Servicing of Engine

Cooling System

1
 Cleaning of Cooling
System
For smooth and trouble free service the cooling
system should be cleaned at periodic
intervals to prevent the accumulation of
excessive rust and scale. The commercial
cleaning compounds available must be
carefully used in accordance with the
manufacturer's instructions.
If considerable amount of scale and rust has
accumulated, it may not be possible that
cleaning alone will remove it. In that case the
radiator and the engine water jackets must
be flushed out with special air pressure gun.

2
Cooling System Cleaning
Procedure
It involves the following steps:
Case: 1, when the scale formation is not hard
 Drain the system by opening the drain Plug.
 Prepare a solution of washing soda (Sodium
Carbonate) and water with a ratio of 1kg soda
to 10 litres of water.
 Fill up this solution in the engine cooling
system(radiator + water jackets) and run the
engine on the idle load for 8 to 10 hrs.
 Drain this solution and flush the system with
clean water.

3
Cont’d…
Case: 2, When scale formation is hard.
In this case when scale formation is hard
and cannot be completely removed with
washing soda, an other cleaning agent can
be prepared with 40 parts of water, 5 parts
of commercial hydrochloric acid and 1 part
of formaldehyde. This solution is allowed to
remain in the system for 2 to 3 hrs at
normal load. Then drain this solution and
flush the system with clean water.

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 Cont’d…
Pressure Flushing:
In this the air pressure is used to agitate as well as
to circulate the water through the cooling system.
1. Straight flushing: Connect the lead away hose
to the water outlet connection on the engine.
Insert the flushing gun in the hose attached to
the water pump inlet connection. Turn on the
water until the water passages are filled and then
release the air in short blast allowing the water to
fill the engine after such blast.
2. Reverse flushing: Before making connections
for reverse flushing the thermostat should be
removed from the cooling system.
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 Procedure for Reverse
Flushing
1- Radiator: Disconnect the
top hose of the radiator from
the engine and attach a lead-
away hose to the radiator.
Disconnect the bottom of the
radiator from water pump
and attach the flushing gun.
Connect water and air hoses
to the gun. Turn on the water
and fill the radiator to the
top. Release the air in short
blasts and allow the water to
fill the radiator between each
blast. Continue the operation
until the water from the lead-
away hose is clear.

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Cont’d…
2. Engine:
Connect the lead-
away hose to the
inlet of the water
pump and the
flushing gun to
the water outlet
connection the
engine cylinder
head, follow the
same procedure.
7
Cooling System Test
The procedure adopted for testing
the cooling system is given below.
 Testing Thermostat: The action of the thermostat can
be tested by placing it in a pan of water and heating the
pan. If the thermostat does not function according to
the water temperature, it means it is defective.
 Testing rust and scale: If the radiator water is rusty
and dust laden, and the capacity of the cooling system
is known, the following is suggested. First drain the
water of the cooling system and fill it with a measured
quantity of fresh water. Now compare the amount of the
water added and specified capacity of the system. The
difference is an indication of the amount of rust and
scale present.

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 Cont’d…
 Test for the radiator tube choked:
 Disconnect the radiator hose and put water into
the top of the radiator. The water should run
through the radiator and flow out from the
bottom. If the water runs out slowly, the radiator
is clogged.
 Start the engine, allow it to warm up and turn it
off and feel the radiator by hand. It should be
hot at the top and warm at the bottom with an
even temperature increase from the bottom to
top. Cold spots indicate clogged section.
 Test for water pump: Disconnect the upper
hose of water pump and start the engine. If
pressure can be felt as the engine is speed up, it
is indication that the water pump is operating
normally. 9
 Cont’d…
 Test for exhaust gas leakage: Disconnect the upper hose,
remove the thermostat valve and fan belt. Drain the system
until the water level stands just above the top of the cylinder
head. Start the engine and accelerate it several times. If the
water level rises or bubble appear, it indicates that there is
leakage of exhaust gases into the cooling system.
 Test for antifreeze solution strength:
The strength of this solution can be tested by using a special
antifreeze hydrometer, which measures its specific gravity or
heaviness. A specific gravity reading will determine the
percentage of the water and the anti freeze compound in the
solution.
 Test for pressure radiator cap:
To test the radiator cap use a pressure tester with an
adopter and rubber seal. Dip the radiator cap in water and
install it on the adopter. With the pump apply 12 to 14 psi
pressure to the cap. Replace the cap, if it fails to hold the
pressure within this range.

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 Test for air in cooling system:
The mixing of air with water speeds
up the formation of rust and increase
corrosion of the cooling system
metal. This also adds to the
overheating of engine and the
overflow loss of coolant. The air gets
into the cooling system due to i) a
leak ii) less coolant and turbulence.
if air leaks in cooling system are
suspected it can be checked by
attaching one end of a rubber tube to
the overflow pipe and dipping its
other end in a water bottle. If bubbles
appear in the bottle when the
temperature becomes stationary on
temperature gauge. It is an indication
for air being drawn in the system.
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Chapter No. 10
Engine Trouble
Shootings

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 Trouble-Shouting Chart
Given below are various troubles along with their possible
causes and remedies.
Troubles Causes Remedies
A. 1. Self starter does 1.
Engine not turn: (i- i- Check battery.
does Battery Charge Ii- clean terminals, coat with acid
not low. ii.- Terminals free grease and tighten them.
start loose or corroded)
2. No fuel in tank 2- Fill tank with diesel fuel.
3. Cock on tank pipe 3- open cock.
closed 4- wash and blow with compressed
4. One or several fuel air.
pipes are closed.
5. Air in fuel system 5- Remove air from fuel system.
6. Clogged fuel filter 6- Clean or replace the fuel filter
depending upon the material of
7. Defective fuel feed the element.
pump 7- Remove the fuel feed pump
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inspect and eliminate fault.
 Troubles Causes Remedies
A. Engine 8- Defective Fuel 8- Send the fuel injection pump for
does not Injection Pump. repairs to an authorized dealer.
start a- Pump element worn
off
b- Pump plunger
jammed
c- Delivery valve do
not close 9- Clean the nozzles
d- Spring broken
9- Nozzles orifice
chocked

B- 1- same as causes Same as remedies 5,6,7,8 and 9 for

Irregular 5,6,7,8 and 9 for Trouble (A)
performan Trouble (A)
ce and 2- Nozzles worn or 2- Replace nozzles
lack of seized. 3- Adjust fuel pump
power 3- Fuel pump timing
inaccurate 4- Adjust injection pressure
4- Fuel injection
pressure
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inaccurate
 Troubles Causes Remedies
B- 5- Poor Compression 5-
Irregular a. Loss of a-
Performan compression
ce and through valves i- Clean and regrind valves
lack of due to:
power i. Coke deposits on ii. Adjust tappet clearance
the valves iii. Regrind valve and valve seat or
ii. Wrong tappet replace them.
clearance
iii. Worn valves and
valve seat b. Fasten the cylinder head and if
b. Loss of necessary change the gasket
compression at
cylinder head c. Change worn out parts
gasket
c. Worn out piston d. Clean
group, i.e. piston
rings and linear e. Clean air cleaner
d. Partially chocked
exhaust pipe or
muffler
6- Air cleaner clogged
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Troubles Causes Remedies
C. Smoky A- Black Smoke A-
Exhaust (incomplete fuel
combustion) 1. Same as remedies 8 & 9 for
1. Same as causes 8 & 9 trouble (A)
for Trouble (A)
2. Engine overloaded
3. Poor fuel quality 2. Lower engine load or engage
4. Insufficient air supply lower speed
5. Improper fuel pump 3.Change fuel
timing 4.Clean air cleaner
6. Improper valve timing 5.Adjust
7. Low injection pressure 6.Adjust
B- White Smoke 7.Adjust
1. Engine too cold B-
2. Insufficient 1.Warm up
compression 2.As per remedy 5 of trouble (B)
3. Presence of water in 3.Change Fuel
fuel C-
C- Blue smoke
(Burning of oil in
Combustion 1.Remove extra oil
Chamber) 2.Use proper grade of oil
1. Excessive oil in 3.Replace worn out parts 16
Troubles Causes Remedies
D- 1. Same as causes 2, 4, 5 1. Same as remedies 2, 4, 5 and 6
Engine and 6 for trouble (A) for trouble (A)
Suddenly 2. Vent hole of diesel 2. Clean
stops tank clogged
3. Fuel contains water 3. Check and change
4. Piston seized in 4. Check and replace
cylinder 5. Check and replace
5. Connecting rod
bearing or main 6. Check and replace
bearing seized
6. Camshaft bushes
seized

E- Engine 1. Fuel pump installed 1. Check adjustment of beginning of

Knocks after repairs or fuel feed pump. If required adjust
dismantling with large as per spill-off-cut method
advance of beginning
of fuel feed pump
(Loud knocks at to of
cylinder block) 2. Check and if necessary wash or
2. One or more fuel replace defective injectors
injectors inoperative 3. Adjust valve clearance
3. Incorrect Valve 17
Troubles Causes Remedies
E- Engine 4. Piston rings worn out by height or 4. Replace worn out
Knocks wrong piston groove. (Excessive parts
land clearance)
5. Worn out piston pin or piston boss 5. Replace worn out
holes and connecting rod small parts
end
6. Worn out piston and liner (Rattling 6. Replace worn out
knock heard clearly along the parts
entire length of cylinder)
7. Worn out big end bearing ( dull
knock heard along entire height of 7. Immediately stop
cylinder block; when fuel supply is engine. Inspect and if
stopped knocks disappear) required change worn
out part

F- Engine 1. Insufficient water in the cooling 1. Add water into

Overheat system radiator up to normal
s level.
2. Weak tension of fan belt 2. Tighten it as required
3. Radiator clogged outside 3. Clean with
compressed air and
4. Scale deposition water
5. Thermostat valve opens partly 4. Flush the system 18
 Troubles Causes Remedies
G- Low Oil 1. Engine oil level low 1. Fill up oil
Pressure 2. Thinner grade of oil 2. Change the oil
3. Blocked oil pump sump screen 3. Clean it
4. Oil pressure relief valve faulty 4. Set it as per
5. Oil Pump drive shaft worn recommendation
6. Excessive oil pump clearance 5. Replace
7. Excessive main or connecting 6. Replace
rod bearing clearance 7. Repair
8. Defective oil pressure gauge
9. Leakage through pressure 8. Change
gauge pipe 9. Check
10.Very low engine idle speed 10.Raise speed and check

H- High 1. Use of thicker grade engine oil 1. Change the oil

Oil 2. Pressure relief valve sticky or 2. Adjust as per
Pressure jammed recommendation
3. Main oil gallery chocked 3. Clean
4. Inaccurate oil pressure gauge 4. Repair / Change

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