No.

:
MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 1
TAREA: DIAGNOSTICO PRIMARIO DEL MOTOR DIESEL: MEDICION DE COMPRESIÓN
Semester: 2
NOMBRE:

SECURITY

SERVICE MANUALS

New systems and features are incorporated into the new models according to the evolution of the industry.
automotive. Therefore, it is becoming increasingly difficult for technicians to provide service to vehicles.
highly complex relying solely on their own experience.

In order to inform maintenance personnel worldwide about the procedures of

adequate maintenance and new technologies, one must be informed about the new
work techniques and/or technical variations that engines have undergone over time,
For this, it is necessary to work hand in hand with the service manuals.

USE OF TOOL AND INSTRUMENT INSURANCE:

Automotive repairs require the use of a variety of tools and instruments.

of measurement. These tools are manufactured for use in a specific way; they can only be
guarantee precision work and safety if used properly.

Basic concepts for the use of measurement tools and instruments:

- Learn the correct uses and functions: Learn the correct uses and functions of each
tool and measuring instrument. If used for a purpose other than the specified one, the
the tool or measuring instrument may be damaged and consequently the parts
the quality of the work can be damaged or put at risk.

- Learn the proper use of the instruments: Each tool and measuring instrument
has well-defined operating procedures. Make sure to apply them correctly.
tools with the workpieces, apply the appropriate force to the tools and adopt
appropriate work postures.

- Make a correct selection: There are several tools available to loosen the
bolts based on size, position, and other criteria.
Always select the tools to fit the shape of the piece and the place where
work is being done.

- Try to be organized: The measuring tools and instruments should be placed in a way
that they be easily accessible when needed and must be placed back in their place
when they have been used.

- Keep tools and instruments clean and in perfect condition: Tools and
instruments must be cleaned, and if necessary, greased, as soon as they have...
used. Any necessary repairs must be made immediately so that the
tools and instruments are always in perfect condition.

TO OBTAIN ACCURATE MEASUREMENT VALUES

 No.:
MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 2
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

Measuring instruments are used to diagnose the condition of a vehicle by checking if the
dimensions of the parts and the fitting conditions correspond to the standardized values and if the
parts of the vehicle or engine function correctly.

Aspects that must be checked before measurement:

- Clean the part to be measured and the measuring instrument: The debris or the oil.
Used can lead to errors in measurement values. Surfaces must be cleaned.
before taking the measurements.

- Select an appropriate measuring instrument: Select the measuring instrument of

agreement with the required degree of accuracy and the type of work to be performed.

- Calibrate the zero: Check that the zero is aligned in its correct position. The zero is the base.
for a correct measurement.

NOTICE:

1. Do not drop or strike the tool or any measuring instrument; the internal parts of the
precision instruments can be damaged.
2. Avoid the use or storage of these at high temperatures or high humidity levels.
they can produce errors in the measurement values if used under these conditions
environmental. The tool or instrument can deform if subjected to high
temperatures.
3. Clean the tool and instrument after use and store it in its original condition. Store it
tools and instruments only when the oil or waste dirt has been cleaned.
All measurement tools and instruments used must be returned in their original condition.
original and any equipment equipped with a dedicated case must be stored in it. The
Measuring tools should be stored in a defined place. If the tools are going to
store for a long period of time, apply rust protection oil
when necessary and remove the batteries from those instruments that have them.
 No.:
MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 3
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semestre: 2
NOMBRE:

IMMEDIATE TECHNOLOGY

OBJECTIVES At the end of the task, the student will be able to:

- Carry out compression measurement in diesel engines.

- Use the instruments appropriately for this process.
- Give a clear diagnosis based on the obtained and compared results.
with the manufacturer's technical specifications.

RESOURCES MATERIALES:
- Worksheet.

EQUIPMENT AND TOOLS:

- Instruction module. Diesel compression tester.
- Toolbox. - Batteries.

ENGINE DIAGNOSTIC - COMPRESSION TEST

The engine compression test is a

a good indicator of the engine condition is
very simple, quick, requires tools
low cost and helps a lot in the
correct diagnosis of the condition of the
motor.
Internal combustion diesel engines
require what the
compression of each
the cylinder be the same for
function properly
y dependent of the
air compression for
maximize energy
produced by the engine
during the process of
combustion. The
upward movement
of the piston in the stroke of
compression compresses the air in the combustion chamber. If there are leaks in the chamber of
combustion, part of the compression will escape, resulting in a loss of power
and excessive fuel consumption.

2. ENGINE SYMPTOMS BY COMPRESSION

When an engine has compression problems, it may exhibit one or several of the following.
symptoms:
- It emits smoke of any color.
- It is necessary to accelerate more than normal to move (lack of power).
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 4
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NAME:

- High fuel consumption.

- The idle revolutions are very variable.
- Starting problems.
- It keeps turning off constantly.

- Drink water or soda

3. CAUSAS DE PROBLEMAS DE COMPRESION

The causes of poor compression are due to the fact that the chamber does not have the necessary sealing and there are
leaks through some element of the camera, for example:

- Glow plug hole: The glow plug (preheater) may be faulty

placed, not tightened or the hole and/or thread may be damaged.
- Injectors: They may be loose or poorly adjusted, the seal at the tip of the injector worn or defective.
the seat or the hole and/or thread may be damaged.
- Valves: A damaged valve does not allow for a good seating in the head hole.
motor, allowing leaks. Burnt, worn, scratched, bent valves can be
the cause. Likewise, worn or damaged springs.
- Piston Rings: If the piston rings are loose in the piston or in the sleeve, they present
leaks.
- Cylinder head gasket: A damaged, poorly tightened, improperly seated, or poorly
Selected will allow leaks.
- Damaged head: An engine head with cracks will allow leaks.
- Engine block: If the engine block has cracks in any of the cylinders
then leaks occur.
- Poor synchronization: If the engine synchronization is not correct, they may not settle.
correctly the valves or not doing it on time, this may be due to a belt of
wasted synchronization or some problem in this subsystem.

4. HOW TO MEASURE COMPRESSION:

[Link] TEST
Engine compression can be easily checked with a compression tester.
(pressure gauge/compression gauge) that can be purchased on the market. This review provides a
good information about the condition of the engine wear.

To do this, you must follow the proper procedure:

 No.:
MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 5
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

a. Bring the engine to the normal operating temperature; a cold engine will allow for greater leaks of
compression due to the engine parts not having fully expanded.

b. Disconnect the power cable to the injection pump, the engine

diesel should not inject fuel during this process, so it is
it is advisable to disconnect the fuel cutoff solenoid cable
from the injection pump.

c. Remove all the preheaters and their electrical connections (3) or in such
in case all the injectors (2) and their high-pressure lines (1), depending
Wherever you are going to place the compression tester, do not remove the preheaters.
and injectors at the same time.

d. Select the appropriate coupling type for the preheater or injector where it can be connected to
compressor and place it instead of the preheater or injector, ensuring that when connecting it, it is
completely tape the hole where the preheater or the injector is installed in the engine head,
Then, place the manometer/compressor gauge. We will start the measurement with cylinder No. 1.

e. Turn the ignition key to the 'START' position to start the engine for a few seconds with the
accelerate all the way until the engine has turned a few times and the compression gauge registers the value
of the cylinder compression to be measured, it will rise from a value of 'zero' and will stop when the
compression should be the maximum that can be recorded for the cylinder.
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 6
TASK: PRIMARY DIAGNOSIS OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NAME:

f. Write down the pressure indicated by the pressure gauge on a piece of paper and then press the valve of
Download the manometer so that the needle of the compression gauge returns to zero.

Measurement of
Test in File No. 1 Case No. 2 Cil. No. 3 Cil. No. 4
compression
dry Kg/cm2 12
Psi 170

g. Press the release valve of the compression gauge to reset the indicator to zero, remove the
compressor and insert it into the next cylinder, repeat steps d, e, and f until finished with
all the cylinders.

The pressure of each cylinder must be very similar in all cylinders and match the one specified by the
engine manufacturer. The pressure difference should not exceed 10%. It is always advisable
refer to the specifications in the manual for each engine.

[Link] TEST:
The engine's wet compression test is performed by adding two tablespoons of oil.
(two strokes from a hand oil dispenser) before the placement of the compresimeter. This test provides a
good information about the wear state of the piston-ring-cylinder engine set.
 No.:
MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 7
TASK: PRIMARY DIAGNOSIS OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

To do this, you must follow the same procedure as the dry test, with the difference that you must
inject two shots of motor oil through the preheater or injector hole before each
verification.
Measurement of
Test Cil. No. 1 File No. 2 Cil. No. 3 File No. 4
compression
damp Kg/cm2 12
Psi 170

5. ANALYSIS OF THE COMPRESSION RESULTS:

5.1. DRY TEST:

For compression to be considered normal and to assume that the engine is in
good conditions, the difference between the reading of one cylinder and another should not exceed 10%
and must be within the normal ranges specified by the manufacturer, for this it must
refer to the specifications set forth in the manufacturer's manual. Consult the manual.
To better understand it, we will use as an example three cases of the same brand and model of
motor: Toyota 2C:

Case 1: When the compression is even and good in all cylinders:

Datos del fabricante: Dry test Diagnosis
Cil. 1 395 psi Good
Compression pressure:
30.0 kg/cm2(427 psi).
Cil. 2 380 psi Well
-Presión mínima:
25.0 kg/cm2(356 psi) Cil. 3 382 psi Good

Difference between each cylinder:

Cil. 4 394 psi Good
Less than 5 kg/cm2(71 psi).

Case 2: When the difference is greater with respect to the minimum pressure given by the manufacturer:

Manufacturer's data: Dry test Diagnostico

Compression pressure: Sole. 1 330 psi Bad

30.0 kg/cm2(427 psi).
Cil. 2 325 psi Bad
-Presión mínima:
25.0 kg/cm2(356 psi). Cil. 3 325 psi Bad
-Difference between each cylinder:
Less than 5 kg/cm2(71 psi). Cil. 4 320 psi Bad

If we have this case, it can be:

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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 8
TASK: PRIMARY DIAGNOSIS OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

- If the intake or exhaust valves have been miscalibrated, check the calibration and redo it.
to measure.
- That the air intake of the intake manifold has been blocked or obstructed, check and redo.
to measure, the entrance must be completely clear.
- Low compression in all cylinders can indicate a problem with washed cylinders. This
It means that too much fuel has been injected into the engine and it has washed the oil from the
cylinder walls. The oil creates a sealing effect between the piston, the rings, and the walls
of the cylinder. Without this thin layer of oil, the engine compression escapes into the crankcase.

- Although the results indicate low compression, less than specified by the manufacturer,
is paired in all cylinders and the difference between them is no more than 10 psi (See that the
the maximum difference according to the manufacturer is 71 psi), still, we consider that the engine already has
wear of cylinders or valves, to rule that out, we would proceed to the wet test.

Case 3: When the difference is greater between cylinders:

Manufacturer's data: Dry test Diagnosis

Compression pressure: File. 1 420 psi Good

30.0 kg/cm2(427 psi).
Cil. 2 315 psi Bad
Minimum pressure:
25.0 kg/cm2 (356 psi).
Cil. 3 310 psi Bad
Difference between each cylinder:
Less than 5 kg/cm2(71 psi). Cil. 4 415 psi Good

- The results indicate good compression in cylinders 1 and 4, but there is low compression in
cylinders 2 and 3.
- The maximum difference can be seen between the cylinders that register the highest compression (cylinder 1:
420 psi) and the one with the lowest compression (Cylinder 3: 310 psi), the maximum difference between them
it is 110 psi, 39 psi more than what the manufacturer indicates.

- In addition, it can be seen that cylinders 2 and 3 are the ones that record this greater variation, here the
Compression test will make us think about other possible problems that the engine may have such as
damaged packaging and compression leaks that would be the most likely, or broken rings,
poor valve calibration in cylinders 2 and 3, etc. possible causes will be found in the
disassembly of the engine.

[Link] TEST:

When performing the wet compression test, two things could happen:

a. That the compression does not rise or rises very little:

Manufacturer's data: Dry test Wet test

 No.:
MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 9
TASK: PRIMARY DIAGNOSIS OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

File. 1 330 psi 335 psi

Compression pressure:
30.0 kg/cm2(427 psi).
Cil. 2 325 psi 330 psi
Minimum pressure:
25.0 kg/cm2(356 psi). Cil. 3 325 psi 332 psi

Difference between each cylinder:

Less than 5 kg/cm2(71 psi) Cil. 4 320 psi 338 psi

If we have this case, it can be:

- It could be that the intake or exhaust valves are stuck or improperly seated.
incorrect. It could also happen that there were leakages from the surface of the packaging.
cylinder head and there may be compression leaks, in which case, the problem would be focused on the cylinder head.

b. That the compression increases significantly compared to the dry test.

Manufacturer details: Dry test Wet test

-Compression pressure: Cil. 1 330 psi 375 psi

30.0 kg/cm2(427 psi).
Cil. 2 325 psi 362 psi
Minimum pressure:
25.0 kg/cm2(356 psi).
Cil. 3 325 psi 364 psi
-Difference between each cylinder:
Less than 5 kg/cm2(71 psi). Cil. 4 320 psi 370 psi

If we have this case, it could be:

- The piston rings and/or the cylinder bore are worn.

6. OTROS PROBLEMAS EN LA COMPRESION:

- If the engine seems to be functioning normally, but is weak and blows a small amount of smoke
Bluish could be an indicator of worn rings and/or cylinder.
- If it is found that the compression reading is very low or nil in a cylinder, it is very likely
that there are internal damages in the engine such as:

. The piston could have broken a connecting rod or have a hole.

. A valve can be stuck or leaking.

. There could be a broken valve spring or a bent push rod.

. The camshaft has excessive wear and does not provide the necessary lift to the
valve.
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 10
TAREA: DIAGNOSTICO PRIMARIO DEL MOTOR DIESEL: MEDICION DE COMPRESIÓN
Semester: 2
NOMBRE:

- If the compression is low or absent in two adjacent cylinders, it may indicate that the head gasket
is not working properly either because it is damaged, or due to problems with the surface or due to
a bad tightness among others. It can also be due to a damaged camshaft in a
area that operates between the valves of two adjacent cylinders.
- When the compression is too high in one or more cylinders, this may indicate
excessive carbon buildup in the engine. It can only be corrected by performing a
chemical process of decarbonization in the engine or removing the engine head to clean it
carbon (soot) from the top of the piston head and the valve opening area of
the head.

ANOTHER TEST:
Another test that allows for diagnosis consists of injecting air through the spark plug hole.
incandescence or injector and identify where the air escapes. For this, the duct must be removed.
between the filter and the motor to be able to observe if the air comes out from there.

- If air escapes from the exhaust, then the problem is in the exhaust valve.
- If air escapes through the intake valve, you will see the air coming out of the air intake.
- If the leak is from the rings, air will escape from the oil plug like a mist.
greasy.
- If the leak is from the head gasket, air will be seen escaping between the block and the head like
water bubbles or from the radiator cap.
- If the leak is from the radiator cap, it may also indicate that the problem is internal, that is to say
a crack in the block.
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 11
TASK: PRIMARY DIAGNOSTICS OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

PRACTICE
I PERFORMED THE COMPRESSION TEST FOR TWO ENGINES:

MOTOR A:

- REQUEST THE ENGINE SERVICE MANUAL AND COMPLETE THE FOLLOWING DATA:

BRAND: MODEL:

Compression pressure:
Minimum pressure:
Difference between each cylinder:

PERFORM THE COMPRESSION MEASUREMENT FOLLOWING THE INDICATED STEPS:

DRY TEST:

a. Bring the engine to normal operating temperature.

b. Disconnect the power cable to the injection pump.
c. Dismantle all preheaters and their electrical connections or in that case all the
injectors and their high-pressure lines.
d. Install the compression gauge in the preheater or injector housing. We will start the measurement.
through cylinder No. 1.

e. Turn the ignition key to the 'START' position to start the engine and let it run.
for a few seconds.
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 12
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semestre: 2
NOMBRE:

f. Write down the pressure indicated by the pressure gauge on a piece of paper and then press the valve of
Release the manometer so that the needle of the compressometer returns to zero.

Measurement of To be continued.
Cil. Cil. Cil.
Test in
compression Number 1 No. 2 No. 3 No. 4
dry Kg/cm2
Psi

g. Press the release valve of the compression gauge, remove the compression gauge and insert it into the
next cylinder, repeat steps d, e, and f until all cylinders are finished.

Note: If the compression is low, proceed with the wet test:

WET TEST:

Measurement of Purpose. Nothing. Cil. Cil.

Test
compression Number 1 No. 2 No. 3 No. 4
humid Kg/cm2
Psi
NOW OF YOUR DIAGNOSIS REGARDING THE STATE OF THE ENGINE:

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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Página: 13
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NAME:

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2. MOTOR B:

- REQUEST THE ENGINE SERVICE MANUAL AND COMPLETE THE FOLLOWING DATA:

BRAND: MODEL:

Compression pressure:
Minimum pressure:
Difference between each cylinder:

CARRY OUT THE COMPRESSION MEASUREMENT FOLLOWING THE INDICATED STEPS

PREVIOUSLY AND RECORD THE COMPRESSION VALUES:

Measurement of Cil. Cil. Cil. Cil.

Test in
compression No. 1 No. 2 No. 3 No. 4
dry Kg/cm2
Psi

WET TEST:

Measurement of Cil. Screw. Cil. Cil.

Test
compression No. 1 No. 2 No. 3 No. 4
damp kg/cm2
Psi
NOW FROM YOUR DIAGNOSIS REGARDING THE STATE OF THE ENGINE:

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MAINTENANCE AND REPAIR OF DIESEL ENGINES
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TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semestre: 2
NOMBRE:

SELF-EVALUATION
1. What is the purpose of the engine compression test for me?

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2. What are the symptoms of the engine when there is low compression?

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3. Enumere 5 causas comunes de baja compresión:

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4. What does the dry test determine?

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TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

5. When do we carry out the wet test? Explain:

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6. When measuring the compression through the preheater hole, what could happen if I do not disconnect the
fuel cut-off solenoid cable?

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7. Can I use a compression gauge for gasoline engines if I don't have the compression gauge for
diesel engines?, Explain:

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8. What should be the minimum compression of a diesel engine? Explain:

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