Base Engine Analysis

A course handout for tonight's webinar is available at

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Audio Available through PC speakers or by phone

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TECH B Training Series

Q1 TECH
Q1B LEVEL

Q2

Top OBDII
Codes and their
Fixes
on demand
on demand
Q2e-learning module

e-learning module

Q3
on demand

on demand

e-learning module

e-learning module

Smartlive
Charging
and Computer
web
live webControlled Charging
live web
Q3

based training

based training

Q4

based training

live web
based training

Troubleshooting Electrical Accessory Circuits PART 1 including wiring diagrams

Q4

Instructor Led
Training

Instructor Led
Training

Instructor Led
Training

Instructor Led
Training

Base Engine Analysis including Timing Belt and Misfire Diagnostics

live web based
training

live web based

training

live web based

training

live web based

training

TECH B Training Series

Q1

Q2

Q3

Q4

on demand

on demand

on demand

on demand

e-learning module

e-learning module

e-learning module

e-learning module

live web

live web

live web

live web

based training

based training

based training

based training

Instructor Led
Training

Instructor Led
Training

Instructor Led
Training

Instructor Led
Training

live web based

training

Base
live web Final
based in the
live
web based
training Engine Series
training

live web based

training

On Demand and Live Web Training a

technician can view the from ANY PC
With any type of connection or speakers

Live Web Training 7PM / 9PM EST

6 PM
6 PM

7 PM

7 PM
9 PM

Guidelines
Webinar times:
7:00 to 8:00 PM EST
9:00 to 10:00 PM EST
Q and A session at the end of
the training webinar
HOLD YOUR QUESTIONS TO
THE END!
Questions on this technical
topic only

Any questions about

administrative procedures
or course credit for
attendance please refer
them to your service
manager, technical trainer
or training manager
3 Poll questions to verify
participation only, not used
for pass or fail

Objectives
Diagnosis and understand intake manifold
failures
Understand valve adjustments and the
possibility of engine damage
Understanding clogged catalytic
converters and its effect on back pressure

2002 Ford Windstar 3.8 Liter

Ford 3.8 V-6

P0171, 174
Caused By
Leaking Intake
Gasket

Check Freeze Frame for Clues

Freeze Frame Data

Scan Tool PID

Description

Value

FUEL 1 STATUS

BANK 1 FUEL SYSTEM STATUS

CLOSED

FUEL 2 STATUS

BANK 2 FUEL SYSTEM STATUS

CLOSED

LOAD

ENGINE LOAD

15.1%

ECT

ENGINE COOLANT TEMPERATURE

199 F

STFT1

SHORT TERM FUEL TRIM BANK 1

5.5%

LONGFT1

LONG TERM FUEL TRIM BANK 1

25.6%

STFT2

SHORT TERM FUEL TRIM BANK 2

5.8%

LONGFT2

LONG TERM FUEL TRIM BANK 2

25.2%

RPM

ENGINE SPEED

VSS

VEHICLE SPEED

825
0 MPH

Fuel Trim: Short and Long Term

Taking Fuel Away

-25

Adding Fuel

-5

+5

+25

Fuel Trim: HIGH at High RPM?

Taking Fuel Away

-25

Adding Fuel

-5

+5

+25

Fuel Trim HIGH at High RPM

Check MAF and Fuel Pressure First

Fuel Trim: HIGH at Idle?

Taking Fuel Away

-25

Adding Fuel

-5

+5

+25

Fuel Trim HIGH at Idle

Check For a Vacuum Leak

Ford 3.8 Liter Windstar

Ford 3.8 liter and we suspect

an intake gasket leaking
causing a P0171, P0174

Smoke Machine For Vacuum Leaks

EVAP smoke machine

creates white smoke that we
can pump into the intake

Smoke Testing The Intake Manifold

We used the pressure

regulator vacuum hose for
pumping smoke into the
intake

Smoke Exposing A Leak

As the intake manifold fills

with smoke, the vacuum leak
becomes visible

Using A Flammable Agent

Watching Fuel Trims

Using propane, we can affect

fuel trims if directed at a
vacuum leak

Fuel Trims Responding

As we added propane around

the intake gasket, we can
watch the fuel trims react

First poll question

First poll question

Ford Service Bulletin

Article No.
03-16-1
08/18/03
FORD:
1999-2003 WINDSTAR
This TSB supersedes articles 03-4-7 and 00-21-8.
ISSUE
Some vehicles may exhibit a check engine light on and
lean Diagnostic Trouble Codes (DTC's) P0171/P0174
(system too lean bank 1 or 2) stored in memory.

New Valve Cover, Bolts & Vacuum

We will be replacing the left
valve cover, vacuum hose
and gaskets

Upper Intake Removed

The cowl is removed

The upper intake

disassembles in 2 sections

Upper Intake

Upper section of upper intake

manifold

Upper Intake Lower Half

When the upper section of the

upper intake is removed, we
can see the bolts and
insulators that need to be
replaced

Lower Half Needs To Be Removed

The lower section will need to

be removed, but the lower
intake itself will not need to
come off

Lower Intake

Note: While the upper intake

is removed, the EGR ports
are exposed and should be
cleaned as well

Lower Half Of Upper Intake

Make sure you clean the

gasket area thoroughly and
position gaskets correctly

Original Design Valve Cover

The original valve cover

before removal located on the
radiator side of the engine

Upper Intake & Valve Cover Removed

The updated valve cover will

have an improved baffle

New Bolts & Insulators

Replacement bolts and

insulators for the lower
section of the upper intake

New Bolts & Insulators

New insulators with bolts are

installed on the lower section

Rechecked Fuel Trims

After we re-assembled the

intake and valve cover, further
testing shows the lean
condition is fixed

MIL On And Poor Performance

2001 Volvo Clogged
Catalytic Converter

Lack of power
Slow to accelerate
Possible MAF codes

Exhaust Back Pressure Tester

When inserted before the Cat,

we will bring the engine up to
2000 rpm and see how much
pressure is present

Finding The O2 Sensor

Removing O2 Sensor

We need to find the connector

to the O2 sensor so we can
remove it and test back
pressure

Installing Gauge

Remove O2 sensor
Install adapter for gauge
Connect gauge and test

Connecting The Gauge

The adapter installed and now

the gauge is connected. Now
we can start the engine

3 PSI Back Pressure On Our Tool

On our test we see 3psi, more

than double the allowable
pressure we want

Clogged Catalytic Converter

Heres a removed catalytic

converter showing it starting
to clog

Clogged Catalytic Converter

Another picture of a
completely clogged catalytic
converter

Damage Due To Back Pressure

In some cases damage can

occur if the clogged catalytic
converter is not replaced

Second poll question

Second poll question

Valve Adjusting & Timing Belt SVC

Honda Random
Misfires P0300
From Tight Valve
Adjustments

Timing Belt Service

Timing belt service is usually
performed Between 60K
100K mile intervals

Always Follow Manufacturers

recommended intervals

Interference Engine With Timing Belt

If timing belt failure occurs,
depending on the engine it
could cause catastrophic
damage

Interference Engine
Here we see a piston striking
the valve, causing damage to
the valve and or piston.

Interference Engine Damaged

This is the result of an

interference engine after a
timing belt failure. All valves
are bent.

Bent Valve Unable To Seat

After Valve stem bends,

its unable to close.

Bent Valves Removed

Valve Stems Bent From

Hitting Pistons

Non Interference With Timing Belt

Non interference engines are
designed, that if the timing
belt fails, no engine damage
will occur.

Why Valves Need Adjusting

To keep your customers engine running
well
Manufacturers recommended service
intervals
To correct customers complaint of lack of
fuel mileage
To quiet ticking valves
To prevent engine damage

Hydraulic Lifter Self Adjusts

Hydraulic lifters usually dont
have a valve maintenance
valve adjustments

Honda V-6 Valve Followers

In some applications,
including Honda, the valves
require periodic adjustment

Valve Adjusted Too Tight

As the engine wears, and this
is sometimes the case with
Honda, the valve adjustment
gets tighter. This can lead to
the valve failing.

A tight valve adjustment can lead to premature

valve failure

Adjusting Valves
When using the service
information you will be
instructed to start at #1
cylinder TDC, and rotate the
engine incrementally to adjust
all the valves

NOTE: You can begin with any cylinder as

long as you remember where you started

Valve Adjustment

Adjustments are made either

hot or cold depending on the
service information

Screw Adjuster

Some applications use a

locking nut and adjuster
screw

Make Sure Cam Is In Position

Make sure the cam is

positioned correctly

Follower Above Cam

The feeler gauge should have
slight resistance pulling
through, similar to a magnet

Some applications have the

followers above the cam

Followers Underneath Cam

Followers underneath cam,
and the adjuster screw fixed
on the dead

Valve Shims

Applications That
Require Shims to
Adjust Valve Lash
Bucket and shim tappets
Requires special tools
Can be very time consuming
Toyota is a bucket tappet
engine

Adjusting Shim Type Lifters

Some applications, including

Toyota, that have shims
between the lifter and cam
lobe

Very Tight Location

Adjusting shim type valve
adjusters can be very difficult
, they are underneath the cam

Cam Shaft Removed

When the cam is removed we
can clearly see the layout of
the lifters & shims

Valve Lifter & Shim Removed

Also showing the valve
exposed with no lifter and
shim in place

Valve Lifter Not Hydraulic

These lifters are designed to hold
adjusting shims between the lifter
and the cam lobe

Shim Fits Into Lifter

This shows how the top of the

lifter is recessed, allowing the
shim to fit tightly in place

The Cam Needs To Be Positioned

Cam
Clearance
Tappet

Tappet
to
Valve
Stem

Make sure the cam is

positioned correctly

Shims Need To Be Measured

When adjusting valves, the

original shim needs to be
measured against the
replacement to either loosen
or tighten the adjustment

Shim Valve Adjustment Assortments

Depending on how many

vehicles you do you may want
to by assortments of shims

Conversion To Millimeters
When replacing shims have a metric conversion table
in case

New shims have size in

millimeters printed on them

Valve Shim Adjusting Tools

Its important to have the proper tools when servicing
Shim adjusters

Valve Spring Compressed

Valve
Clearance
Adjuster
Valve
Lifter
Retainer

Not only does the valve need

to be compressed but held
down in place with enough
room to pull the shim out

Second Poll Question

Valve Spring Keepers

Valve
Keepers

Valve
Spring
Retainer

Valve
Spring

A typical valve, including spring,

Retainer, and keeper

Valve
Keeper
Grooves

Misfire Causing Vacuum Fluctuation

Misfire and the vacuum gauge fluctuates

Checking for a broken valve spring

Valve Cover Removed

The first thing we saw was a

broken valve spring

Broken Valve Spring

A broken valve spring is

important to replace as soon
as possible

Spring Clearly Broken

The valve spring fell apart

Causing a misfire
Creating a fluctuation on the vacuum
gauge

Valve Fell Into Cylinder

In some instances, a broken
valve spring can let the valve
fall into cylinder

Coolant Leaks

Coolant leaking from rear of engine

Coolant smell from engine

Cooling System Issues

Cooling System
Failures Due To
Lack of
Maintenance

Poor Maintenance Causes Damage

Lack of maintenance causing

heavy rust and sediment build
up can cause gaskets and
seals to fail

Pressure Testing The Cooling System

Pressure testing the cooling system to help find

the leak

Pontiac Grand Am V-6

Intake gasket leaking coolant

from the rear corner of the
intake

Common Leak Area

A common place for oil and

coolant to leak is the rear of
the intake manifold

GM 3400 V-6
Depending on the application,
and this is especially true with
the mini vans, the engine will
need to be positioned to allow
the intake to be removed

Engine Positioning Tool

The tools will allow you to tip
the engine toward the front of
the car

Upper Intake Removed

On this engine the valve
covers mount to the intake
and the head

Lower Intake Removed

With the lower intake

removed, we can now see
where the gasket has failed

Half The Push Rods Under Gasket

Unfortunately, to replace the

intake gaskets, the push rods
will need to be removed

2 Different Length Push Rods

A very important aspect to

note, some vehicles will have
different length push rods

Closer Look At Intake Gasket

A closer look, we see how the

gasket separated

Replacement Gasket

The new gasket will be

updated

Overheating

Engine overheating
Cooling system builds high pressure
White smoke from tail pipe

Testing For A failed Head Gasket

Dual chamber
combustion tester

We may need to use a combustion tester to determine

Head gasket failure

Block Tester Single Chamber

Block testers use a chemical

that changes color to
determine CO2 in the coolant

Block Tester Single Vacuum

A couple of variations of block

testers are available

Dual Stage Block Tester Kit

Testers with 2 chambers are
available, these seem to work
better.

Drawing In Coolant Vapors

Remove some coolant, so the

tester wont draw coolant into
the chamber

Fluid With No Combustion Detected

Fresh detection fluid in a 2

chamber tester, now we begin
to draw vapors into the
chambers

Fluid With Combustion Detected

When we find CO2 in the

coolant vapors, the color of
our fluid changes to yellow

Combustion Gas Changes Fluid

These 2 pictures show the

color change that you should
expect to see

Failed Head Gasket

When we find a bad head
gasket with our combustion
tester the head will need to be
removed

Coolant Burning

An engine burning coolant,

the smoke has a distinct
smell and is white in color

Head Gasket Replacement

If you find the head gasket

failed, then replacement
should due. If the gasket
looks good then the head
should be testes

Third poll question

Third poll question

Summary
Examined fuel trim issues and leaking
intake gaskets
Learned about clogged catalytic
coverts and how to diagnosis them
Learned the importance of valve
adjustments and damage that could
result if not performed correctly
Looked at cooling system failures,
diagnosis and repair

Q and A session-Thank you for attending

Download of handout for tonight's course available at
www.meatraining.com/ttcfaq.htm
Q and A session is voluntary
Questions are repeated to whole group anonymously
No names attached to the questions
Questions on this technical topic only