Level 2 Light Vehicle Maintenance and Repair

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Engine running and performance problems have been greatly reduced in modern cars because many engine management systems are so reliable. If there are problems with modern cars they are often caused by a lack of maintenance or electrical and electronic failure. When carrying out regular maintenance you should check if the fuel and air supply components below need to be replaced:
Key terms Compensate balance out a bad effect of something by making up for it by exerting a positive effect or force.

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The air filter needs to be replaced regularly. If it is not replaced regularly it will in time become blocked and reduce the flow of air into the intake system. Many engine management computers will now compensate for the reduced airflow. However performance will be affected because less fuel will be injected and the volumetric efficiency will have fallen.

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The fuel filter needs to be replaced regularly. If it is not replaced regularly it will in time become blocked and reduce the flow of fuel into the injection system. This will result in less petrol reaching the fuel rail and the car showing signs of a symptom known as starvation when you try to accelerate. If the car is kept to slow engine revs or tick-over, the engine will run smoothly. Starvation takes place if the car is driven much harder as the engine will start to falter and hold back.

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If air is allowed to enter a diesel fuel system, bubbles can form that will cause a vapour lock. This is particularly likely to happen in the pumping elements of the system. Vapour lock can prevent the engine from starting or running. An air leak in the diesel fuel system while the engine is running can lead to erratic idle or stalling.

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Chapter 4 Light vehicle fuel, ignition, air and exhaust systems

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Just like a petrol fuel system the fuel filter of a diesel fuel system can become blocked over a period of time. This can reduce performance or may even stop the engine from starting. A diesel fuel system needs a clean supply of fresh fuel so it can work efficiently. Just like petrol in a petrol fuel system, diesel will be passed through a fuel filter element to help remove particles of dirt (see Figure 4.20).
Bleed screw Fuel outlet Fuel inlet

Filter element Filter housing

Sedimenter Water drain screw

Figure 4.20 Fuel filter element

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Like brake fluid, diesel fuel is hygroscopic. This means that it absorbs moisture from the surrounding air. Over time diesel fuel can be contaminated with large quantities of water. This can result in running problems or prevent the engine from starting. If not fixed quickly this could create a misfire because water is not combustible. The metal components of fuel injectors and pumps will corrode if water is present in the fuel. Many diesel fuel systems use a sedimenter to help overcome the problem of water in fuel. The sedimenter is a small container mounted in the delivery fuel line. Some manufacturers produce the sedimenter as part of the fuel filter housing (see Figure 4.20). Diesel fuel and water have a different density and specific gravity. This means that the diesel fuel will normally float on top of the water. As fuel flows through the sedimenter water particles normally settle out in the bottom of the container. This allows a clean supply of fuel into the injection system. Many manufacturers include a facility in the fuel filter element to drain the sedimenter during routine maintenance procedures.

Key terms Contaminated made impure by contact with or the addition of a poisonous or polluting substance. Density the degree to which a substance is solid.

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Chapter 4 Light vehicle fuel, ignition, air and exhaust systems

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Engine knock in a diesel fuel engine is usually an indication that a fuel with a lower cetane value than recommended is being used. Engine knock in a diesel fuel engine can also be caused by incorrect fuel injection timing and leaking injectors.

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Turbochargers fitted to diesel fuel engines can fail in a number of ways. Air leaks and seizure of the wastegate are common. It is important that a good supply of lubricating oil is available to the spindle bearings of a turbocharger because it spins at very high rotational speeds. If the spindle bearings fail the turbocharger can become noisy or stop working altogether.
Safe working Cars fitted with a turbocharger should be slowed down to tick-over for a short period of time before the engine is turned off. If the engine is not slowed down to tick-over before being turned off oil pressure to the turbocharger spindle bearings is lost. Losing oil pressure to the spindle bearing will result in wear of the bearings because the turbocharger will still be spinning at high speed but without oil to lubricate the spindle bearings.

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An air leak in the petrol fuel system is a common cause of a weak fuel mixture. A weak fuel mixture contains too much air and not enough fuel. This results in erratic idle. This is erratic running which known as hunting, particularly around idle speed. If this occurs, it is commonly caused by an air leak in the intake system, creating a weak mixture (too much air, not enough fuel).

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A rich fuel mixture in a petrol fuel system contains too much fuel and not enough air. A rich fuel mixture can lead to poor engine performance, excessive fuel consumption and high emissions. Common engine faults that may cause a rich fuel mixture include: blocked air filters leaking fuel injectors high fuel pressure.

Safe working

It is important to make sure there are no leaks in a petrol fuel system because they run under pressure. Petrol fuel is very unstable and if allowed to leak around hot engine components it could easily ignite causing a fire.

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