SAFARI

ENGINE2.2LDICOR

Before proceeding to carry out actual reconditioning

of engine, it is desirable to have a preliminary

inspection of engine to ascertain whether an engine

recondition 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 engine,

proceed as follows

1. LossOfPower

Loss of engine power may be due to

Clogged air filter / clogged intercooler fins /loss

of charge air pressure / choked exhaust passage /

catcon.

Loss of engine compression

Defective fuel system

Clutch slippage

Brake binding

a. Clogged Air filter/Loss Of Charge Air Pressure/

Choked Exhaust Silencer/catcon.

Loss of power with unusual black smoke from

engine exhaust indicates lack of air or low air

charging pressure to engine cylinders. Clean air

filter & inter cooler fills Check all joints for air

leakage. If power loss with black smoke is still felt,

check exhaust silencer for choking. Clean and

replace silencer if necessary. Check for kink

formation in exhaust piping.

b. 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

temperature of about 80

C to 100

C. 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.

Preliminary InspectionOf Engine

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

remaining cylinders.

Minimum compression pressure in each cylinder

should be 26 ± 1 bar.

Low compression pressuremay be due to leakage

past valves / piston rings / blown cylinder head

gasket. To ascertain the point of leakage, spray

small quantity of clean engine oil in to cylinder

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 also

on lower side and equal, it may be due to blown

cylinder head gasket.

c. FUELSYSTEM

Check the Fuel system for fuel flow. If the flow is

restricted change the filter.

d. CLUTCHSLIPPAGE

Clutch slipping can be confirmed by any of the

following two methods:

Drive the vehicle in 1st or nd gear at maximum

speed corresponding to that gear. With

accelerator pedal fully pressed, apply brake

gradually with left foot. If the engine stalls it means

that the clutch does not slip.

Drive the vehicle with normal load in 3rd gear on

level ground and let the speed drop down to

approximately 15 Kmph. Now press accelerator

pedal fully. With slipping clutch the vehicle speed

will not pick up and also clutch burning smell will

be noticed. If this does not occur and vehicle picks

up speed, it indicates that clutch does not slip.

e.BRAKEBINDING

During driving apply brakes number of times and

then shift gear to neutral position and check free

rolling of vehicle. Check brake drums/brake discs