Unit 1 : Diagnosis of Engine & its components

Diagnosing Engine Cylinder Head Issues

A cylinder head is a critical component of an internal combustion engine,

responsible for sealing the combustion chamber and directing the flow of coolant
and exhaust gases. When a cylinder head malfunctions, it can lead to a variety of
engine problems. Here's a step-by-step procedure for diagnosing issues with an
engine cylinder head:

1. Observe for Symptoms:

 Loss of power: If the engine is producing less power than usual, it could be
due to a faulty cylinder head.
 Overheating: A warped or cracked cylinder head can prevent the coolant
from circulating properly, leading to overheating.
 Coolant leaks: If coolant is leaking from the cylinder head gasket or the
head itself, it's a strong indication of a problem.
 Rough idle or misfires: A damaged cylinder head can cause uneven
combustion, resulting in a rough idle or misfires.
 Exhaust smoke: Excessive white or blue smoke can be a sign of a blown
head gasket or other cylinder head issues.

2. Inspect for Physical Damage:

 Visual inspection: Check for obvious signs of damage, such as cracks,

warping, or corrosion.
 Pressure test: Use a pressure tester to check for leaks around the cylinder
head gasket and valves.

3. Perform a Compression Test:

  A compression test measures the pressure in each cylinder. If one or more
cylinders have low compression, it could be due to a faulty cylinder head
gasket or valve.

4. Check for Coolant Contamination:

 If coolant is mixing with engine oil, it's a strong indication of a blown head
gasket.

5. Use a Leak Detector:

 A leak detector can help pinpoint the source of a coolant leak.

6. Consider a Cylinder Head Inspection:

 If the above steps don't reveal the cause of the problem, a professional
mechanic can inspect the cylinder head for hidden damage.

Diagnosing Engine Cylinder Head Issues

The diagnosis of an engine cylinder head involves a combination of visual

inspection, compression testing, leak down testing, and in some cases, a cylinder
head removal and inspection. Here's a detailed procedure:

Visual Inspection:

1. External Inspection:
o Look for any obvious signs of damage, such as cracks, warps, or
corrosion.
o Check for leaks around the head gasket, intake manifold, and exhaust
manifold.
o Inspect the spark plug threads for signs of damage or fouling.
2. Internal Inspection:
 o Remove the spark plugs and inspect the combustion chambers for
signs of pre-ignition, detonation, or carbon buildup.
o Check the piston tops and valves for damage or wear.
o Look for any signs of water or coolant in the combustion chambers.

Compression Test:

1. Remove Spark Plugs: Remove the spark plugs from all cylinders.
2. Connect Compression Tester: Attach the compression tester to each
cylinder's spark plug hole.
3. Crank Engine: Crank the engine for a specified number of revolutions
(usually 5-10) and record the compression readings for each cylinder.
4. Compare Readings: Compare the compression readings between cylinders.
A significant difference in readings may indicate a problem with the cylinder
head, such as a warped head or a leaking valve.

Leak down Test:

1. Remove Spark Plugs: Remove the spark plugs from all cylinders.
2. Connect Leak down Tester: Attach the leak down tester to each cylinder's
spark plug hole.
3. Pressurize Cylinder: Introduce compressed air into the cylinder through the
leak down tester.
4. Listen for Leaks: Listen for escaping air around the spark plug hole, intake
manifold, exhaust manifold, or cylinder head gasket.
5. Check for Movement: Observe the piston for movement. If the piston
moves excessively, it may indicate a problem with the head gasket or valves.

Diagnosing a Cylinder Block

A cylinder block is the foundation of an engine, housing the cylinders, pistons, and
connecting rods. Diagnosing issues with a cylinder block often involves a
combination of visual inspection, compression testing, and leak down testing.

Visual Inspection

 External Inspection: Look for cracks, warps, or corrosion on the block's

exterior. Check for leaks around the head gasket, oil pan, and water pump.
 Internal Inspection: If the block is disassembled, examine the cylinder bores
for scoring, wear, or other damage. Check the crankshaft for bearing wear,
cracks, or bends.
Compression Test

 Remove Spark Plugs: Remove the spark plugs from each cylinder.
 Attach Compression Tester: Connect a compression tester to each spark
plug hole.
 Crank Engine: Crank the engine and record the compression readings for
each cylinder.
 Compare Readings: Compare the readings. A significant difference in
compression between cylinders may indicate a problem with the block, such
as a warped head or a damaged piston.

Leak down Test

 Attach Leak down Tester: Connect a leak down tester to each spark plug
hole.
 Pressurize Cylinder: Introduce compressed air into the cylinder.
 Listen for Leaks: Listen for escaping air around the spark plug hole, intake
manifold, exhaust manifold, or head gasket.
 Check for Movement: Observe the piston for movement. Excessive
movement may indicate a problem with the block or head gasket.

Other Tests

 Cylinder Bore Measurement: Use a bore gauge to measure the cylinder bore
diameter. Excessive wear or taper can indicate block damage.
 Crankshaft Run out: Measure the crankshaft's run out to ensure it is within
specifications. Excessive run out can cause premature bearing wear.
 Oil Pressure Test: Check the oil pressure to ensure it is within the
manufacturer's specifications. Low oil pressure can indicate a problem with
the block or oil pump.

Note: If you suspect a problem with your cylinder block, it is recommended to

consult with a professional mechanic for a proper diagnosis and repair.
Diagnosing a Connecting Rod

A connecting rod is a crucial component in an internal combustion engine,

connecting the piston to the crankshaft. Here are some common methods used to
diagnose issues with a connecting rod:

Visual Inspection

 External Inspection: Look for cracks, bends, or other damage on the rod's
surface. Check for wear on the bearing surfaces.
 Internal Inspection: If the rod is disassembled, examine the bearing surfaces
for scoring, pitting, or excessive wear.

Dimensional Measurement

 Length Measurement: Measure the length of the rod to ensure it meets the
manufacturer's specifications. A bent or stretched rod can cause uneven wear
and engine damage.
 Bearing Clearance: Check the clearance between the bearing and the
crankshaft journal. Excessive clearance can lead to excessive noise and
vibration.

Dynamic Testing

 Vibration Analysis: Use vibration analysis equipment to detect abnormal

vibrations that may indicate a problem with the connecting rod or other
engine components.
 Noise Analysis: Listen for unusual noises, such as knocking or rattling, that
may be indicative of a connecting rod issue.

Compression Test

 Compression Test: A drop in compression in a specific cylinder can be a sign

of a connecting rod problem, such as a bent rod or a damaged bearing.
Oil Analysis

 Metal Debris: Analyze the engine oil for metal debris, which can indicate
wear on the connecting rod or other engine components.

Endoscope Inspection

 Internal Inspection: Use an endoscope to inspect the inside of the engine and
look for damage to the connecting rod or other components.

Diagnosing a Connecting Rod

A connecting rod is a crucial component in an internal combustion engine,

connecting the piston to the crankshaft. Diagnosing issues with a connecting rod
often involves a combination of visual inspection and dimensional checks.

Visual Inspection

 External Inspection: Look for cracks, bends, or other damage on the rod's
surface. Check for wear or pitting on the bearing surfaces.
 Internal Inspection: If the rod is disassembled, inspect the bearing surfaces
for excessive wear or scoring. Check the small end (piston end) for damage
or excessive clearance.

Dimensional Checks

 Length Measurement: Measure the overall length of the connecting rod to

ensure it is within specifications. Excessive wear or damage can cause the
rod to lengthen.
 Bearing Clearance: Check the clearance between the bearing and the
crankshaft journal. Excessive clearance can lead to premature wear and
engine noise.
  Small End Clearance: Measure the clearance between the piston pin and the
small end of the connecting rod. Excessive clearance can cause piston slap
and engine noise.

Other Tests

 Hardness Test: In some cases, a hardness test may be performed to ensure

the connecting rod material meets the required specifications.
 Dynamic Balancing: If the connecting rod is suspected of causing engine
vibration, it can be dynamically balanced to ensure it is within
specifications.

Note: If you suspect a problem with your connecting rod, it is recommended to

consult with a professional mechanic for a proper diagnosis and repair.

Diagnosing a Crankshaft

A crankshaft is a critical component in an internal combustion engine, converting

the linear motion of the pistons into rotational motion. Diagnosing issues with a
crankshaft often involves a combination of visual inspection, dimensional checks,
and dynamic balancing.

Visual Inspection

 External Inspection: Look for cracks, bends, or other damage on the

crankshaft's surface. Check for wear or pitting on the journal surfaces.
 Internal Inspection: If the crankshaft is disassembled, inspect the bearing
surfaces for excessive wear or scoring. Check for damage to the keyway or
oil holes.

Dimensional Checks
  Journal Diameter: Measure the diameter of the crankshaft journals to ensure
they are within specifications. Excessive wear can cause the journals to
become undersized.
 Run out: Measure the run out of the crankshaft to ensure it is within
specifications. Excessive run out can cause premature bearing wear and
vibration.
 Twist: Check for crankshaft twist, which can occur due to excessive torque or
damage. Twist can cause misalignment of the pistons and connecting rods.

Dynamic Balancing

 Balance Testing: If the crankshaft is suspected of causing engine vibration, it

can be dynamically balanced to ensure it is within specifications. Dynamic
balancing involves adding or removing weight to the crankshaft to correct
any imbalances.

Other Tests

 Hardness Test: In some cases, a hardness test may be performed to ensure

the crankshaft material meets the required specifications.
 Magnetic Particle Inspection: This test can be used to detect subsurface
cracks in the crankshaft material.

Note: If you suspect a problem with your crankshaft, it is recommended to consult

with a professional mechanic for a proper diagnosis and repair.

Diagnosing a Piston

A piston is a crucial component in an internal combustion engine, converting the

pressure of the combustion process into mechanical energy. Diagnosing issues with
a piston often involves a combination of visual inspection, dimensional checks, and
performance testing.
Visual Inspection

 External Inspection: Look for cracks, scuffs, or other damage on the piston's
skirt and crown. Check for wear or pitting on the piston rings.
 Internal Inspection: If the piston is disassembled, inspect the piston pin
holes for wear or damage. Check the connecting rod bearing surfaces for
wear or scoring.

Dimensional Checks

 Diameter: Measure the piston diameter to ensure it is within specifications.

Excessive wear can cause the piston to become undersized.
 Ring Gaps: Measure the gaps between the piston rings to ensure they are
within specifications. Excessive gaps can lead to blow by and reduced
engine performance.
 Piston Pin Clearance: Check the clearance between the piston pin and the
piston pin holes. Excessive clearance can cause piston slap and engine noise.

Performance Testing

 Compression Test: A compression test can help to identify problems with the
piston or rings. Low compression readings may indicate a problem with the
piston, rings, or valves.
 Leak down Test: A leak down test can help to identify problems with the
piston or rings. If air leaks past the piston rings, it can indicate wear or
damage.

Other Tests

 Piston Skirt Clearance: Check the clearance between the piston skirt and the
cylinder wall. Excessive clearance can cause piston slap and engine noise.
  Piston Pin Twist: Check for piston pin twist, which can occur due to
excessive wear or damage. Twist can cause misalignment of the piston and
connecting rod.

Basic Principles of Automotive Diagnostics

Automotive diagnostics is a systematic process used to identify and isolate

faults in vehicles. It involves a combination of technical knowledge, diagnostic
tools, and problem-solving skills. Here are the basic principles:

1. Gather Information:

 Vehicle History: Collect information about the vehicle's

mileage, maintenance history, and any recent modifications.
 Symptoms: Understand the specific symptoms the driver is
experiencing, such as engine noise, loss of power, or warning lights.
 Diagnostic Codes: Retrieve any fault codes stored in the vehicle's on-board
diagnostic (OBD) system.

2. Inspect Visually:

 External Inspection: Look for any visible signs of damage, leaks, or loose
connections.
 Internal Inspection: If necessary, access components under the hood,
beneath the vehicle, or inside the cabin to inspect for abnormalities.

3. Test Relevant Components:

 Diagnostic Tools: Use tools like code readers, multi meters, and
oscilloscopes to test specific components and measure their
performance.
 Functional Testing: Perform tests to assess the functionality of various
systems, such as the engine, transmission, brakes, and electrical components.
4. Analyze Data:

 Compare Readings: Compare test results with known specifications

or reference values.
 Identify Patterns: Look for patterns or correlations between
different symptoms or test results.

5. Isolate the Fault:

 Elimination Process: Use a systematic approach to eliminate

potential causes based on the gathered information and test results.
 Component Replacement: If necessary, replace suspected components to
confirm the cause of the problem.

6. Verify Repair:

 Retest: After making repairs, retest the vehicle to ensure the issue has
been resolved.
 Road Test: Conduct a road test to evaluate the vehicle's performance
under various driving conditions.

7. Document Findings:

 Record Information: Document all relevant information, including

symptoms, test results, and repairs made.
 Provide Recommendations: Offer recommendations for future
maintenance or repairs.

Various Key Diagnostic Tools:

 Code Readers: Used to retrieve and interpret fault codes stored in

the vehicle's OBD system.
 Multi meters : Used to measure voltage, current, and resistance in
electrical circuits.
  Oscilloscopes: Used to visualize electrical signals and identify problems
in electronic components.
 Scan Tools: Advanced diagnostic tools that can communicate with
various vehicle systems and perform complex tests.

Requirements for an Automotive Diagnostic System

An effective automotive diagnostic system should meet the following key

requirements:

Hardware Requirements:

 Code Reader: A device capable of communicating with the vehicle's on-

board diagnostic (OBD) system to retrieve and interpret fault codes.
 Multi meter: A tool used to measure voltage, current, and resistance
in electrical circuits.
 Oscilloscope: A device used to visualize electrical signals and
identify problems in electronic components.
 Scan Tool: A more advanced diagnostic tool that can communicate
with various vehicle systems and perform complex tests.
 Laptop or Computer: A device for running diagnostic software and
analyzing data.
 Diagnostic Cables: Cables that connect the diagnostic tools to the
vehicle's OBD port.

Software Requirements:

 Diagnostic Software: Specialized software that can interpret fault

codes, access vehicle data, and perform various diagnostic functions.
 Technical Service Bulletins (TSBs): A database of information on known
vehicle issues and recommended solutions.
  Wiring Diagrams: Diagrams that show the electrical connections
and components in the vehicle.

Technical Knowledge:

 Automotive Mechanics: A solid understanding of vehicle

systems, components, and operation.
 Electrical Systems: Knowledge of electrical circuits, components,
and troubleshooting techniques.
 Diagnostic Procedures: Familiarity with diagnostic procedures
and troubleshooting methods.
 Vehicle-Specific Information: Knowledge of the specific vehicle
models and systems being diagnosed.

Additional Requirements:

 Access to Repair Information: Access to repair manuals, service bulletins,

and other technical documentation.
 Regular Updates: Regular updates to diagnostic software and
technical information to keep up with changes in vehicle technology.
 Safety Measures: Adherence to safety procedures and precautions when
working on vehicles.

Applications of Automotive Diagnostic Systems

Automotive diagnostic systems have become indispensable in the modern

automotive industry, serving a wide range of applications. Here are some of the
key applications:

1. Fault Code Diagnosis:

  Identifying Issues: Pinpointing specific problems within the vehicle's
systems based on fault codes stored in the on-board diagnostic (OBD)
system.
 Reducing Repair Time: Streamlining the troubleshooting process by
providing targeted information.

2. Performance Monitoring:

 Tracking Vehicle Health: Monitoring key performance indicators like

engine temperature, fuel consumption, and emissions.
 Identifying Potential Problems: Detecting early signs of issues before they
escalate into major repairs.

3. Emission Testing:

 Ensuring Compliance: Verifying that the vehicle's emissions meet

regulatory standards.
 Identifying Emissions Issues: Diagnosing problems that contribute to
excessive emissions.

4. Maintenance Scheduling:

 Predictive Maintenance: Predicting when maintenance tasks need to be

performed based on vehicle usage and data analysis.
 Optimizing Costs: Reducing unexpected breakdowns and associated costs.

5. Research and Development:

 Testing New Technologies: Evaluating the performance and reliability of

new automotive technologies.
 Improving Vehicle Design: Gathering data to inform future vehicle design
and development.
6. Security and Theft Prevention:

 Vehicle Immobilizers: Implementing security features to prevent

unauthorized access.
 Tracking Stolen Vehicles: Assisting in locating stolen vehicles using GPS
tracking technology.

7. Remote Diagnostics:

 Over-the-Air Updates: Providing software updates and diagnostic

information remotely.
 Reducing Downtime: Enabling technicians to diagnose and address issues
without the vehicle physically present.

8. Customer Service:

 Improving Customer Satisfaction: Providing customers with information

about their vehicle's health and maintenance needs.
 Building Trust: Enhancing the customer experience through transparent
and informative communication.

Types of Automotive Diagnosis - Manual Methods.

Automotive diagnostic manual methods are traditional techniques used to identify

and troubleshoot problems in vehicles. They rely on the mechanic's knowledge,
experience, and the use of specialized tools. Here are some common types:

1. Visual Inspection:

 External Examination: Inspecting the vehicle for visible signs of

damage, leaks, or loose connections.
 Internal Examination: Examining components under the hood, beneath the
vehicle, or inside the cabin.
2. Listening and Feeling:

 Audible Cues: Listening for unusual noises, such as grinding, squealing, or

knocking.
 Tactile Feedback: Feeling for vibrations, overheating, or other abnormal
sensations.

3. Test Drives:

 Reproducing Symptoms: Driving the vehicle under various conditions to

replicate the reported symptoms.
 Observing Behavior: Monitoring the vehicle's performance and
identifying any deviations from normal operation.

4. Component Testing:

 Using Specialized Tools: Employing tools like multi meters, pressure

gauges, and thermometers to test specific components.
 Functional Tests: Performing tests to assess the functionality of various
systems, such as the engine, transmission, brakes, and electrical components.

5. Diagnostic Charts and Flowcharts:

 Guided Troubleshooting: Following step-by-step procedures outlined in

diagnostic charts or flowcharts.
 Narrowing Down Possibilities: Using these guides to eliminate
potential causes and isolate the root problem.

6. Technical Manuals and Service Bulletins:

 Reference Materials: Consulting manuals and bulletins for information on

specific vehicle models, components, and diagnostic procedures.
 Troubleshooting Guidance: Finding detailed instructions and
troubleshooting tips.
7. Experience and Knowledge:

 Intuitive Diagnosis: Relying on a mechanic's experience and knowledge

to identify and solve problems based on past experience.
 Pattern Recognition: Recognizing patterns in symptoms and relating
them to known issues.

Types of Automotive Diagnostic OBD Methods

OBD (On-Board Diagnostics) is a standardized system used to monitor a vehicle's performance

and detect potential problems. It allows for the retrieval and interpretation of diagnostic trouble
codes (DTCs) stored in the vehicle's computer. Here are the primary types of OBD diagnostic
methods:

1. Code Reading:

 Retrieving DTCs: Using an OBD code reader to access and read the stored DTCs.
 Interpreting Codes: Referencing a DTC lookup table or diagnostic software to
understand the meaning of the codes.
 Identifying Potential Issues: Pinpointing specific problems based on the codes and their
descriptions.

2. Data Stream Analysis:

 Monitoring Real-Time Data: Using an OBD reader or diagnostic software to monitor

real-time data from various vehicle sensors.
 Identifying Anomalies: Comparing sensor readings to expected values and identifying
any deviations or inconsistencies.
 Diagnosing Performance Issues: Analyzing data to diagnose problems related to engine
performance, fuel consumption, emissions, and other systems.

3. Freeze Frame Data:

 Capturing Conditions: Accessing freeze frame data that records vehicle conditions at
the time a DTC was set.
  Understanding Context: Using freeze frame data to gain insights into the circumstances
that led to the problem.
 Aiding Troubleshooting: Providing additional information to help isolate the root cause
of the issue.

4. Live Data Monitoring:

 Observing Vehicle Functions: Watching real-time sensor data to monitor vehicle

functions and identify any abnormalities.
 Diagnosing Dynamic Issues: Detecting problems that may only occur under specific
driving conditions.
 Assessing Component Performance: Evaluating the performance of individual
components and systems.

5. Actuator Testing:

 Controlling Components: Using diagnostic software to command specific components

(actuators) to perform actions.
 Verifying Functionality: Observing the response of the components to ensure they are
working correctly.
 Identifying Faulty Components: Identifying components that are not responding as
expected.

6. Specific Tests:

 Manufacturer-Specific Tests: Performing tests that are specific to a particular vehicle

make and model.
 Specialized Software: Using manufacturer-specific diagnostic software to access
additional features and functions.
 Addressing Vehicle-Specific Issues: Troubleshooting problems that are unique to
certain vehicles.
 Car trouble shooting chart

Symptom Possible Causes Troubleshooting Steps

Dead battery, faulty starter, fuel problems, Check battery voltage, test starter, inspect fuel
Engine Won't Start ignition issues system, check ignition components
Engine Stalls or Fuel delivery problems, ignition problems, Check fuel pressure, inspect spark plugs and wires,
Misfires sensor issues, vacuum leaks test sensors, check for vacuum leaks
Low coolant level, coolant leak, Check coolant level, inspect for leaks, test
thermostat failure, radiator problems, thermostat, inspect radiator and hoses, check water
Engine Overheats water pump failure pump
Engine Knocking or Pre-ignition, detonation, low octane fuel, Use higher octane fuel, clean carbon deposits, check
Pinging carbon buildup ignition timing, inspect engine for mechanical issues
Transmission issues, clutch problems, Check transmission fluid level, inspect clutch, check
Car Won't Shift linkage problems linkage for damage
Brakes Squeak or Worn brake pads or shoes, warped rotors Replace brake pads or shoes, resurface rotors or
Grind or drums, caliper problems drums, inspect calipers
Steering Wheel Unbalanced wheels, worn tires, Balance wheels, replace tires, inspect suspension
Vibrates suspension problems components
Check Engine Light Sensor issues, emissions problems, engine Use a code reader to retrieve DTCs, test sensors,
On performance issues inspect exhaust system
Loose parts, worn components, bearing Inspect components for damage, replace worn parts,
Weird Noises problems check bearings
Parasitic drain, faulty alternator, faulty Use a multi meter to check for parasitic drain, test
Battery Draining battery alternator, test battery