BASIC COMPETENCIES

o Receive and respond to workplace communication

o Work with others
o Demonstrate work values
o Practice basic housekeeping procedures

    COMMON COMPETENCIES

o Apply appropriate sealant/adhesive

o Move and position vehicle
o Perform mensuration and calculation
o Read, interpret and apply specifications manuals
o Use and apply lubricants/coolants
o Perform shop maintenance
o Perform job estimates
o Interpret/draw technical drawing
o Practice health, safety and environment procedures
o Inspect technical quality of work
o Maintain quality systems
o Provide work skill instructions
o Identify and select original automotive parts and products

            CORE COMPETENCIES

 Perform diesel engine tune up

o Perform gas engine tune up
o Remove and replace electrical/electronic units/assemblies
o Remove and tag engine system components
o Remove and tag automotive steering, suspension and brake
system components
o Remove and tag transmission system components

Engine Tune up Procedure-gasoline

1. 1. Engine Tune-Up Procedure (121-125)
2. 2.  INTRODUCTION : WHAT DO YOU MEAN BY ENGINETUNE-UP?- The tune-up is a
routine maintenance operation which is essential for the efficient & economical operation , as
well as for long life of yours cars engine.- INTERVAL BETWEEN ENGINETUNE-UP.- The
interval between engine tune up should be after completion of 30,000miles (48,309km).
3. 3. • NECESSARY TOOLS:1). Service manual2). Feeler gauge3) Safety glasses & goggles4).
Spark plug socket & ratchet5). Spark plug gauge6). Oil , Oil filter & Oil pan7). Screwdrivers
 4. 4. 1.Loose spark plug, start engine shut of engine &remove spark pug.2.Test engine
compression.3..Check the compression ratio.
5. 5. 4.Check battery cables for damage ,corrosion &loose connection .5.Check intake manifold
bolts for tightness to proper specification.Even a slight leak will reduce engine
performance.6.Check & adjust acclerator linkages.7.Check intake manifold and air inject
system.8.Check steering system for looseness and ease of action.9.Ceck suspension
system and shock absorber for excessive
6. 6. PROBLEMS WHICH ARE TO BECHECK IN “ENGINE TUNING” UP PROCESS
7. 7. *.CRANK SHAFT THUMPING Metallic, heavy & dull knocks which increase in
frequency.Causeses-1.Excessive main bearing clearance.2.Excessive crankshaft axial
play.3.Crankshaft out of balance.4.Low oil pressure.5.Loose fly wheel.
8. 8. *.CONNECTING ROD NOISE. 1.Excessive big end bearing clearance. 2.Insufficient
lubrication. 3.Low oil pressure. 4.Misaligned connecting rod. 5.Ovalized crank pin.
9. 9. *PISTON NOISE. Oscillation of piston in barrel. More evident at low r.p.m. “ Noise may
be single out by pouring SAE 50.”*IF NOISE IS PERSISTING THEN REPLACE THE
PISTON.
10. 10. *PISTON PIN NOISE. Excessive clearance between pin and piston bore. Excessive
clearance between pin and bush. Bush loose in connecting rod small end.
11. 11. *VALVE & TAPPET NOISE. Excessive tappet clearance. Broken valve spring .
Excessive wear of one or more cams on camshaft .
12. 12. *ENGINE VIBRATIONS. Defective ignition. Defective lubrication. Crankshaft out of
balance. Clutch out of balance. Conn-rods & piston are out of weight. Too stiff engine
support.
13. 13. Engine Tune up Checklist1. Fuel Filter2. Spark plugs3. Car manual4. Air Filter5.
Distributor Cap6. Spark plug Gapping tool
14. 14. 1.Air Filter 2.Fuel Filter 3.Fluids 4.Distributor Cap
15. 15. Air Filter Specifications
16. 16. Spark Plug Defects : Deposits Insulator Breakage Melting Carbon deposites
17. 17. The correct colours for the tip and insulator Grayish or brown= properly burning. Black
or wet= not firing or engine problem.
18. 18. Spark plug replacement Most new engines do not require spark plug replacement for up
to (100,000 miles)
19. 19. Types of Spark plugs
20. 20. Tune-up safety rules to follow : Wear eye protection. Set parking break . Place vent
hose on exhaust pipe. Disconnect battery.
21. 21. Tuning Up a Jeep Engine(Sequence)
22. 22. Clean and Check Battery Electrolyte level Specific Gravity Battery terminals and
cable connectors Tightness of terminal screws Tightness of negative ground cable
connection Replacing with new one.

Presentation Transcript

1. Engine Tune-Up By Jonathan Rollins

2. Tune – Up Procedures are done as part of a routine maintenance rather than to
correct a drivability problem.
3. Wear safety glasses!
4. Spark plug replacement Most new engines do not require spark plug replacement for up
to (100,000 miles)
5. Normal service and replacement items in a minor tune-up are… Perform a visual
inspection for obvious problems Check for trouble codes on computer controlled vehicles
Replace spark plugs Service the ignition system, including checking secondary components
Replacing the air and fuel filter Changing oil and lubricating the chassis Testing and servicing
emission control system, and resetting the reminder circuit Adjusting the fuel system if
applicable Cleaning the throttle body and idle air bypass on fuel injected engines Road testing
before and after tune-up to check engine performance

6. Service and replacement items in a major tune-up are… Perform a scope analysis of

engine system Testing and replacing spark plug wires Testing and replacing fuel pump
Replacing drive belts Replacing brake, transmission, and other fluids Replacing or rebuilding
the throttle body Rebuilding or replacing the distributer Adjusting the valve train (some
engines) Replacing weak sensors: oxygen sensor, cam position sensor, crank shaft position
sensor, ect
7. Six of the diagnostic tools used during a tune-up are… scan tool, an exhaust gas
analyzer, a compression gauge, a multi meter, an oscilloscope, a vacuum gauge, and other
tools
8. Some performance factors affected by a tune-up are… Engine power acceleration
Fuel consumption Exhaust emissions Smoothness of engine operation Ease of starting
Engine service life
9. General Tune-Up Rules It is important to gather engine and vehicle performance info
before performing the tune-up because this gives you clues on what you need to investigate
or replace.
10. It is important to bring the engine up to full operating temperature prior to diagnosing
an operating condition because when the engine is cold you cannot obtain accurate test
results.
11. Its important to maintain a vehicles service records because if a problem occurs you
can check your record to correct the trouble.
12. Tune-up safety rules It is important for the battery to be disconnected before
maintenance so it does not accidentally crank the engine or electrical fire.
13. Tune-up safety rules to follow Wear eye protection Set parking break Place vent hose
on exhaust pipe Disconnect battery
14. Typical tune-up procedures Battery problems-dirty case top, corroded terminals, and
physical damage Air cleaner problems –clogged or contaminated filter, inoperative air flaps or
disconnected vacuum hoses. Belt problems- looseness, fraying, and slippage. Low fluid
levels- engine oil, brake fluid, power steering fluid, ect. Deteriorated hoses- hardened or
softened cooling system, fuel system, and vacuum hoses. Poor electrical connections-loose or
corroded connections : frayed, pinched, or burned wiring and terminals.
15. Three important steps in replacing spark-plug wires are… To remove the spark-plug,
first check that the spark-plug wires are numbered or located correctly in their clips. Grasping
the spark-plug wire boot, pull the wire off the plug. Twist the boot back and forth if it sticks
Ignition coils must be numbered before plugs can or located correctly in their clips. grasping
the spark-plug wire boot, pull the wire off the plug. Twist the boot back and forth if it sticks.
Ignition coils must be removed before plugs can be replaced. Be sure engine is cool before
 removing spark-plugs. Removing a spark-plug from a warm aluminum head can damage the
threads in the spark-plugs holes.
16. Tools used to remove spark-plugs Swivel ratchet, an extension, and a spark –plug
socket.
17. The correct colors for the tip and insulator  Grayish or brown= properly burning Black
or wet= not firing or engine problem
18. If the spark-plug wire is not put on the right cylinder spark-plug, the plug will not fire.
19. Oxygen sensors One and two wires need to be replaced at 50,000-60,000 miles Heated
three-wire oxygen sensors should be replaced at about 100,000 miles
20. Recommended procedures for replacing a sensor  Disconnect the negative battery
cable. then, separate the sensor from the wiring harness by unplugging the connector. Never
pull on the wires them selves, as damage may result.
21. Three primary adjustments performance during a tune-up Pick up coil air gap
adjustment Idle speed adjustment Ignition timing adjustment
22. Diesel engine tune-up Diesel engines require periodic maintenance similar to gasoline
engines but don’t have spark plugs to replace or an ignition system.
23. Typical service tasks performed during diesel engine maintenance intervals are
Replacing the air filter element Cleaning, draining, or replacing the fuel filters Adjusting engine
idle speed Adjusting accelerator and governor linkage Inspecting the engine and related
systems Adjusting valve and injector timing Changing engine oil and oil filter Servicing
emission control systems maintenance intervals are specific periods ( in miles or months ) for
component service.