No.

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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 1
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

SECURITY

SERVICE MANUALS

New systems and features are added to 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 for

appropriate 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
ensure 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 specified, the
The tool or measuring instrument may become damaged and consequently the parts.
they can damage or endanger the quality of the work.

- Learn the correct use of instruments: Each tool and measuring instrument
it has well-defined operating procedures. Make sure to apply them correctly.
herramientas con las piezas de trabajo, aplique la fuerza adecuada a las herramientas y adopte
proper work postures.

- Make a correct selection: There are several tools available to loosen the ...
bolts according to 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 measurement tools and instruments should be placed in a way
They should be easily accessible when needed and must be placed back in their spot.
when they have been used.

- Keep the tools and instruments clean and in perfect condition: The tools and
instruments must be cleaned, and if necessary, greased, as soon as they have been
utilizado. Cualquier reparación necesaria debe realizarse inmediatamente de forma que las
tools and instruments are always in perfect condition.

TO OBTAIN ACCURATE MEASUREMENT VALUES

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

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

Aspects that must be checked before measurement:

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

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

agreement with the required degree of precision and the type of work to be carried out.

- 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 hit the tool or any measuring instrument, the internal parts of the
precision instruments can be damaged.
2. Avoid using or storing them in 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 be deformed if subjected to high
temperatures.
3. Clean the tool and instrument after use and store it in its original condition. Keep it
tools and instruments only when the dirt from oil or waste has been cleaned.
All tools and measuring instruments used must be returned in their condition.
original and any equipment equipped with a dedicated case must be stored in it. The
Measuring tools must be stored in a defined place. If the tools are going to
store for a long period of time, apply protective oil against oxidation
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
Semester: 2
NOMBRE:

IMMEDIATE TECHNOLOGY

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

- Carry out the 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.

1. ENGINE DIAGNOSIS - COMPRESSION TEST

The engine compression test is a

a good indicator of the engine condition is
very simple, fast, 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 the 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 DUE TO COMPRESSION

When an engine has compression problems, it may present one or several of the following
síntomas:
- It expels smoke of any color.
- It is necessary to accelerate more than normal to move (lack of power).
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TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NAME:

- High fuel consumption.

- Idle revolutions are very variable.
- Starting problems.
- It keeps turning off.
- Drink water or soda

3. CAUSES OF COMPRESSION PROBLEMS

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 tight or the hole and/or thread may be damaged.
- Injectors: They could be loose or poorly adjusted, the seal at the tip of the injector worn out or faulty.
the seat or the hole and/or thread may be damaged.
- Valves: A damaged valve does not allow for a proper 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 cylinder, they are presented
leaks.
- Cylinder head gasket: A damaged, poorly tightened, poorly seated, or poorly
selected will allow leaks.
- Damaged head: An engine head with cracks will allow leaks.
- Engine block: If the engine block shows 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 issue in this subsystem.

4. HOW TO MEASURE COMPRESSION:

4.1. DRY TEST

Engine compression can be easily done with a compression tester.
(pressure gauge/compression meter) available for purchase in the market. This review provides a
good information about the wear state of the engine.

To do this, you must follow the appropriate procedure:

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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 normal operating temperature, a cold engine will allow for greater leaks.
compression due to the fact that the engine parts have not fully expanded.

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

diesel should not inject fuel during this process, which is why it is
It is advisable to disconnect the fuel shut-off solenoid cable.
from the injection pump.

c. Remove all the preheaters and their electrical connections (3) or in such
if all the injectors (2) and their high-pressure lines (1), depending
wherever you are going to place the compression gauge, but 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 seal the hole where the preheater or 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
accelerator to the floor until the engine has made a few revolutions and the compression gauge registers the value
of the cylinder compression to be measured, it will rise from a 'zero' value and will stop when the
compression should be the maximum that can be registered for the cylinder.
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 6
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 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 compressimeter goes back to zero.

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

g. Press the discharge valve of the compression gauge to bring the indicator back to zero, remove the
compressor and insert it into the following 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 specified one.
engine manufacturer. The pressure difference should not exceed 10%. It is always advisable
refer to the specifications of the manual for each engine.

[Link] TEST:
The wet compression test of the engine is done by adding two tablespoons of oil.
(two squirts from a portable oil can) before the placement of the compressimeter. This test provides a
Good information about the wear condition of the piston-ring-cylinder assembly engine.
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MAINTENANCE AND REPAIR OF DIESEL ENGINES
Page: 7
TASK: PRIMARY DIAGNOSTIC 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 squirts of motor oil through the preheater or injector hole before each
verification.
Measurement of
Test File No. 1 File No. 2 N°3 File No. 4
compression
damp kg/cm2 12
Psi 170

5. ANALYSIS OF THE COMPRESSION RESULTS:

[Link] TEST:
So that the compression can be considered normal and 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 three cases of the same brand and model as an example.
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).
B. 2 380 psi Good
-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 Diagnosis

Compression pressure: Cil. 1 330 psi Bad

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

If we have this case, it could be:

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

- Que se hayan calibrado mal las válvulas de admisión o escape, revise la calibración y vuelva a
to measure.
- That the air intake of the intake manifold has been blocked or obstructed, check and return to.
measure, the entry must be completely free.
- 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 has washed out the oil from the
cylinder walls. The oil creates a sealing effect between the piston, the rings, and the walls.
from the cylinder. Without this thin layer of oil, the engine compression escapes to the sump.
- Although the results indicate a low compression, less than specified by the manufacturer,
it is paired on 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), even so, we consider that the engine already has
cylinder or valve wear, to rule that out, we would proceed to the wet test.

Case 3: When the difference is greater between cylinders:

Datos del fabricante: Dry test Diagnosis

Compression pressure: Cil. 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 Mal
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 record 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 the greatest variation, here the
compression test will make us think of other possible problems that the engine may have such as
Example: Damaged packaging and compression leaks that would be the most likely, or broken rings.
poor calibration of valves in cylinders 2 and 3, etc. these 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 increase or increases very little:

Manufacturer data: Dry test Wet test

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Page: 9
TAREA: DIAGNOSTICO PRIMARIO DEL MOTOR DIESEL: MEDICION DE COMPRESIÓN
Semester: 2
NOMBRE:

Volume 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). Clause 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 leaks through the surface of the packaging of the
the cylinder head may have compression leaks, in that case, the problem would be centered on the cylinder head.

b. That the compression rises with a great difference than in the dry test.

Manufacturer data: Dry test Wet test

Compression pressure: Annex. 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 can be:

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

6. OTHER PROBLEMS IN COMPRESSION:

- If the engine seems to be running normally, but is weak and blowing a small amount of smoke
Bluish, it could be an indicator of worn rings and/or cylinder.
- If it is found that the compression reading is very low or null 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 may 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 opening for the
valve.
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TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NAME:

- If the compression is low or none in two adjacent cylinders, it may indicate that the head gasket
it is not working properly either because it is damaged, or due to surface issues or due to
a bad tightening 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 accumulation of carbon 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 the
carbon (soot) from the top of the piston head and from the valve opening area
the head.

ANOTHER TEST:
Another test that allows for the 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 see if the air comes out from there.

- If the air escapes through the exhaust, then the problem is in the exhaust valve.
- If air escapes through the intake valve, you will see air coming out of the air intake.
- If the leak is from the rings, air will escape from the oil cap 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 through the radiator cap.
- If the leak is from the radiator cap, it may also indicate that the problem is internal, that is
a crack in the block.
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TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semestre: 2
NAME:

PRACTICE
PERFORMED THE COMPRESSION MEASUREMENT 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:

CARRY OUT 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 the 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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Page: 12
TASK: PRIMARY DIAGNOSTIC OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NAME:

f. Write down the pressure indicated by the manometer on a piece of paper and then press the valve of
Drain the manometer so that the gauge needle returns to zero.
Measurement of Cil. Prick. Cil. Cil.
Test in
compression N°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 Cil. Cil. Cil. Cil.

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

…………………………………………………………………………………………………………………………….

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

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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 I RECORDED THE COMPRESSION VALUES:

Measurement of Cl. Cil. Cil. Cool.

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

WET TEST:

Measurement of Cil. Cil. Cil. Cil.

Test
compression No. 1 No. 2 No. 3 No. 4
humid 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 DIAGNOSIS OF THE DIESEL ENGINE: COMPRESSION MEASUREMENT
Semester: 2
NOMBRE:

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

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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
NAME:

5. When do we perform 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 solenoid cable?

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

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

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