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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Unit 157: Knowledge of diagnosis and rectification of light

vehicle engine faults
Handout 8: Diagnosing and rectifying faults

Fault diagnosis
In order to carry out efficient fault diagnosis it is important to have a thorough
understanding of the operation of the relative system and components and be able to
adopt a logical approach to finding the fault. In order to locate the fault you also need to
fully understand the symptom; this will initially be obtained from the driver/owner.

Remember that many of the components are linked; a fault in one component can cause
a symptom of a fault in another component, so it is important to check this and isolate
any other associated faults. For example, when testing for an ignition system fault and a
fault at the spark plug is indicated, it may be that the component providing the spark is
faulty, therefore producing a faulty spark at the plug (the fault being not in the spark plug,
but some other component).

Systems are interlinked and a fault in one system can produce a symptom of a fault in
another system. For example, fuel and ignition systems share common sensors, which
can sometime cause confusing results. Make sure you fully check all associated
systems and components before deciding where the fault is.

At all times it is important to adopt the correct and safe working procedures. You may
have covered this in some of the other units, but have a look at Handout 1 from Unit
152. If you have covered this in a previous unit it will allow you to confirm your
knowledge, otherwise you may need to study the information further.

The diagnosis of some faults is very complex and may involve specific test equipment.
This handout will only cover the general and basic requirements and refer to example
procedure and equipment. Your tutor will provide you with specific handouts on the
diagnostic procedure to be adopted, and the equipment used for the vehicle you are
working on in your centre. If you are on work experience, or working in the automotive
industry, then your workplace will provide you with the appropriate vehicle and
equipment information.

Engine symptoms and faults

The symptoms can include some of the following:
 excessive noise from components such as:
o crankshaft and bearings
o pistons and piston rings
o valves and valve operating mechanisms.
 poor performance or incorrect running and these can be caused by:
o engine mechanical faults
o system faults such as:
 cooling
 electrical
 fuel
 ignition.
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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

The initial testing for excessive noise will usually be by aural testing; in many cases,
once the initial diagnosis has been carried out it may then require the engine to be
dismantled to confirm the fault. These faults may be due to excessive wear or failure of
the component. Once dismantled, some of the checks you may have to make are to:
 check the crankshaft for cracks
 check the crankshaft for distortion
 check component security such as flywheel
 check the flywheel for distortion
 check the main and big end bearings for wear
 measure the crankpins for wear
 measure the main bearing journals for wear.
Note that these are only examples and your tutor will demonstrate how to carry out these
checks and take any measurements.

Below are some of the tools that you may use to make these checks.

dial gauge vernier gauge external micrometer

If the fault results in poor performance, such as excessive exhaust smoke, loss of
coolant or misfiring, and an engine mechanical fault is suspected then, then it is often
possible to carry out tests to diagnose the fault or eliminate suspected faults. There are
two tests commonly used for diagnosing these faults:
 compression test
 cylinder leakage test.
These tests are carried out in different ways, but will both allow checking of:
 cylinder head/cylinder head gasket fault
 excessive piston/ring wear
 faulty valves/valve seats.
Your tutor will demonstrate how to carry out some of these tests and provide you with
information on the use of the equipment at your centre.

Fuel system symptoms and faults

Some of the symptoms that can occur to the fuel system are:
 engine stalling
 excessive black smoke
 excessive fuel consumption
 incorrect CO/HC output
 incorrect idle speed
 poor starting
 poor acceleration.
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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Some of the faults that can occur are:

 incorrect fuel pump pressure
 blocked or partially blocked air filter
 blocked or partially blocked fuel filter
 blocked tank breather or breather control fault
 carburettor, fuel metering, injector faults
 electrical faults (fuse, connections, etc)
 incorrect adjustments
 induction air leaks
 linkage faults
 sensor faults.

A range of equipment is available to carry out fault diagnosis on fuel systems, including:
 exhaust gas analysers
o used to check the CO and HC readings
 fault code reader/scanners
o used to read fault codes for the various sensors, etc.
 multi-meters
o used to check electrical circuits, connections, etc
 oscilloscopes
o used to check the waveform patterns for various sensors, etc. (see
diagrams below)
 pressure gauges
o used to check the fuel delivery pressure
 smoke meter
o exhaust gas density of compression ignition engines

Examples of oscilloscope patterns for some sensors/components:

Hot wire air flow meter

(Picoauto)
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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Fuel pump output (Picoauto)

Fuel injector (Pico)

Compression ignition glow

(heater) plug (Picoauto)

Your tutor will demonstrate how to carry out some of these tests and provide you with
information on the use of the equipment at your centre.

For further examples of patterns access Pico Auto at http://www.picoauto.com

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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Some of the following additional symptoms and faults may occur on compression ignition
engine fuel systems:
 poor starting
o heater plug faults
 excessive black exhaust smoke
o too much fuel
 excessive white exhaust smoke
o head gasket fault
o incorrect pump timing
o low compressions
 excessive blue exhaust smoke
o excessive oil entering the combustion chamber

Ignition system symptoms and faults

Some of the symptoms that can occur to ignition system are:
 backfiring
 detonation
 engine stalling
 low power output
 misfire
 poor or no starting.

Some of the faults that can occur are:

 damage to insulation particularly HT components
 faulty coil insulation
 faulty coil windings
 faulty HT leads
 faulty switching device
 incorrect ignition timing
 incorrect spark plug
 linkage faults
 sensor faults
 spark plug faults.

A range of equipment is available to carry out fault diagnosis on ignition systems and
they can include:
 fault code reader/scanners
o used to read fault codes for the various sensors, etc.
 multi-meters
o used to check electrical circuits, connections, etc
o used to check lead resistance
 oscilloscopes
o used to check the waveform patterns for various sensors, components,
o etc. (see diagrams below).
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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Examples of oscilloscope patterns for some sensors/components/systems:

Ignition secondary circuit

(Picoauto)

Magnetic field strength of

primary circuit (Picoauto)

Dwell period (Picoauto)

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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Your tutor will demonstrate how to carry out some of these tests and provide you with
information on the use of the equipment at your centre.

For further examples of patterns access Pico Auto at http://www.picoauto.com

Engine management systems

These systems are used to control ignition, fuel and other engine systems, so faults in
these systems, as indicated above, can also be caused by faults in the engine
management system. Management systems can control:
 dwell angle
 exhaust gas recirculation
 idle speed
 ignition timing
 lambda
 valve timing.
This needs to be taken into account when carrying out fault diagnosis on the various
systems.

Your tutor will demonstrate how to carry out some of these tests and provide you with
information on the use of the equipment at your centre.

Induction and exhaust system symptoms and faults

Some of the symptoms that can occur to induction and exhaust systems are:
 loss of power
 excessive fuel consumption
 excessive noise
 vibrations.

Some of the faults that can occur are:

 blocked or partially blocked air filter
 blocked or partially blocked silencer
 excessive exhaust noise
 faulty catalytic converter
 faulty pressure charger
 insecure or broken components.

Some of these faults can be diagnosed by aural or visual checks and in some cases
special equipment may be required, this can include:
 exhaust gas analysers
o used to check the catalytic converter
 fault code reader/scanners
o used to read fault codes for the various sensors, etc.
 multi-meters
o used to check electrical circuits, connections, etc
 oscilloscopes
o used to check the waveform patterns for various sensors, etc. (see
diagrams below)
 pressure/vacuum gauges
o used to check turbo charger operation.
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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

Example of oscilloscope pattern for some sensors/components/systems.

Lambda sensor
(Pico)

Your tutor will demonstrate how to carry out some of these tests and provide you with
information on the use of the equipment at your centre.

Heating and cooling system symptoms and faults

Some of the symptoms that can occur to heating and cooling systems are:
 coolant loss
 interior heating/demisting/cooling not working
 overheating
 undercooling.

Some of the faults that can occur are:

 sensor fault
o poor connections
o unit not working.
 coolant leakage from
o engine unit
o heater unit
o hoses
o radiator
o water pump (impeller).
 control fault
o cable damaged or broken
o relay fault.
 fan fault
o drive belt slipping or broken
o electrical connection or unit fault.
 interior cooling fault
o condenser
o receiver
o dryer
o refrigerant.
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Level 3 Diploma in Light Vehicle Maintenance & Repair Principles Unit 157 Handout 8

 poor coolant circulation

o blockage in radiator
o blockage in water jacket
o faulty water pump (impeller).
 thermostat fault
o not closing
o not opening
o opening at incorrect temperature.

A range of equipment is available to carry out fault diagnosis on ignition systems,

including:
 Air conditioning test unit
o Do not carry out work with the refrigerant system unless you have
the appropriate qualification, this is a legal requirement.
 fault code reader/scanners
o used to read fault codes for the various sensors, etc.
 multi-meters
o used to check electrical circuits, connections, etc
 pressure tester
o used to pressure test the system for leakage
o used to test the pressure cap operation
 temperature sensor
o used to check temperature through the radiator
o used to check temperature through the cylinder block.

Your tutor will demonstrate how to carry out some of these tests and provide you with
information on the use of the equipment at your centre.