General Engine Information: Section: 1A
General Engine Information: Section: 1A
General Engine Information: Section: 1A
DIAGNOSIS
COMPRESSION TEST
Important : Disconnect the Crankshaft Position (CKP) Sensor connector to disable the fuel and the ignition systems. Test the compression pressure for each cylinder. Low compression pressure may be the fault of the valves or the pistons. The following conditions should be considered when you check the cylinder compression: S The engine should be at normal operating temperature. S The throttle must be wide open. S All the spark plugs should be removed. S The battery must be at or near full charge. 1. Place approximately three squirts of oil from a plunger type oiler into each spark plug port. 2. Insert the engine compression gauge into each spark plug port. 3. Crank test each cylinder with four to five compression strokes using the starter motor.
5.
4 5 6
825 rpm
Go to Step 6 Go to Step 8
7 8
Go to Step 1 Go to Step 9
Go to Step 10
9 10
Go to Step 1 Go to Step 11
Go to Step 12
11
Go to Step 1
12 13 14 15 16 17
18 19
Go to Step 19 Go to Step 1
Go to Step 20
21 22 23 24
Replace the bearing, if necessary. Is the repair complete? Inspect the oil galleries. Are the oil galleries cracked, porous, or plugged? Repair or replace the engine block. Is the repair complete? Inspect the gallery plugs. Are any of the gallery plugs missing or installed improperly? Install the plugs or repair, as necessary. Is the repair complete? Inspect the camshaft. Is the camshaft worn or is there evidence of poor machining? Replace the camshaft. Is the repair complete?
Go to Step 24 Go to Step 26
25 26
Go to Step 1 Go to Step 27
System OK
27
Go to Step 1
2) Dry the area. 3) Operate the vehicle for several miles at normal operating temperature and varying speeds. 4) After operating the vehicle, visually check the suspected component. 5) If you still cannot locate the leak, try using the powder or black light and dye method.
Powder Method:
1. 2. 3. 4. Clean the suspected area. Apply an aerosoltype powder, (such as foot powder), to the suspected area. Operate the vehicle under normal operating conditions. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source.
2.
4.
There are scratches, burrs or other damage to the sealing surface. The gasket is damaged or worn. There is cracking or porosity of the component. An improper seal was used, (where applicable).
Seals:
S S S S S S S S The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning. The seal bore is damaged, scratched, burred or nicked. The seal is damaged or worn. Improper installation is evident. There are cracks in the component. The shaft surface is scratched, nicked or damaged. A loose or worn bearing is causing excess seal wear.
Gaskets:
S S S S The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning. The fasteners are improperly tightened or the threads are dirty or damaged. The flanges or the sealing surface is warped.
KNOCK DIAGNOSIS
Definition for Knock
Engine knock refers to various types of engine noise. Heavy knock is usually very loud and the result of broken or excessively worn internal engine components. Light knock is a noticeable noise, but not as loud. Light knock can be caused by worn internal engine components. Loose or broken external engine components can also cause heavy or light knock.
Engine Knocks Cold and Continues for TwoThree Minutes and/or Knock Increases with Engine Torque
Step 1 Action Does the engine knock when it is cold and continue for two to three minutes or does the knock increase with torque? Inspect the flywheel. Is the flywheel contacting the splash shield? Reposition the splash shield. Is the repair complete? Inspect the balancer and the drive pulleys. Is either the balancer or the drive pulleys loose or broken? Tighten or replace the balancer or the drive pulleys. Is the repair complete? Inspect the pistontobore clearance. Is the clearance more than the specified value? 1. Rebore the cylinder and hone to size. 2. Replace the piston. Is the repair complete?* Inspect the connecting rod. Is the connecting rod bent? Replace the connecting rod. Is the repair complete? Value(s) Yes Go to Step 2 No System OK
2 3 4
Go to Step 4 Go to Step 6
5 6 7
Go to Step 8
8 9
Go to Step 9 Go to Step 1
System OK
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disappears in about 1.5 minutes, is considered acceptable.
8 9 10 11 12
13 14
Go to Step 1 Go to Step 15
System OK
15
Go to Step 1
Go to Step 1
4 5 6 7 8
Go to Step 1
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed lifter down. Attempts to repair this should be made only if the problem is consistent. An engine that is only operated for short periods between startups may have lifter noise that lasts for a few minutes. This is a normal condition.
DAEWOO V121 BL4
10 11 12 13 14 15 16 17 18
19
Go to Step 1
NOISE DIAGNOSIS
Main Bearing Noise
Step 1 2 3 Action Are dull thuds or knocks heard with every engine revolution? Check the oil pump pressure. Is the oil pump pressure low? Inspect the crankshaft end play. Does the crankshaft end play exceed the specified value? Inspect the crankshaft journals. Are the crankshaft journals outofround? Value(s) 0.1 mm (0.0039 in.) Yes Go to Step 2 Go to Oil Pressure Test Go to Crankshaft Replacement Procedure Go to Crankshaft Replacement Procedure Go to Timing Belt Replacement Procedure Go to Crankshaft Replacement Procedure No System OK Go to Step 3 Go to Step 4
Go to Step 5
Inspect the belt tension. Does the belt tension exceed the specified value?
Go to Step 6
System OK
3 4
Check the oil pump pressure. Is the oil pump pressure low? Inspect the crankshaft connecting rod journals. Are the journals outofround?
Go to Step 4 Go to Step 5
Go to Step 6
Inspect the connecting rod bolts. Are the connecting rod bolts torqued properly?
Go to Pistons and Rods Replacement Procedure Go to Pistons and Rods Replacement Procedure Go to Pistons and Rods Replacement Procedure Go to Pistons and Rods Replacement Procedure
Go to Step 3
Go to Step 4
Go to Step 5
System OK
Go to Step 4
Inspect the valve lifters. Are the valve lifters dirty, stuck or worn?
Go to Step 5
Inspect the camshaft lobes. Are the camshaft lobes damaged or improperly machined? Check the oil supply to the valve train. Is the oil supply insufficient or poor?
Go to Step 6
Go to Step 7
Go to Step 8
Inspect the valve spring seat. Is the valve spring seat incorrect?
System OK
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the tenthousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed.
Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.
ONENGINE SERVICE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. Notice : Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.