TABLE OF CONTENTS

Page

How to Use this Module ………………………………………….. i

Introduction……………………………………………………………. Ii

Technical Terms …………………………………………………….. iii

Learning Outcome 1 ………………………………………………… 1

Learning Experiences/ Activities ……………………….. 1

Operation Sheet 1... 2

………………………………………..

Operation Sheet 2... 3

………………………………………..

Operation Sheet 3... 5

………………………………………..

Operation Sheet 4... 6

………………………………………..

Assessment Performance ………………………………… 9

Learning Outcome 2 ………………………………………………… 10

Learning Experiences/ Activities ……………………….. 10

Operation Sheet 1... 11

………………………………………..

Operation Sheet 2... 12

………………………………………..

Operation Sheet 3... 13

………………………………………..

Operation Sheet 4... 14

………………………………………..

Assessment Performance ………………………………… 17

Learning Outcome 3 ………………………………………………… 18

Operation Sheet 1... 19

………………………………………..

Assessment Performance ………………………………… 24

HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL

This module contains training materials and activities for you to

complete. The unit of competency “PERFORM DIESEL ENGINE TUNE UP”
contains the knowledge, skills and attitudes required for Automotive
Servicing. It is one of the specialized modules at National Certificate level I
(NCI).

You are required to go through a series of learning activities in order to

complete each learning outcomes of the module. In each learning outcome
there are operation sheets that are perform the given task.
 Information sheet – This will provide you with information (concepts,
principles and other relevant information) needed in performing certain
activities.
 Operation sheet – This will guide you in performing single task,
operation or process in a job.

You may already have some or most of the knowledge and skills covered in this
learner’s guide because you have:
 Been working for some time
 Already completed training in this area.

If you can demonstrate to your teacher that you are competent in a

particular outcome, you don’t have to do the same training again. Talk to your
teacher about formally recognized. If you have a qualification or certificate of
competence from previous training, show it to your teacher. If the skills you
acquired are still current and relevant to the unit/s of competency they may
become part of the evidence you can present for RPL. If you are not sure about
the currency of your skills, discuss this with your teacher.

Inside this learner’s guide you will find the activities for you to complete
and at the back are the relevant operation sheets for each learning outcome.
Each learning outcome may have more than one learning activities.

Course Title : AUTOMOTIVE SERVICING

Unit of Competency : PERFORM DIESEL ENGINE TUNE-UP

Module Title : Performing Diesel Engine Tune-up

Introduction

This module consists of three (3) learning outcomes with nine (9)
important operation sheets that both teacher and students can use to show
actual applications of the following; procedures in installing injection pump
and timing gear case for Isuzu diesel engine C-240,procedures in installing the
injection pump timing gear to engine the vintage type vehicle, procedures in
setting fuel injection timing, procedures in proper usage of special tools in
setting injection timing, procedures in bleeding the diesel fuel system when
engine not functioning, procedures in bleeding injection line during cranking
the engine or even the engine is running, procedures in bleeding the fuel
system, essential steps in bleeding the fuel system and procedure in
compression testing and precaution.
 TECHNICAL TERMS

1. Air bleeder – a device used to removed air from a hydraulic system.

Types include the bleed plug or screw bolt, needle valve and capillary
tubing to the reservoir.

2. Combustion – the act or process during burning.

3. Compression – the process by which a confined gas is reduced in

volume through the application of pressure.

4. Compression check – a measurement of the compression of each

cylinder at cranking speed or as recommended by the manufacturer.

5. Compression gauge – a test instrument used to test the cylinder

compression.

6. Compression pressure – pressure in the combustion chamber at the

end of the compression stroke, but without any of the fuel being
burned.

7. Compression ration – the ratio between the total volume in the

cylinder when the piston is at BDC and the volume remaining when
the piston is at TDC.

8. Injection period – it is a period of injecting fuel covering the daily

period, rapid combustion and at the end of combustion.

9. Retard (Injection timing) – to set the timing so that injection occurs

later than TDC or fewer degrees before TDC.
 10. Stroboscope (Timing light) – an instrument used to observe the
periodic motion of injection visible only at certain points of its path.

11. Timing gears – gear attached to the crankshaft, camshaft, idler

shaft, or injection pump to provide a means to drive the camshaft and
injection pump and to regulate the speed and performance.

12. Timing marks (injection) – the marks located on the vibration

damper or flywheel. Used to check injection timing.

Program/Course: Automotive Servicing NC I

Unit of Competency: DIESEL ENGINE TUNE-UP
Module Title: Perform Diesel Engine Tune-up

Learning Outcome 1. Install Injection Pump Following the Correct Timing

ASSESSMENT CRITERIA

1. Injection timing is set as per engine specifications

2. Required injection pump installation process is set-up as SOP requirement.
3. Mounting bolts are tightened as per specifications and torque sequence

Resources

 Automotive Mechanics, 10th edition

 By: Crouse/ Anglin
 Modern Automotive Technology
 By: James E. Duffy
 Manufacturer’s Manual
 Toyota Corporation
 Diesel Mechanics by: Erich J. Schulz Copyright ©1977 by Mc Graw-Hill,
Inc..
 Diesel Engines by J.N. Seale Copyright © 1977 by Butterworth & Co.
(publishers) Ltd.
 Diesel Engine Manual by: Perry O. Black Copyright © 1964 by Howard
W. Sams & Co., Inc., Indianapolis, Indiana.

LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome # 1 : Install injection pump following the correct

timing

Learning Activities Special Instructions

LO1 Install Injection Pump Following the Correct Timing

 Perform the installation of  See the operation sheet no.1
injection pump and timing gear under LO1
 case for (Isuzu Diesel Engine C-
240)

 Perform the installation of  See the operation sheet no.2

injection pump timing gear to under LO1
engine for vintage type.

 Perform the setting fuel  See the operation sheet no.3

injection timing under LO1

 Perform the proper usage of  See the operation sheet no.4

special tools in setting injection under LO1

 Follow the safety measures in  See the operation sheet no.4

installing the injection pump under LO1
engine

OPERATION SHEET NO.1

LO1
TITLE: INSTALL INJECTION PUMP FOLLOWING THE CORRECT TIMING

Condition

Supplies and materials

 CD
 Bond paper
 Board marker
 White board

Tools
 A set of open wrench
 Set of special service tool

Equipment
 Engine
 Injection system mock-up
 TV monitor with VCD/LCD
 Vehicle

PROCEDURE IN INSTALLING THE INJECTION PUMP AND TIMING GEAR

CASE FOR ISUZU DIESEL ENGINE C-240:

1. Prepare the supplies, materials, tools and equipment needed;

2. Preparation for installation of timing gear case.

a. Position a piece of wood under
the timing gear case and install
the crankshaft front oil seal
using special tool; installer (5-
85200-013-0).
Note: Fill the clearance between
lips of oil seal with grease.

b. Assemble the O rings to the timing gear case.

Note:
 Make certain O rings are,
properly fitted into position.
 Discard used O rings and
install new one.
 3. Installation of injection pump.
a. Align the marks X and Y on the
crankshaft gear, idler gear and
camshaft gear.
b. Install the injection pump by aligning the mark Z on the
injection pump gear with the mark Z on the camshaft gear.
Note: Apply a thin coat a liquid gasket to both faces of the
gasket.

4. Installation of timing gear case.

a. Install the oil thrower with its
rear face turned to the gear side
on the front part of the
crankshaft gear.
b. Install the timing gear case and
fix the injection pump in
position of installation.

OPERATION SHEET NO.2 under LO1

TITLE: INSTALL INJECTION PUMP FOLLOWING THE CORRECT TIMING

Condition

Supplies and materials

 CD
 Bond paper
 Board marker
 White board

Tools
 A set of open wrench
 Set of special service tool

Equipment
 Engine
 Injection system mock-up
 TV monitor with VCD/LCD
 Vehicle

Procedure in installing of Injection pump, timing gear to engine

vintage type vehicle.

1. Prepare the supplies, materials, tools and equipment needed;

2. Loosen the four nuts attaching the pump to the mounting flange
plate and align the center timing mark on the pump flange with
the pointer on the plate. Tighten the four nuts.
3. Be sure that the O-ring is in place on the forward face of the pump
mounting flange.
4. Remove the threaded timing port plug on the governor housing
behind the control lever to expose the camshaft bushing timing
mark. Rotate the pump drive gear to align the timing mark on the
camshaft bushing with the pointer on the governor. The guide
plate notch will be approximately the 8 o'clock position as viewed
from the front. Be sure the engine is positioned as described in
step 10 of the removal procedure.
 5. Insert the automatic timer into the timing gear case and with the
injection pump rotated against the crankshaft, rotate the pump
driver gear to mesh the drive and idler gears. Do not force the
pump into position.
6. Push the pump forward into the case. Rotate it away from the
crankcase to align the attachment holes.
7. Attach the pump to the timing gear case.
8. Rotate the engine crankshaft in the opposite direction of normal
operation until the crankshaft reaches the 18° before TDC mark on
the crankshaft pulley. The governor pointer and the injection
pump camshaft bushing timing marks should now be aligned. If
they are not aligned, the pump has been installed incorrectly and
must be removed and reinstalled.
9. Install the governor housing timing port plug and proceed with the
pump installation by reversing the remainder of the removal
procedure. Do not connect the no. 1 injecting pipe, fuel control rod
or the batteries.
10. Bleed the air from the fuel filter and the injection pump by
removing the air bleeder screws.

Interpretation of timing marks.

a. Diesel Timing Marks Signifying

letters

b. Diesel Timing Marks Signifying

numbers

OPERATION SHEET NO.3 under LO1

TITLE: INSTALL INJECTION PUMP FOLLOWING THE CORRECT TIMING

Condition

Supplies and materials

 CD
 Bond paper
 Board marker
 White board

Tools
 A set of open wrench
 Set of special service tool

Equipment
 Engine
 Injection system mock-up
 TV monitor with VCD/LCD
 Vehicle

PROCEDURES IN SETTING FUEL INJECTION TIMING

1. Prepare the supplies, materials, tools and equipment needed;
2. Disconnect the batteries and the fuel shut off rod at the stop lever.
3. Rotate the crankshaft in the direction of normal operation until no. 1
cylinder reaches top dead center of the compression stroke. This is
done by aligning the lines on the crankshaft pulley rear face with the
pointer on the bottom of the case.
 4. Remove the forward oil filler cap on the rocker cover and check the
no. 1 cylinder valves for looseness. If they are loose, you are at TDC.
5. Rotate the crankshaft in the normal direction of engine operation 1 3/4
turns.
6. Disconnect no. 1 injection pipe from the delivery valve holder.
7. Turn the crankshaft in the normal direction of engine operation in
small steps. Stop when fuel begins to flow from the delivery valve
holder. Injection begins at this point. The control lever must be in the
idle position.
8. Read the injection timing point from the scale on the back of the
crankshaft damper. If the timing is correct, the timing mark should be
at the value shown on the Vehicle Emission Control Information label
on the rocker cover +- 2 degrees.
9. If the timing point determined differs from the standard value, minus
2 degrees, loosen the four pump-to-flange plate nuts and rotate the
pump (toward the crankcase to advance the timing, away from the
crankcase to retard it) to correct the difference. Each mark on the
injection pump timing scale represents 6 degrees. Tighten the flange
plate nuts and repeat the timing procedure to be sure the timing is
correct.

Interpretation of timing marks.

a. Injection pump timing marks

b. Camshaft bushing timing mark

OPERATION SHEET NO.4 under LO1

TITLE: INSTALL INJECTION PUMP FOLLOWING THE CORRECT TIMING

Condition

Supplies and materials

 CD
 Bond paper
 Board marker
 White board

Tools
 A set of open wrench
 Set of special service tool
Equipment
 Engine
 Injection system mock-up
 TV monitor with VCD/LCD
 Vehicle

PROCEDURE IN PROPER USAGE OF SPECIAL TOOLS IN SETTING

INJECTION TIMING

1. Prepare the supplies, materials, tools and equipment needed;

2. Installation of crankshaft gear
Install the crankshaft gear using special tool;
gear installer (9-8522-0021-0)
Note: Install the crankshaft
gear, so that its side with the mark
X is turned to front of engine.

3. Installation of front plate

Install the gasket and front plate by aligning the holes with the locating dowels
on the cylinder body using 3 bolts.
Note: Apply a thin coat of liquid gasket evenly to both faces
of the gasket before installation.
4. Installation of camshaft
Apply engine oil to the camshaft journals and cams, then install the camshaft
on the cylinder body.
Install the thrust plate bolts and tighten then securely by fitting tool into the
hole in the camshaft gears
Note: When installing the camshaft, exercise care not to scratch
the camshaft bearing.

5. Installation of Idle gear.

5.1 Install the idle gear, so that the oil
port in the idle gear shaft is turned to
the crankshaft gear side and bolt holes
are aligned.

5.2 Apply engine oil to the idle gear

shaft and install the idle gear by
aligning the marks X and Y on
the gear with those on the
crankshaft gear and camshaft
gear.

5.3 Install the thrust cellar with its

chamfered side out using 2 bolts.

6 Installation of camshaft gear bolt

6.1 Install the plain washer with its chamfered side out, then install
the bolt.
6.2 Torque the camshaft gear fixing bolts to specification by inserting a bar into position
between the crankshaft and cylinder body to prevent turning of the crankshaft.
Bolt torque 7m-kg

7. Installation of crankshaft rear oil seal

Install the oil seal spaces and oil seal in position
from the rear side of the cylinder body using
special tool: installer. (9-8522-1279-0). Fill the
clearance between lips of the seal with grease
before installing the oil seal.
Note: If the oil seal fitting face of
the crankshaft is found to be worn,
adjust fitting of the oil seal by
installing the oil seal without the
spacer.

D. SAFETY IN INSTALLING INJECTION PUMP TO ENGINE

1. Do not over tighten pump drive gear nut. The replacement pump
shaft should be aligned in position to eliminate the need to set pump-
to-engine timing for this is not the final torque for the drive gear.
2. Do not steam-clean the injection pump while the engine is running.
(The temperature difference may cause serious damage to the pump.
3. When using a timing pin, do not forget to remove it before turning the
engine over; otherwise the injection pump will be damaged.
4. Be careful of mounting the injection pump to engine, dropping it by
accident would damage the body parts of the pump.
5. Do not apply heavy rotational force on pump after gear back lash is
removed as this may preload the pump and effect pump-to-engine
timing.
6. Be sure that the area is clean.

ASSESSMENT PERFORMANCE
LO 1.Installing the injection pump following the correct timing.

Workmanship/Performance
Points

A. Setted injections pump following the timing mark safely. 35

 Accurate timing - - - - - - - - - - - - - - - - - - - 35

 Minus or plus one tooth ahead or delay - - - 25

 Wrong timing - - - - - - - - - - - - - - - - - - - - - 15

B. Installed injection pump to the engine safely.

35

 1st – 2nd attempts - - - - - - - - - - - - - - - - - - 35

  3rd – 5th attempts - - - - - - - - - - - - - - - - - 25

 More than 6 attempts - - - - - - - - - - - - - - - 15

C. Tightened bolts safely as per specification. 30

 All bolts are tightened according to specification and

sequence - - - - - - - - - - - - - - - - - - - - 30
 3 bolts are tightened specification and
Sequence - - - - - - - - - - - - - - - - - - - - - - - 20
 Less than 3 bolts tightened in specification and
sequence - - - - - - - - - - - - - - - - - - - - - - - 10
100

Program/Course: Automotive Servicing NC I

Unit of Competency: DIESEL ENGINE TUNE-UP
Module Title: Perform Diesel Engine Tune-up

Learning Outcome 2. Bleed Injecting Fuel System

ASSESSEMENT CRITERIA

1. Fuel level, line leakage and fuel strainer/filter are checked

2. Air lock free fuel system is determined screw and primer pumps are
bleed

Resources

 Automotive Mechanics, 10th edition

 By: Crouse/ Anglin
 Modern Automotive Technology
 By: James E. Duffy
 Manufacturer’s Manual
 Toyota Corporation
 Diesel Mechanics by: Erich J. Schulz Copyright ©1977 by Mc Graw-Hill,
Inc..
 Diesel Engines by J.N. Seale Copyright © 1977 by Butterworth & Co.
(publishers) Ltd.
 Diesel Engine Manual by: Perry O. Black Copyright © 1964 by Howard
W. Sams & Co., Inc., Indianapolis, Indiana.

LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome # 2 : Bleed the Injecting Fuel System

Learning Activities Special Instructions

 LO1 Install Injection Pump Following the Correct Timing

 Perform the air bleeding of  See the operation sheet no.5

diesel fuel system under LO2
 Perform the air bleeding of  See the operation sheet no.5
diesel fuel system when not under LO5
cranking or running the
engine.
 See the operation sheet no.6
 Perform the air bleeding of under LO2
diesel fuel system when
cranking or running the
engine.
 Perform in bleeding the Fuel  See the operation sheet no.7
System when shut off engine. under LO2
 Perform the essential steps in  See the operation sheet no.8
bleeding the fuel system under LO2
 Follow the safety measure in  See the operation sheet no.8
air bleeding under LO2

OPERATION SHEET No. 5

LO2
TITLE: BLEED INJECTING FUEL SYSTEM

Condition

Supplies and materials

 Diesel fuel
 Rags
 Container

Tools
 One set of open wrench
 One set of box wrench
 One set of screw driver

Equipment
 Diesel engine mock-up
 TV monitor with VCD/LCD
 Vehicle

PROCEDURE IN BLEEDING THE DIESEL FUEL SYSTEM WHEN ENGINE

IS NOT FUNCTIONING.
1. Prepare the supplies, materials, tools and equipments
2. After the injection pump is timed to the engine and its mounting
bolts are torque to specifications connect the low-pressure fuel
line, the injection lines, the throttle, and the shut off control to the
injection pump.
3. Bleed the air from the filters, fuel lines, and the injection pump to
prevent lock of lubrication to the pump elements and possible
damage to the closely fitted parts.
4. To bleed the system, first check the level of the fuel tank. If it is
below the injection pump, fill the tank.
5. Open the shut off value, the primary filter, the secondary filter,
and the injection-pump vent screws. Allow fuel and air to flow
 from the vents until the fuel is free of air bubbles. Then tighten
the vent screws in sequence, one after the other.

OPERATION SHEET No. 6 under LO2

TITLE: BLEED INJECTING FUEL SYSTEM

Condition

Supplies and materials

 Diesel fuel
 Rags
 Container

Tools
 One set of open wrench
 One set of box wrench
 One set of screw driver

Equipment
 Diesel engine mock-up
 TV monitor with VCD/LCD
 Vehicle

Procedure in bleeding injection line during cranking the engine or

running the engine.

1. Prepare the supplies, materials, tools and equipment

2. To vent the injection line, set the

throttle to the full-fuel position.
3. shut off lever or the switch in the “run”
position.
4. Place the decompression lever in the
“decompression” position.
5. Loosen all the injection-line fitting at
the injectors.
 6. Crank the engine until fuel squirts from
the injection lines, and then tighten the
connection.

The high-pressure side of the

injection lines is usually self-bleeding
since the air is forced out through the
action of the pumping element.
However, when the cranking motor is
only moderate when the engine fails to
start, or when it continues to run
rough, venting of the injection line is
necessary.

OPERATION SHEET No. 7 under LO2

TITLE: BLEED INJECTING FUEL SYSTEM

Condition

Supplies and materials

 Diesel fuel
 Rags
 Container

Tools
 One set of open wrench
 One set of box wrench
 One set of screw driver

Equipment
 Diesel engine mock-up
 TV monitor with VCD/LCD
 Vehicle


Procedure in bleeding the Fuel System shut off engine.

1. Prepare the supplies, materials, tools and equipments

2. Loosen the fuel filter petcock or valve and operate the priming pump
on the feed pump. If the filter is filled with fuel, fuel containing air
bubbles will be discharged from the petcock or valve. Continue
pumping until the discharge fuel contains no more air bubbles. Then
tighten the fuel valve or petcock securely.
3. Loosen the air bleeder screw at the top of the injection pump and
operate the priming pump. Continue pumping until all air is bled
from the fuel in the pump reservoir. Then close air bleeder screw
securely.
 OPERATION SHEET No. 8 under LO2

TITLE: BLEED INJECTING FUEL SYSTEM

Condition

Supplies and materials

 Diesel fuel
 Rags
 Container

Tools
 One set of open wrench
 One set of box wrench
 One set of screw driver

Equipment
 Diesel engine mock-up
 TV monitor with VCD/LCD
 Vehicl

Essential Steps in Bleeding the Fuel System
1. Prepare the supplies, materials, tools and equipments
2. Make sure that fuel tank shut off is in “on” position.
3. Bleed the air from fuel filter. Loosen the air bleed screw at the top
of the fuel filter expel in the fuel flowing from the filter.
4. Bleed the air from the fuel return pipe installed on the fuel injector,
and bleed the air by operation the manual handle of the lift pump.
(If there is more than one injector, bleed the one at the end of the
line).
5. Bleeding the air from the fuel line – (line from the filter to the
injector pump). Loosen the air venting screw at the injection
pump and operate the manual handle of the lift pump until all
the air bubbles are out.
6. Bleed the air from the fuel injector. Loosen the nipple on the
fuel injector side, set the throttle to half and the decompression
lever to the decompression position and crank engine. When
no more bubbles appear in the fuel flowing from the end of the
injection pipe, re-tighten the nipple.

B. SAFETY MEASURE IN BLEEDING

1. If your bleed the system by using the hand priming pump, do not
forget to lock it. If the pump is not locked, there will be no transfer-
pump pressure because fuel will circulate within the transfer pump.
2. Since the presence of air in the fuel system anywhere between the fuel
tank and the injector will cause a no start of erratic running
condition. Always bleed the air when the system if disassembled,
filter changed or run out of fuel.
3. Air entrapped in the fuel system can cause inadequate fuel injection,
poor operation, and hard starting. Whenever the fuel system is
serviced, it should be bled of entrapped air in the proper sequence.
4. Be sure that every fittings of the Diesel fuel line are all air tight in
order to prevent atmospheric air pressure enters the line loose
fittings.
5. Be sure that each fuel line is installed onto the same pump outlet port
position from which it was removed value holders from injection
pump delivery valve holders from turning when installing the lines
onto the pump.

ASSESSMENT PERFORMANCE
LO 2.Bleed Injecting Fuel System
 Workmanship/Performance Points

A. Checked the fuel level, line leakage and fuel strainer / 35

filter safely.

 All parts are checked properly - - - - - - - - - 35

 Two parts are checked properly while the other one

does not - - - - - - - - - - - - - - - - - - - - - 25

 Only one part of the three is checked - - - - - 15

B. Determining the fuel system safely if it is free from air

lock. 35

 All lines are working - - - - - - - - - - - - - - - - 35

 Three lines are working except one which

failed - - - - - - - - - - - - - - - - - - - - - - - - - - 25

 Either any of them one or two one lines only are

working - - - - - - - - - - - - - - - - - - - - - - - - 15
C. Bleeding the bleeder screw by hand priming the primer 30
pump safely.
 One to tow minutes - - - - - - - - - - - - - - - - 30

 Three to two minutes - - - - - - - - - - - - - - - 20

 6 minutes or more - - - - - - - - - - - - - - - - - 10

100

Program/Course: Automotive Servicing NC I

Unit of Competency: DIESEL ENGINE TUNE-UP
Module Title: Perform Diesel Engine Tune-up

Learning Outcome 3. Conduct Compression Testing

ASSESSMENT CRITERIA

1. Engine requirements in compression testing is determined

2. Specification compression test result is read and interpreted per SOP.
3. Corresponding recommendation/prescription is given based on the test result

Resources

 Automotive Mechanics, 10th edition

  By: Crouse/ Anglin
 Modern Automotive Technology
 By: James E. Duffy
 Manufacturer’s Manual
 Toyota Corporation
 Diesel Mechanics by: Erich J. Schulz Copyright ©1977 by Mc Graw-Hill,
Inc..
 Diesel Engines by J.N. Seale Copyright © 1977 by Butterworth & Co.
(publishers) Ltd.
Diesel Engine Manual by: Perry O. Black Copyright © 1964 by Howard W.
Sams & Co., Inc., Indianapolis, Indiana.

OPERATION SHEET No. 9

LO3
TITLE: CONDUCTING COMPRESSION TESTING

Condition

Supplies and materials

 Ball pen
 Bond paper
 watch

Tools
 Compression tester for diesel engine
 One set of open end wrench
 One set of combination wrench
 Adjustable wrench

Equipment
 Diesel engine mock-up
 TV monitor with VCD/LCD
 Vehicle

PROCEDURES IN COMPRESSION TESTING AND PRECAUTION

1. Prepare the supplies, materials, tools and equipments Tools

2. Remove the air cleaner and install a manifold cover.

3. Disconnect the wire from the fuel shutoff solenoid terminal of the
injector pump. This prevents delivery of fuel during the test.

4. Disconnect glow-plug wires and remove glow plugs

5. Screw the compression-tester fitting into the glow-plugs. Hole of

the cylinder to be checked.

6. Then, crank the engine for at least 12 crankshaft revolutions (six

“puffs”).
7. Check all cylinders on the same way. Get the reading of every
cylinder.

Note:
a. Clean the injector bore or sleeve with the recommended tool,
but make certain that no carbon remains in the combustion
space.
 b. Be sure the crankcase is at the proper level, the battery is
properly charged and with a good effective starter that
produces high efficiency in cranking the engine.

B. INTERPRETATION OF RESULTS FROM COMPRESSION TESTING

The lowest compression pressures reading will be not less than 70

percent of the highest. Therefore, the cylinder will read less than 275
pounds (Pounds per square inch or PSI. In the metric measurement
system, this will be 1,892kpa.)
In connection with the pressure shown not less than 70 percent, I
think, everything is normal, the compression builds up quickly and
evenly. But if, there will be leakage past the piston rings, the
compression pressures will become low on the first strokes but will tend
to build up toward normal with later strokes. However, it does not reach
normal since one of the piston cylinders is lower than minimum
standard and the pressure is rapidly lost, this concluded low
compression.

.70% = 275 PSI

275 ÷ .7 = 393
392 – 275 = 118
118 ÷ .3 = 393

EXAMPLES

A. 126 ÷ .7 = 180
180 – 126 = 54
54 ÷ .3 = 180
180 x 1.0 =
B. 275 ÷ .7 = 393
393 – 275 = 118
118 ÷ .3 = 393
393 x 1.0 = 393
C. 140 ÷ .75 = 187
187 – 140 = 47
47 ÷ .25 = 187
1.0 x 140 = 140
D. 105 ÷ .75 = 140
140 – 105 = 35
35 ÷ .25 = 140
1.0 x 140 = 140

In some manufacturer like ford, specified that the indicated

compression pressures are considered normal if the lowest reading
cylinder is within 75% of the highest. Refer to the following example and
chart. Seventy-five percent of 140, the highest cylinder reading are 105.
Therefore, if cylinder no.1 being less than 75% of cylinder no.4 in firing
orders 1-3-4-2, this indicates an improperly seated valve or worn or
broken piston rings.
If one or more cylinders read low squirts approximately one (1) table’s
spoon of engine oil on top of the piston in the low reading cylinder.
Repeat compression pressure check on these cylinders. Then, observed
the reading compared previous read pressured test:
1. If compression improves considerably, the piston rings are at
fault.
 2. If compression does not improve, valves are sticking or seating
poorly.
3. If two other cylinder indicate low compression pressure and
squirting oil on the piston does not increase the compression, the
cause maybe a cylinder head gasket leak between the cylinders.
Engine oil and/or coolant in the cylinders could result from this
problem.
Note: an engine compression test is easy to do but, if the result need
to be tempered with the knowledge of testing conditions that reduce
the accuracy of your test. As the battery gets hotter and the engine
cools down, your results from any one cylinder will change. It is
important to do the test a quickly as possible, with as little cranking
as needed to complete the test. Circumstances arise where a more
accurate leak down test should be utilized before you start tearing
the engine down. Reading that are at the extremes of the chart.
(Meaning over-all very high or very low readings), may indicate
conditions inside the cylinders that a compression test won’t depict
properly.

C. RECOMMENDATIONS ARE GIVEN BASED ON THE RESULTS

INTERPRETED
Compute the mathematic by yourself but the following chart
reference will be used by the mechanic when checking cylinder
compression pressures (to avoid mathematical errors) the chart (below
has been calculated so that the lowest reading number is 75% of the
highest reading.
Note: the “actual” compression readings are all important, keep in
mind that few engines will run with a compression under 100 PSI.
However, there are some engines that will test with readings in the
90 PSI range at a regular basis.

CHART OF COMPRESSION PRESSURES THAT RANGES MINIMUM AND

MAXIMUM WILL BE THE BASES OF TECHNICIAN RECOMMENDATION.

Maximum
Minimum PSI Maximum PSI Minimum PSI
PSI
135 . . . . . . . . . .101 192 . . . . . . . . . .144
136 . . . . . . . . . .102 193 . . . . . . . . . .145
139 . . . . . . . . . .104 196 . . . . . . . . . .147
140 . . . . . . . . . .105 197 . . . . . . . . . .148
143 . . . . . . . .. . 107 200. . . . . . . . . . 150
144 . . . . . . . . . .108 201 . . . . . . . . . .151
147 . . . . . . . . . .110 204 . . . . . . . . . .153
148 . . . . . . . . . .111 205. . . . . . . . . . 154
151 . . . . . . . . . .113 208 . . . . . . . . . 156
152 . . . . . . . . . .114 209. . . . . . . . . . 157
153 . . . . . . . . . .115 211 . . . . . . . . . 158
156 . . . . . . . . . .117 213 . . . . . . . . . .160
157 . . . . . . . . . .118 216. . . . . . . . . . 162
160 . . . . . . . . . .120 217 . . . . . . . . . .163
161 . . . . . . . . . .121 220 . . . . . . . . . .165
164 . . . . . . . . . .123 221 . . . . . . . . . .166
165 . . . . . . . . . .124 224 . . . . . . . . . .168
168 . . . . . . . . . .126 225 . . . . . . . . . .169
169 . . . . . . . . . .127 228. . . . . . . . . . .171
172 . . . . . . . . . .129 229 . . . . . . . . . .172
175 . . . . . . . . . .131 232 . . . . . . . . . .174
176 . . . . . . . . . .132 233. . . . . . . . . . 175
177 . . . . . . . . . .133 236. . . . . . . . . . 177
180 . . . . . . . . . .135 237. . . . . . . . . . 178
181 . . . . . . . . . .136 240 . . . . . . . . . .180
184 . . . . . . . . . .138 241 . . . . . . . . . .181
 187 . . . . . . . . . .140 244. . . . . . . . . . 183
188 . . . . . . . . . .141 245. . . . . . . . . . 184
189 . . . . . . . . . .142 248 . . . . . . . . . .186
249 . . . . . . . . . .187

I therefore recommend that if below the minimum specified

compression pressure the Engine, will be subjective to General Engine
Overhaul.
Note: No top overhaul will be allowed by the car manufacturer.

ASSESSMENT PERFORMANCE
LO 3. Conduct Compression Testing

Workmanship/Performance Points

A. Tested the compression pressure of four cylinders diesel 35

engine safely within the time frame required.

 25 to 40 minutes - - - - - - - - - - - - - - - - - - 35

 41 to 59 minutes - - - - - - - - - - - - - - - - - - 25

 1 hour – up - - - - - - - - - - - - - - - - - - - - - - 15

B. Computed the test result of compression pressure of

every cylinder (4 cylinders) 35

 All cylinders computed correctly - - - - - - - - 35

 Three cylinders computed correctly - - - - - 30

 Two cylinders computed correctly - - - - - - - 25

  One cylinders computed correctly - - - - - - - 20

 None - - - - - - - - - - - - - - - - - - - - - - - - - - 15

C. Recommending solution to specific trouble per result of 30

the cylinder.
 All cylinders recommended correctly - - - - 30

 Three cylinders recommended correctly- - - 25

 Two cylinders recommended correctly- - - - 20

 One cylinders recommended correctly - - - - 15

 None - - - - - - - - - - - - - - - - - - - - - - - - - - 10

100

ACKNOWLEDGMENT

Copyright Department of Education 2008

First Published May 2008

This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Development of the Philippines on
May 5-10, 2008.

This learning instrument was developed by the following personnel:

Technology Teachers:

TEAM LEADER: GEORGE CALLANTA

Members : ROBERT DOMINGO

JOHN DIEGO

LINO OLIT

ROMEO IBLOGUIN

NELSON SENEDO

ENGLISH : BELEN TADO

Facilitator : Beatriz Adriano

This work was produced with funding provided by the Department of

Education.
REFERENCES

1. Diesel Mechanics by: Erich J. Schulz Copyright ©1977 by Mc

Graw-Hill, Inc..
2. Diesel Engines by J.N. Seale Copyright © 1977 by Butterworth &
Co. (publishers) Ltd.
3. Diesel Engine Manual by: Perry O. Black Copyright © 1964 by
Howard W. Sams & Co., Inc., Indianapolis, Indiana.
4. Automotive Mechanics 8th Edition by William H. Crouse Copyright
© 1982 by MC Graw-HiIl, Inc.
5. Automotive Mechanics 10th Edition by: William A. Crouse and
Donald L. Anglin. Copyright © 1993 by: GLENCOE Division of Mc
Millan /Mc Graw-Hill School Publishing CO

Manuals:
1. ISUZU WORKSHOP MANUAL C240 MODEL DIESEL ENGINE BY
ISUZE MOTORS LIMITED TOKYO, JAPAN.
2. SERVICE TRAINING MANUAL OF MITSUBISHI 4D56 DIESEL
ENGINE. BY OVERSEAS SERVICE DEPARTMENT MITSUBISHI
MOTOR CORPORATION.

Internets
1. http://dodgeram.info/tsb/recalls/605.htm
2. http://www.autozone.com/az/cds/en_us/0900823d/80/16/f3/5
7/0900823d8016f357/repairInfoPages.htm#hd1-1-2
3. http://www.valvoline.com/carcare/articleviewer.asp?
pg=ccr20060201d2&cccid=2&scccid=5
4. http://www.tpub.com/content/construction/14264/css/14264_1
05.htm