Diagnosis, Repairs, Rebuilding of Vehicle

Case Study in consultation with 4 Dealers, 28 Customers and 10 Mechanics.

Problem Cuases
1 Engine Overheats Lack of water
Late Ignition timing
Loose fan belt
Defective thermostat
Clogged water jackets
Defective water pump
Lack of engine oil
Wrong valve timing
High altitude (Hilly area), hot climate condition
Restricted exhaust gas (Ex: Exhaust chocked)
Tight piston & cylinder
2 Excessive Fuel Consumption High speed drive
Short run operation
Pump leakage/excessive pump pressure
Clogged air cleaner
High carburetor float level
Worn carburetor jet
Idle too rich/too fast
Faulty ignition
Defective valve action
Clutch slippag
Low tyre pressure
Dragging of brakes
3 Excessive Oil Consumption External leakages
Burning of Lubricating Oil
Worn out piston rings
4 Low Oil Pressure Worn engine bearing
Engine overheating
Lub. Oil foaming
Defective oil pump
Clogged oil filter
5 Black Smokes Choke is in operation
(Diesel Engine) Weak spark
Incomplete combustion smoke Clogged air filter
present in exhaust gas Punctured float
Wrong ignition timing
Wornout piston rings
6 Blue Smokes Petrol mised with oil
Oil entered in to cutch chamber
Crank case oil seal damaged
Broken piston rings
7 Car Suddently Stops No spark, No fuel in tank, No cooling water
 Fuel filter blocked
Loose battery terminal
No proper CB gap
Broken fan belt
Clogged thermostat
Dynamo not charging
Fuel pump failure
Water entered into ignition system
8 Blue Smokes Excessive Lubrication oil comsumption
(Diesel Engine) Wornout piston rings
Wornout valve gides
9 Engine Noise Valve & Tappet noise (Pinking noise)
Worn/Loose piston pin
Lack of oil on pin
Wornout main bearings & end thrust bearings
Missalignment of connecting rod
Excessive clearance between piston & cylinder
10 Engine does not pickup speed Retard ignition timing
Wrong spark plug gap
Defective spark plug
Defective C.B. points
Sticky Throttle linkages
Defective accelerating pump
Leaky flat valve
Defective fuel pump
Clogged air filter
Brakes binding
Wornout bores/piston, rings
11 Engine Back fires Ignition timing of
Wrong heat range of spark plugs
Overheating of engine
More carbon deposits in cylinder
Excessive/Less mistures
Sticky valve
Cracked distributor cap
12 Discharged battery
Engine does not trun when starting Open starting circuit
Jammed bendix drive
Jammed engine
Jammed cranking drive
Wornout ring gear
13 Engine turn slowly but does not Discharged battery
start Defective cranking motor
Bad starting circuit connection
Under size battery cable
14 Engine turn at normal speed but
does not start
15 Engine runs but misses at one
cylinder
16 Engine runs but miss fires at
diferent cylinders
17 Engine stalls after high speed drivin Vapour lock
18 Engine stalls after idling
19 Engine stalls at cold
20 Engine stops immediately after startSpark plug gap incorrect
21 Engine poor pickup
22 Too hot running engine results
Defective ignition system
Defective fuel system
Air leakage in intake manifold
Defective engine
Defective spart plugs
Defective distributor lead/cap
Stuck valve
Defective piston rings
Defective cylinder head gasket
Defective ignition system
Defective fuel system
Loss of compression
Defective valve action
Overheated engine
Defective piston rings
Clogged exhaust manifold
Sticking manifold heat control valve
Water presents in petrol
Float ball level incorrect
Defective carburetor
Engine overheating
Improper idle screw adjustment
Defective fuel pump
Engine overheating
Float level high
Incorrect idling adjustment
Defective ignition coil/weak condenser
Closed ckoke valve
Fuel getting not correct
Manifold heat control valve stick
Too low idle speed setting
Engine overheating
Use of high viscosity oil
Improper C.B. point gap
Loose wiring connection
Dirty spart plut
Retard ignition timing
Improper spark plug
Poor compression
Improper C.B. point gap
Sticky Throttle linkages
Defective accelerator pump
 Pre-Ignition 28% of fuel energy
Detonation 45% Exhaust gas
Knocking 20% Brake power
Burning of Piston/Rings 5% Friction
Burning of Valves 2% Friction in transmission
Failure of Lubrication
23 Too cold running engine results
Fast engine parts wear
More fuel consumption

Cooing System:
1 External Leakage Loose hose pipes
Defective rubber hose
Damaged radiator cores
Excessive wear in water pump
Loose core plugs
Damaged gaskets
Leak at water temperature gauge
Leak at heater plug cores
Worn water seal at pump
2 Internal Leakage Defective cylinder head gaskets
Cracked cylinder wall
Loose cylinder head bolts
3 Water loss Boiling of water
External/Internal leakages
Restricted radiator
Defective thermostat valve
4 Poor Circulation Insufficient coolant
Defective water pump
Loose fan belt
Defective thermostat valve
Clogged jockets
Defective pressure cap
5 Over heating Poor circulation of water
Loose fan belt
Low oil level
Chocked radiator fins
Wrong ignition timing
High viscocity oil
Tight engine
Wrong valve timing
More sludge formation
6 Over cooling Defective thermostat valve
Defective temperation
No antifreeze mixture
7 Corrosion Excessive impurity in water
Infrequent flushing/draining of the system
Incorrect antifreeze mixture

Lubrication System
1 High Oil Consumption High oil level
Wornout oil seal (crank shaft/cam)
Loose bearing
Wornout piston rings
Wornout main bearings
Excessive oil pressure
Loose connection of oil filter
Clogged oil breather
Improper crank case ventilation
High speed/High temprature
Loose drain plug
Excessive clearance in valve guides
2 Low Oil Pressure Less oil in the oil pan
Loose connection in the oil lines
Faulty oil pressure gauge
Excessive bearing clearance
Too weak relief valve spring
8074307738