ignition system must be determined prior to troubleshooting. Therefore, the purpose of ignition timing is to check if the ignition system is operating properly.

IGNITION TIMING
CHECK CONDITION - WARMING UP TEMPERATURE - ALL ELECTRICAL LOADS OFF - A/T : "P" OR "N" - IDLE RPM IS NORMAL CHECK PROCEDURE 1. INSTALL A TIMING LIGHT 2. GROUND THE IGNITION TIMING ADJUST TERMINAL 3. CHECK THE IGNITION TIMING THROUGH TIMING LIGHT

IGNITION TIMING
4. ADJUST THE IGNITION TIMING IF THE IGNITION TIMING IS OUT OF SPECIFICATION 5. IF THE TIMING CAN NOT BE ADJUSTED(some of engine ignition timing can not be adjusted), PLEASE CHECK THE RELEVANT COMPONENT

IGNITION TIMING

NOTICE !

DO NOT USE THE SCAN TOOL TO CHECK THE IGNITION TIMING . THE IGNITION TIMING SHOWN IN CURRENT DATA ON THE SCAN TOOL IS NOT ACTUAL IGNITION TIMING BUT IT IS ELECTRICAL TIMING .

IDLE SPEED ADJUSTMENT


PURPOSE
The engine running condition must be checked at the initial stage of troubleshooting. During idle state, the RPM and torque is low and the reaction of the engine may be easily seen. Also, basic idle RPM may be checked and adjusted during idle and various information regarding the effects of a problem can be obtained.

IDLE SPEED ADJUSTMENT


CHECK CONDITION

WARMING UP TEMPERATURE ALL ELECTRICAL LOADS OFF A/T : "P" OR "N" IGNITION TIMING IS NORMAL

CHECK PROCEDURE
1. LOOSEN THE ACCELERATOR CABLE 2. INSTALL THE SCAN TOOL TO THE DATA LINK CONNECTOR

IDLE SPEED ADJUSTMENT


CHECK PROCEDURE
** DC MOTOR TYPE **
3. TURN THE IGNITION SWITCH ON(DO NOT START) AND LEAVE IT IN THAT POSITION FOR 15 SECONDS OR LONGER. 4. TURN THE IGNITION SWITCH OFF AND DISCONNECT THE ISC MOTOR CONNECTOR

CHECK PROCEDURE
** STEP MOTOR TYPE ** 3. IF THE SCAN TOOL IS NOT USED, CONNECT A TACHOMETER, 4. GROUND THE NO. 15 PIN OF THE 16 PIN DATA LINK CONNECTOR(NO. 10 PIN OF THE 12 PIN CONNECTOR)

DATA LINK CONNECTOR

12 PIN CONNECTOR
5 4 3 2 1 12 11 10 9 8 7 6

16 PIN CONNECTOR
1 2 3 4 5 6 7 8 9 10 11 1213 14 15 16

IDLE SPEED ADJUSTMENT


CHECK PROCEDURE
5. GROUND THE IGNITION TIMING ADJUSTMENT TERMINAL 6. START THE ENGINE 7. CHECK THE IDLE RPM

IDLE SPEED ADJUSTMENT


CHECK PROCEDURE
8. IF THE BASIC IDLE SPEED IS OUT OF SPECIFICATION, ADJUST THE IDLE SPEED BY USING THE IDLE SPEED ADJUSTING SCREW AFTER CHECK ING IGNITION TIMING AND CARBON BUILD UP. IDLE RPM CANNOT BE ADJUSTED MANUALLY IN THE SOME OF ENGINES. THEREFORE, IF THERE IS A PROBLEM IN RPM, ACQUISITION COMPONENTS SHOULD BE CHECKED.

THROTTLE POSITION SENSOR


PURPOSE
The Throttle Position Sensor(TPS) senses the throttle position and has a significant influence on the ignition timing and RPM. The corresponding output voltage of the throttle position must be checked and adjusted accordingly.

THROTTLE POSITION SENSOR


CHECK PROCEDURE-EXCEPT IDLE SWITCH INTEGRATED TYPE
APPLICABLE VEHICLE : EXCEL, ELANTRA(95MY), SONATA(EXCEPT V6) 1. CONNECT SCAN TOOL TO THE DATA LINK CONNECTOR 2. TURN THE IGNITION SWITCH TO THE ON POSITION (DO NOT START) AND CHECK THAT THE TP SENSOR OUTPUT VOLTAGE IS 480mV - 520mV

THROTTLE POSITION SENSOR


CHECK PROCEDURE-EXCEPT IDLE SWITCH INTEGRATED TYPE
3. IF IT IS OUT OF SPECIFICATION, MAKE CORRECT ADJUSTMENT.

THROTTLE POSITION SENSOR


CHECK PROCEDURE-IDLE SWITCH INTEGRATED TYPE
1. CONNECT THE SCAN TOOL 2. CHECK CURRENT DATA WHILE THE THROTTLE LEVER OPERATION 3. THE THROTTLE POSITION SENSOR DATA SHOULD BE INSIDE OF SPECIFICATION WHEN THE IDLE SWITCH IS ON 4. IF NOT, ADJUST IDLE SWITCH FIRST. CHECK THE CURRENT DATA OF THROTTLE POSITION SENSOR 5. IF THE CURRENT DATA IN NOT WITHIN THE SPECIFICATION AFTER ADJUSTMENT OF IDLE SWITCH. REPLACE THROTTLE POSITION SENSOR

FUEL PRESSURE TEST


PURPOSE
A correctly functioning fuel system is essential for the engine to run smoothly. The fuel pressure test may be used to determine the conditions of fuel pipe, fuel hose, fuel filter, fuel pressure regulator, fuel pump and return hose.

FUEL PRESSURE TEST


CHECK PROCEDURE
1. REDUCE THE INTERNAL PRESSURE OF THE FUEL PIPES AND HOSES (DISCONNECT THE FUEL PUMP CONNECTOR START THE
ENGINE AND TURN THE IGNITION SWITCH "OFF" AFTER IT STOPS BY ITSELF CONNECT THE FUEL PUMP CONNECTOR)

2. INSTALL A FUEL PRESSURE GAUGE AND A FUEL PRESSURE GAUGE ADAPTER

FUEL PRESSURE TEST


CHECK PROCEDURE
3. START THE ENGINE AND CHECK THAT THERE IS NO FUEL LEAKAGE 4. DISCONNECT THE VACUUM HOSE FROM THE PRESSURE REGULATOR AND PLUG THE HOSE END. MEASURE THE FUEL PRESSURE 5. MEASURE THE FUEL PRESSURE WHEN THE VACUUM HOSE IS CONNECTED TO THE PRESSURE REGULATOR

FUEL PRESSURE TEST


SUSPECTED ITEMS

FUEL PRESSURE TOO LOW FUEL FILTER, FUEL PRESSURE REGULATOR, FUEL PUMP

FUEL PRESSURE TOO HIGH FUEL PRESSURE REGULATOR, RETURN HOSE OR PIPE

FUEL PRESSURE DROPS SLOWLY AFTER ENGINE HAS STOPPED INJECTOR LEAKAGE

FUEL PRESSURE DROPS IMMEDIATELY AFTER ENGINE HAS STOPPED CHECK VALVE OF THE FUEL PUMP

VALVE CLEARANCE ADJUSTMENT


MECHANICAL LASH ADJUSTER

Shim Tappet

VALVE CLEARANCE ADJUSTMENT


VALVE CLEARANCE CAN BE ADJUSTED BY SHIM. PROCEDURE 1. SET NO1 CYLINDER TO TDC COMPRESSION 2. CHECK TDC POSITION OF CAMSHAFT 3. MEASURE THE CLEARENCE FOR #1 INTAKE VALVE, EXHAUST VALVE #2 INTAKE VALVE, #3 EXHAUST VALVE 4. TURN THE CRANK SHAFT ONE REVOLUTION 5. MEASURE THE CLEARENCE FOR #2 EXHAUST VALVE, #3 INTAKE VALVE #4 INTAKE VALVE, EXHAUST VALVE

VALVE CLEARANCE ADJUSTMENT


6. IF THE VALVE CLEARENCE IS NOT WITHIN THE SPECIFICATION, REPLACE THE ADJUSTING SHIM SPECIFICATION (20C) INTAKE 0.12 ~ 0.28mm EXHAUST 0.2 ~ 0.36mm USE SPECIAL TOOLS TO REPLACE ADJUSTING SHIM 7. SEE THE ADJUSTING SHIM SELECTION CHART

VALVE CLEARANCE ADJUSTMENT

SHIM SHIM SELECTION SELECTION CHART CHART FOR FOR INTAKE INTAKE VALVE VALVE

SHIM SHIM SELECTION SELECTION CHART CHART FOR FOR EXHAUST EXHAUST VALVE VALVE

TIMING BELT ALIGNMENT


PURPOSE
The function of the timing belt is to mechanically connect the crankshaft and camshaft so the action of the valves(opening and closing) becomes dictated by piston movement. Note : If the timing belt of SIRIUS DOHC becomes misaligned or cut, damage may occur in the cylinder head or the valves.

TIMING BELT ALIGNMENT


PURPOSE
The function of the timing belt is to mechanically connect the crankshaft and camshaft so the action of the valves(opening and closing) becomes dictated by piston movement. Note : If the timing belt of SIRIUS DOHC becomes misaligned or cut, damage may occur in the cylinder head or the valves.

TIMING BELT ALIGNMENT


EXCEL, ELANTRA 1.5L, SCOUPE, ACCENT 1.5L & 1.3L, ATOS

TENSION

TIMING BELT ALIGNMENT


ALPHA DOHC ENGINE - ACCENT 1.5 DOHC

CAMSHAFT CAP MARK CAMSHAFT SPROCKET

TIMING BELT ALIGNMENT


BETA ENGINE - ELANTRA(96MY)

CYL. HEAD

CAMSHAFT CAP MARK CAMSHAFT SPROCKET

TENTIONER

TIMING CHAIN

TIMING BELT ALIGNMENT


SONATA DOHC

Check the balance shaft position

TIMING BELT ALIGNMENT


SONATA SOHC

Check the balance shaft position

TIMING BELT ALIGNMENT


SONATA SOHC

Timing belt B

TIMING BELT ALIGNMENT


EF SONATA 2.5L

Tensioner Pulley

Idler Pulley

TIMING BELT ALIGNMENT


XG 3.0L

TIMING BELT ALIGNMENT


SONATA(Y-3) V6

260-380N(57-84lbs)

TIMING BELT ALIGNMENT OMEGA 4.5


1. Align the camshaft timing mark on camshaft cap timing mark

TIMING BELT ALIGNMENT OMEGA 4.5


2. Align the sprocket timing mark and camshaft timing mark

.. .

...

TIMING BELT ALIGNMENT OMEGA 4.5


3. Align timing mark between sprocket and head(Left bank)

TIMING BELT ALIGNMENT OMEGA 4.5


4. Align timing mark between sprocket and head(Right bank)

TIMING BELT ALIGNMENT OMEGA 4.5


5. Align timing mark between crankshaft sprocket and front case

TIMING BELT ALIGNMENT OMEGA 4.5


6. Install the timing belt as following order Check the timing mark after 8 rotation of crankshaft

TIMING BELT ALIGNMENT OMEGA 4.5


Checking the timing mark on the vehicle

TIMING BELT ALIGNMENT OMEGA 4.5


Checking the timing mark on the vehicle

You might also like