1 Conduct engine compression test.

DEFINITION
Vehicle Engine Overhauling is a scope of competency to
examine and restore the diesel / petrol engine

components to meet manufacturers specifications and

tolerances during overhaul. Proper dimensions and

tolerances must be met to obtain proper performance

and maximum engine life.
Tools, equipment and parts confirmed
according to job requirement.
Tools, equipment and parts confirmed
according to job requirement.
Tools, equipment and parts confirmed
according to job requirement.
Tools, equipment and parts confirmed
according to job requirement.

ADD ON!..
 Engine compression tests are completed in accordance
with the workshop manual

Compression Test

A compression test will give you a general idea about the condition of the top

end of the engine. It’s a good idea to do a compression test before

doing any engine maintenance or servicing. If the compression is low,

synchronizing carburetors or changing the engine oil will be of no value until the cause of

the low compression is identified and corrected. Keeping a written record of the

compression will provide a history of the engine’s condition and may point out a

developing problem.
 Engine compression tests are completed in accordance
with the workshop manual

This is a :- COMPRESSION TESTER

A compression test reveals the condition of
your engine's valves, its valve seats, and piston rings and
whether these parts are wearing evenly.
Healthy engines should have compression over 100 psi
per cylinder, with no more than 10 percent variation
between the highest and lowest readings.
Engine compression tests are completed in accordance
with the workshop manual

HOW TO DO A COMPRESSION TEST?

STEP 1 Remove the fuel pump and fuel-

injection fuses. Disconnect the main wire to
the coil and spark plug wires; remove spark
plugs.
Engine compression tests are completed in accordance
with the workshop manual

STEP 2 Start the threaded end of

the compression gauge in a spark
plug hole by hand.

STEP 3 Turn the ignition on, depress the throttle, and crank the
engine four revolutions. This should result in a stable reading; if
not, crank up to 10 revolutions, but do the same with all
cylinders.
 Engine compression tests are completed in accordance
with the workshop manual

STEP 4 Mark the pressure reading for

each cylinder on the valve cover in chalk, then
move to the next cylinder.

TIP For a cylinder below 100 psi, pour 1 teaspoon of

engine oil into the plug hole and retest. If the reading
jumps, the piston rings are worn. If not, think valve problems.
2 Conduct engine cylinder leakages test.

A leak down test requires the removal of all the spark plugs. The

crankshaft is then turned so that each piston is at top dead center

(both valves closed) when each cylinder is tested. ... Compressed air

(80 to 90 psi) is then fed into the cylinder. An engine is great

condition should generally show only 5 to 10% leakage.

 Conduct engine cylinder leakages test
Instead of measuring the engine's ability to create pressure, compressed
air is introduced into the cylinder through the spark plug hole. One
gauge on the tester measures the pressure of the air entering This is a :-CYLINDER LEAKAGE TESTER
the cylinder and the other measures the percentage of the air escaping
(or leaking) from the cylinder.

A BIT INFO
An internal combustion engine makes power by first drawing air
and fuel into the combustion chamber. Next is the compression
of the mixture and the addition of a spark. The harnessing of the
resulting contained explosion is ultimately what powers the car.
As an engine gets on in miles, the containment of this power can
be lost due to piston ring, valve or cylinder wall wear. Engine
performance will suffer as a result.
 Conduct engine cylinder leakages test

KNOW THIS FIRST BEFORE DOING LEAK TEST!

Pressure reading
A common test of an engine’s ability to compress the air-fuel mixture is an engine
compression test. A pressure gauge is connected in place of the spark plug. The engine is
then cranked to create a pressure reading. A compression test is a good way to check the
engine’s ability to create pressure. The gauge reads the positive pressure created by the
cylinder.

Loss reading
An engine leakdown test is a compression test in reverse. Instead of measuring the
engine’s ability to create pressure, compressed air is introduced into the cylinder through
the spark plug hole. One gauge on the tester measures the pressure of the air entering the
cylinder and the other measures the percentage of the air escaping (or leaking) from the
cylinder. The loss percentage will indicate the condition of the cylinder and overall
condition of the engine.
 Conduct engine cylinder leakages test

KNOW THIS FIRST BEFORE DOING LEAK TEST!

Top dead center

the cylinder being tested must be placed at Top Dead Center (TDC). The piston must be at
the top of its travel. The intake and exhaust valves must be closed. When the air is
compressed into the cylinder, the leakdown tester will measure any loss of air escaping
past valves or piston rings. If the cylinder is not at TDC, air escaping past an open valve
will give a false reading.

Reading results
No engine will have perfect sealing with 0 percent loss. Five to 10 percent loss indicates
an engine in great to good running order. An engine between 10 and 20 percent can still
run OK, but it’ll be time to keep an eye (or ear) on things. Above 20 percent loss and it
may be time for a teardown and rebuild. Thirty percent? Major problems. The percent of
leakage should also be consistent across the cylinders. Any great differences indicate a
problem in that cylinder.
 Conduct engine cylinder leakages test

KNOW THIS FIRST BEFORE DOING LEAK TEST!

Hearing problems
Beyond getting an overall picture of engine condition, the engine leakdown test is an
excellent way to pinpoint where problems are before tearing down the engine.
Listening for where the air is escaping by ear can isolate the problem.

•Intake valve : Air whistling out of the intake, carburetor or throttle body indicates a leak
at the intake valve.
•Exhaust valve : Air heard hissing out of the tailpipe, turbocharger or exhaust manifold
means an exhaust valve leak.
•Piston rings : Whistling or hissing out of the PCV valve, oil filler cap hole or dipstick tube
means the air is pushing past the rings. Suspect ring or cylinder wall wear.
•Head gasket : Air bubbles in engine coolant seen at the radiator filler cap could mean air
escaping into the coolant past the head gasket.
•Cracked cylinder head : Bubbles in coolant or coolant being pushed up out of the
radiator neck can also indicate cracks in the cylinder head or cylinder walls.
 Conduct engine cylinder leakages test

HOW TO DO LEAK TEST

Tools, supplies and instructions
You will need a compressed air source, a leakdown gauge kit, spark
plug socket, basic hand tools, vehicle service manual and a
notepad to record results.

Step 1 : Remove the spark plugs and rotate the engine to put the cylinder to be tested at
TDC. Tip: Insert a long screwdriver or extension into the spark plug hole and turn the
engine by hand with a socket on the crankshaft. When the screwdriver stops rising or
falling, you’re at TDC. Don’t turn the engine backward if TDC is missed. Go around again. In
a four-cylinder engine, cylinders one and four and two and three are at TDC at the same
time.
 Conduct engine cylinder leakages test

HOW TO DO LEAK TEST

Step 2 : Figure out which spark plug adapter works best and connect the gauge into
the hole. Put the vehicle in gear and set the parking brake to prevent the engine
from turning when air is compressed into the cylinder. Start with the regulator
turned counterclockwise to zero the incoming pressure. Connect compressed air.
Turn the regulator clockwise to pressurize air into the cylinder.
 Conduct engine cylinder leakages test

HOW TO DO LEAK TEST

Step 3 : Record leakage percentage for the cylinder. Remove the oil dipstick,
radiator cap and oil filler cap. Open the throttle body or remove the air cleaner.
Listen and watch. Wherever air is escaping will indicate where the problem is.
Disconnect the gauge and move to the next cylinder.
 Conduct engine cylinder leakages test

HOW TO DO LEAK TEST BY PICTURE

 Remove engine from vehicle.
Head mark 1

cam mark 1

crank mark 1

pully mark 1