ࡱ> gif BbjbjUU =x??:UUUUUiii8<ipy}nUUUs*UUS''ik@0ps,. . . U`p.  : AT 261 - Power Balancing and Compression Testing - Chapter 13 Name: _________________________________________ Group: ______________ Date: __________________________________________ (Power balancing will pinpoint a low or weak (missing) cylinder. This is done by comparing the RPM drop from one cylinder to against the other cylinders. Several operating parameters must be met to get accurate results. In order to pinpoint a weak or low cylinder you must either remove spark, or fuel from the cylinder. This narrows your search down and saves valuable time! It also verifies that the vehicle is not running at its full power. Items like the oxygen sensor and EGR valve must be disconnected. These items are computer controlled, and will skew your readings. The computer can compensate within time as short as 20 milliseconds of detecting the misfire (when you short out the cylinders). Disconnecting these items prevents the computer for correcting for the problems; in fact some customers never realize that their engine is not running properly! ( STATION 1 Power Balance (#1) Tools you will need: 2009 Ford Focus Infrared Pyrometer Noid Light Spark Tester Firing order and plug/coil pack schematic WARNING! High Voltage! Be caution while performing this lab. Ignition system voltages are approximately 25,000~50,000 volts DC. NEVER run an open (disconnected, ungrounded) ignition system! This will lead to damage to the vehicles ignition system! ( Warm up the engine to operating temperature (Typ 170~190 Deg F). Verify temperature by pointing infrared pyrometer at the water outlet (Thermostat housing). Run the vehicle at fast idle (2000 RPM). ( The (primary) Oxygen Sensor(s) must be disconnected. (This is already done for you) ( Unplug each injector one at a time, noting the DROP in RPM. Write down that number that the RPM drops to while fuel is removed from the cylinder Cyl 1Cyl 2Cyl 3Cyl 4RPM Q- The cylinder the least drop or no drop in RPM is the weak cylinder. The weak cylinder is ______________________ Check for spark with the spark tester on the weak cylinder, is their spark? ___________________ Check for injector power with the noid light. Is their power? ________________ (Instructors Signature _________________________________________________________________ ( STATION 2 Compression Testing (#2) Tools you will need: 2001 Acura 3.5 RL Compression Tester Tool Board Oil Squirt Bottle Mitchells On Demand Compression testing is a basic test of the engine's ability to seal and compress air in the combustion chamber. Generally speaking a difference of 10% indicates a problem in a cylinder. All cylinders must be checked against each other. Testing compression on just one cylinder is not a reliable way to test an engine. ( Look Up the following data in Mitchells On Demand for Specs. Compression Spec _______________________ Plug Torque ___________________________ ( Remove and LABEL plug wires and ALL spark plugs ( DISABLE the fuel system (either injectors or fuel pump). ( This prevents fires ( DISABLE or ground ignition coil to prevent damage. ( This prevents damage to the ignition system, and prevents getting shocked ( BLOCK OPEN throttle plates. ( This allows an unrestricted flow of air into the cylinders ( Install a battery charger. (This keeps the battery charged, and keeps the starting spinning at the same rate ( Install the compression gauge. ( CRANK engine 4 times (4 seconds) to get highest compression reading. (Measure the 1st puff (1st revolution of crank), then dry test the cylinders. After all the cylinders have been dry tested, add a small squirt of oil into each cylinder and then re-measure the compression of each cylinder. Typically a dry test is done first, then if a problem is found - a wet test. For the purposes of this lab, we are doing a wet test on all cylinders, needed or not. Compression Spec: _____________________ Cylinder No. 1st puff Dry ______1___________________________________________________________________________ ______2___________________________________________________________________________ ______3___________________________________________________________________________ ______4___________________________________________________________________________ ______5___________________________________________________________________________ ______6___________________________________________________________________________ ( Replace the plugs, and warm the vehicle up to normal operating temperature. Q- If the compression spec goes up after a wet test, this means that the ________________ , ______________ , or _________________________ are worn, and that the _______________ and the _________________ are in good condition. If it does NOT go up a significant amount then the ________________________ may be in question. - If two adjacent compression readings were low that would indicate a bad ____________________________. - A reading of zero or near zero would indicate a _____________________________. (Instructors Signature _________________________________________________________________ ( STATION 3 Power Balance (#3) Tools you will need: 2003 Ford Mustang Infrared Pyrometer 12 Volt Test Lamp DVOM with RPM pickup (Tachometer) Noid Light Spark Tester Firing order and plug/coil pack schematic WARNING! High Voltage! Be caution while performing this lab. Ignition system voltages are approximately 25,000~50,000 volts DC. NEVER run an open (disconnected, ungrounded) ignition system! This will lead to damage to the vehicles ignition system! ( Warm up the engine to operating temperature (Typ 170~190 Deg F). Verify temperature by pointing infrared pyrometer at the water outlet (Thermostat housing). Run the vehicle at fast idle (2000 RPM). ( The (primary) Oxygen Sensor(s) must be disconnected. (This is already done for you) ( Connect the tachometer to a spark plug wire. ( Unplug each injector one at a time, noting the DROP in RPM. Write down that number that the RPM drops to while it is shorted out. Cyl 1Cyl 2Cyl 3Cyl 4Cyl 5Cyl 4RPM ( The paperclip method of shorting out cylinders works as well (see demo) the best. Some (lame) techs short out each plug wire by just stabbing the test light into the spark plug wire. This is a bad idea since this makes a hole in the plug wire that can lead to corrosion or a short to ground form the ignition system. WARNING! Do NOT short a cylinder out for more than 10 seconds at a time! Doing so causes raw fuel to be "dumped" into the exhaust. Q- The cylinder the least drop or no drop in RPM is the weak cylinder. The weak cylinder is ______________________ Check for spark with the spark tester on the weak cylinder, is their spark? ___________________ Check for injector power with the noid light. Is their power? ________________ (Instructors Signature _________________________________________________________________ ( Important Note! It is a long-standing tradition that spark plugs never be removed on a hot engine with an aluminum cylinder head. This is because aluminum becomes much softer when it is hot, removing or installing spark plugs on a hot engine runs the risk of damaging the threads in the cylinder head. However, sometimes this practice is unavoidable as shop-time and flat-rate dictate. Spark plug torque is critical! (STATION 4 Compression Testing (#4) Tools you will need: 2001 Honda Accord Compression Tester Tool Board Oil Squirt Bottle Mitchells On Demand Compression testing is a basic test of the engine's ability to seal and compress air in the combustion chamber. Generally speaking a difference of 10% indicates a problem in a cylinder. All cylinders must be checked against each other. Testing compression on just one cylinder is not a good way to test an engine. ( Look Up the following data in Mitchells On Demand for Specs. Compression Spec _______________________ Plug Torque ___________________________ ( Remove and LABEL plug wires and ALL spark plugs ( DISABLE the fuel system (either injectors or fuel pump). ( This prevents fires ( DISABLE or ground ignition coil to prevent damage. ( This prevents damage to the ignition system, and prevents getting shocked ( BLOCK OPEN throttle plates. ( This allows an unrestricted flow of air into the cylinders ( Install a battery charger. (This keeps the battery charged, and keeps the starting spinning at the same rate ( Install the compression gauge. ( CRANK engine 4 times (4 seconds) to get highest compression reading. (Measure the 1st puff (1st revolution of crank), then dry test the cylinders. After all the cylinders have been dry tested, add a small squirt of oil into each cylinder and then re-measure the compression of each cylinder. Typically a dry test is done first, then if a problem is found - a wet test. For the purposes of this lab, we are doing a wet test on all cylinders, needed or not. Compression Spec: _____________________ Cylinder No. 1st puff Dry Wet ______1___________________________________________________________________________ ______2___________________________________________________________________________ ______3___________________________________________________________________________ ______4___________________________________________________________________________ Replace the plugs, and warm the vehicle up to normal operating temperature. ( STATION 5 Combustion Leak Testing and Inspection Tools you will need: Test Engine on Stand Combustion Leak Tester Combustion Leak testing is the last test step while trying to pinpoint an engine performance mechanical problem. Other tests like power balance and compression tests should be done first. Combustion leak testing would be preformed on a cylinder that failed either a wet test or a dry test. Here are some simple rules; Follow the directions with the tester; Bring the cylinder in question up to TDC using the whistle. The whistle will sound when the cylinder is at TDC. Remove the oil fill cap, dipstick, and radiator cap. Using the leak tester measure the percentage of leakage in the cylinder. Generally leakage of up to 20% is acceptable. However if it is lower than that listen for air escaping from the cylinder. If air is heard from the air intake, the intake valve is not sealing; If air is heard out of the exhaust, the exhaust valve is not sealing; If air is heard out of the oil fill cap, or dip-stick the rings, piston, or cylinder wall may be worn; If bubbles are seen out of the radiator coolant, a head gasket leak is present. Test the engine on the stand. And write the percentage of leakage below. Note any additional hissing sounds coming from any of the above sources. Engine 2008 Honda Accord This engine has misfire on cylinder number 2. Using the boroscope inspect all the cylinders for damage. Note your findings. Cylinder 1 - Notes: ______________________________________________________ Cylinder 2 - Notes: ______________________________________________________ Cylinder 3 - Notes: ______________________________________________________ Cylinder 4 - Notes: ______________________________________________________ Q- If air is heard from the air intake, the ______________________ is not sealing; If air is heard out of the _______________________, the exhaust valve is not sealing; If air is heard out of the _______________________, or dip-stick the rings, piston, or cylinder wall may be worn; If bubbles are seen out of the radiator coolant, a ________________________ is present. (Instructors Signature _________________________________________________________________ (STATION 6 Engine Diagnosis Tools you will need: Handout at the end of this lab. Describe Basic Meanings for the following "smoke colors"; 1. Engine Smoke is black (soot like) ________________________________________________________ 2. Engine Smoke is gray ____________________________________________________ 3. Engine Smoke is white __________________________________________________ And if the gray smoke happens; 4. When engine is started _______________________________________________________ 5. When engine is accelerated ___________________________________________________ 6. When engine is de-accelerated ___________________________________________________________ 7. An engine runs rough, what test should be done to pinpoint the cylinder? _______________________________ Scenario #1 - After doing that test - you remove the spark plugs. You find that Plug #1 is "washed clean". The car also was low on coolant, and had wisps of white smoke from the tail pipe once it was warmed up. 8. What is wrong with this car? ___________________________________________________________ Scenario #2 - After doing the above test - you remove the plugs. You find that #4 plug is soaked with oil. You check the oil and find it was low. The car also burned gray smoke while it was accelerated. 9. What test would be done next? _________________________________________________________ 10. Based on these findings what is most likely the problem? ___________________________________________ A technician performs a dry compression test. They find the following readings; Spec 95 PSI (+/- 10 PSI) Cyl 1 - 100 PSI Cyl 2 - 60 PSI Cyl 3 - 95 PSI Cyl 4 - 100 PSI 11. What test should be done next? __________________________________________ A technician performs a WET compression test. They find the following readings; Spec 95 PSI (+/- 10 PSI) Cyl 1 - 100 PSI (was 90) Cyl 2 - 70 PSI (dry 70) Cyl 3 - 100 PSI (was 90) Cyl 4 - 100 PSI (was 90) 12. What is most likely wrong with this vehicle? __________________________________________ 13. What test is done next? __________________________________________ A technician performs a dry compression test. They find the following readings; Spec 95 PSI (+/- 10 PSI) Cyl 1 - 100 PSI Cyl 2 - 60 PSI Cyl 3 - 60 PSI Cyl 4 - 100 PSI 14. What is most likely wrong with this vehicle? __________________________________________ A technician performs a dry compression test. They find the following readings; Spec 95 PSI (+/- 10 PSI) Cyl 1 - 120 PSI Cyl 2 - 125 PSI Cyl 3 - 120 PSI Cyl 4 - 125 PSI 15. What is most likely wrong with this vehicle? __________________________________________ A technician performs a dry compression test. They find the following readings; Spec 95 PSI (+/- 10 PSI) Cyl 1 - 70 PSI Cyl 2 - 75 PSI Cyl 3 - 70 PSI Cyl 4 - 70 PSI 16. What is most likely wrong with this vehicle? __________________________________________ A technician performs a WET compression test. 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