SAFARI STORME

ENGINE

2.1.2 MAINTENANCE, INSPECTION AND TESTS:

2.1.2.1 PRELIMINARY INSPECTION:

NOTE

It is always advisable to first use the diagnostic tool

and rectify the electrical faults, before commencing

with mechanical repairs/ troubleshooting. Refer EMS

section in this group for procedure.

GENERAL

•

Check for leakage of Oil, fuel, and Coolant.

•

Check for overheating of engine.

•

Check for unusual smoke.

•

If there is any fault in the Engine Management

system

(EMS)

then the MIL indicator in the in-

strument cluster will come ON. In such a case

connect the diagnostic tester.

(For procedure

refer EMS section).

Before proceeding to carry out actual reconditioning

of engine, it is desirable to have a preliminary in-

spection of engine to ascertain whether an engine

reconditioning is necessary and if so, to what extent.

Most common reasons for which engine is

reconditioned are

1. Loss of power.

2. Excessive engine oil consumption.

3. Extremely low engine oil pressure.

4. Mechanical failures.

To know exact reason and general condition of en-

gine, proceed as follows

1. LOSS OF POWER

Loss of engine power may be due to

EMS is in limp-home mode due to some critical

fault.

Clogged air filter / clogged intercooler fins /loss of

charge air pressure / choked exhaust passage /

catalytic converter.

Loss of engine compression

Defective fuel system

Clutch slippage

Brake binding

A. EMS is in limp-home mode

If the EMS detects some major fault in the system it

switches to limp-home mode, where it runs at a re-

duced torque. Connect the diagnostic tester and

check if any faults are present in the Engine EMS, if

found rectify them.

(For details refer Engine Man-

agement Section)

B. Clogged Air filter/Loss of Charge Air Pressure/

Choked exhaust system.

Loss of power indicates lack of air or low air charging

pressure to engine cylinders. Clean air filter & inter

cooler fins. Check all joints for air leakage. If power

loss still felt, check exhaust system for choking, recti-

fy if ON as per procedure mentioned in owner’s

manual. Clean and replace silencer if necessary.

Check for kink formation in exhaust piping.

C. Checking Engine Compression Pressure

•

If loss of power is not on account of defective

fuel system, lack of air, choked exhaust system,

clutch slipping and brake binding, check engine

compression as follows.

•

Warm up engine preferably by road drive to get

a coolant temperature of about 90ºC. Stop the

engine.

•

Remove the air filter.

•

Remove the injector back-leak pipes and high

pressure pipes from rail to injector .Disconnect

rail pressure sensor.

•

Plug the common rail outlet with suitable caps.

•

Remove all injectors.

•

Fit adapter

(Part no 2868 5890 07 01)

in place of

one injector.

•

Connect compression tester to adapter and

tighten vent knob.

•

Crank the engine with starter motor by 200-350

rpm approximately. Pressure gauge needle will

start rising. Continue cranking till gauge needle

stops rising any further. Note down the reading.

Loosen vent knob to make sure the tester needle

returns to zero. Repeat this operation for remain-

ing cylinders.

•

Minimum compression pressure in each cylinder

should be 23 ± 1 bar.

•

Low compression pressure may be due to leak-

age past valves / piston rings / blown cylinder

head gasket. To ascertain the point of leakage,

spray small quantity of clean engine oil in to cyl-

inder showing low pressure. If it improves, wear

in piston rings / cylinder bore is indicated. If it

does not, leakage past the valves is indicated. If

compression pressure of adjacent cylinder is al-