SAFARI

6 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 sl ipping and brake binding, check engine compression as follows. Warm up engine preferably by road drive to get a temperature of about 80 0 C to 100 0 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. Wi th accelerator pedal fully pressed, apply brake gradually with left foot. If the engine stalls it means that the clutch does not slip. OR 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