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Engine Mechanical Diagnosis: EMD - Course Guide 01
Engine Mechanical Diagnosis: EMD - Course Guide 01
COURSE GUIDE
Diagnostic Tools
Oil Consumption & Analysis
Cooling System Checks
Timing Belt Analysis
Continuously Variable Valve Timing Tests
Spark Plug Analysis
COURSE GOALS Upon completion of this course, the Kia Service Technician
will have the ability to diagnose Engine Mechanical concerns
the first time, every time.
ABOUT THE TRAINING Today’s complex automotive technology demands that you,
MATERIAL the professional Kia service technician, stay up-to-date with
the latest service information, special tools, and complex
repair procedures. We have adopted a modular training
delivery system that breaks down the critical information
into logical groupings. First, you will be presented with
system theory and operation, and then you will be given a
chance to practice what you have learned. Finally, we will
test what you have learned through a Performance
Assessment.
GETTING THE MOST OUT OF This training material is designed to be part of a structured
THIS COURSE training plan consisting of lecture, interactive classroom
discussion, and hands-on shop activities under the direction
of a trained Kia Instructor. After completing the course
material, your understanding of the subject matter will be
verified through our Performance Assessment Module and
you must pass a written and hands-on evaluation.
COURSE MANAGEMENT The course and its materials are here for you to learn. Use
them and your time in a way that will benefit you when you
return to your dealership.
TAKE NOTES The course and its materials are here for you to learn. Use
them and your time in a way that will benefit you when you
return to your dealership.
ASK QUESTIONS If you do not understand something in this course, ask your
Instructor for clarification. Asking questions is strongly
encouraged to help you get the most out of this course.
COURSE AGENDA
DAY 1
NO. NAME TYPE
02 Diagnostics Theory
Lunch
DAY 2
NO. NAME TYPE
Lunch
05 External Inspections Guided Practice
Afternoon Break
SCORECARD ROUTING One copy of the scorecard is yours, and one copy is used to
update your Kia technical training records. Should you not
complete the course, the third copy is forwarded to your Kia
District Parts and Service Manager (DPSM).
ICONS
NOTES PAGE
Vacuum Gauge
Compression Gauge
Leak Down Gauge
Borescope
Block Check
Cooling System Pressure Tester
DVOM (Coolant Electrolysis Test)
Stethoscope and Chassis Ears
Global Diagnostic System
Oil Pressure Gauge
Cooling System
Electrolysis
Oil Viscosity
Oil Consumption
Oil Analysis
INSTRUCTIONS Carefully read through the material, take notes based on the
classroom discussion, and study each illustration.
Throughout the material, there will be Progress Check
questions for you to answer. You may use the material to
answer the questions.
Vacuum Gauge
Compression Gauge
Leak Down Gauge
Borescope
Block Check Dye
Cooling System Pressure Tester
DVOM
Stethoscope and Chassis Ears
Global Diagnostic System
Oil Pressure Gauge
During the intake stroke, air and fuel are drawn into the
Intake Stroke engine as the piston moves downward. The intake valve is
open during the intake stroke.
Normal
18”-20" steady at hot idle (at sea level), when the throttle is
snapped to WOT, the gauge goes to 0", as engine RPM
decreases to idle, the gauge comes up to approximately 25”
and quickly goes back to 18-20".
Sticking Valves
Burnt Valves
Blown Head Gasket
Worn or Broken Primary Compression Rings
Slipped Timing Belt (or Chain)
Worn Valves
Cracked Head
Cracked Cylinder (Block)
Restricted Intake Flow
Restricted Exhaust Flow
Performing the Test To perform the test, start the engine and record the reading
(running compression). The result at idle readings is typically
half of the cranking (dry) compression.
Understanding Compression The following results highlight two possible scenarios and
Results what the causes might be.
LEAK DOWN GAUGE A Leak Down Gauge (or cylinder leakage tester) is useful to
determine the amount of leakage in a combustion chamber.
Results
Also, do you FEEL air flowing out the intake, exhaust, etc.
You should be able to feel the air flow if you can hear it. This
may be more difficult at the exhaust.
BORESCOPE The borescope can save a lot of time by viewing inside the
cylinder for damage before disassembling the engine. A
good borescope will typically have a built-in light to view in
dark places.
Several good uses for a borescope are:
On MPI engines, you can view the back side of the intake
valves for carbon deposits by removing the fuel injectors.
BLOCK CHECK A block check can be useful for confirming a combustion leak
into the cooling system via head gasket, cracked cylinder
head, or cracked engine block.
To set up a block check using the block tester and test fluid
(dye), follow these steps:
3. Snug the block tester rubber base into the radiator filler
neck. Do not twist on the glass tube.
4. Start the engine and place the suction bulb onto the top
of the block tester. Squeeze and release the bulb
repeatedly for 1 minute.
COOLING SYSTEM The cooling system is vital for proper engine operation.
Without a cooling system, the engine would obviously
overheat and seize. The typical gasoline engine is about
20% efficient in converting gasoline to mechanical energy,
and the other 80% is carried away in heat (another form of
energy).
There are two tests that can be performed with the Cooling
System Pressure Tester:
Testing the Cooling System To set up the Cooling System Pressure Tester to test the
cooling system, follow these general steps:
2. Remove the Radiator Cap and note the PSI rating on the
cap.
Testing the Radiator Cap To set up the Cooling System Pressure Tester to test the
Radiator Cap, follow these general steps:
STETHOSCOPE AND CHASSIS Stethoscopes and chassis ears can be very helpful in
EARS diagnosing sounds from the engine area. The sensitivity of
this equipment can quickly diagnose a top-end sound from a
bottom-end sound.
These tools can also be used to separate Transaxle sounds
from the engine sounds. For example, a damaged flex plate
or a screw that backs out of a torque converter could make
sounds that increase with RPMs, which may be disguised as
engine sounds.
GLOBAL DIAGNOSTIC The GDS and KDS are powerful tools that can aid with
SYSTEM (GDS) / diagnostics. You can find the latest information by searching
KIA DIAGNOSTIC Technician Times Articles, Technical Service Bulletins, Pitstop
SYSTEM (KDS) Articles, and Campaigns.
POSITIVE (+) fuel trim values mean the PCM is adding fuel
(increasing the pulse width or on-time of the fuel injectors)
to add more fuel to the engine to RICHEN the fuel mixture
because it thinks the engine’s air/fuel mixture is running too
lean.
LUBRICATION It has been said that oil is the “life blood” of an engine,
which means it is important to keep clean and viable. Oil
that has been contaminated with fuel dilution, contaminated
with water, or not maintained where the oil has extended
beyond the manufacturer-recommended service interval will
have adverse effects on the mechanical components that
require lubrication.
The 5w-20 and 5w-30 used in Kia vehicles flows well for a
wide variety of temperatures. The “5” indicates the flow at
cold temperature while the “20” or “30” indicates the flow at
operating temperature.
NOTE: Most Kia models have the oil viscosity listed on the
oil filler cap itself. Check the oil cap, KGIS, or the owner’s
manual for the recommended oil viscosity.
Always check the oil level hot, with the engine at normal
operating temperature. Remember fluid expands when
hot.
Reading the Results The reading will be low, normal, or high relative to
specification.
Low - clogged pick up screen, faulty oil pump, worn
connecting rod or main bearings, aftermarket oil filter,
contamination, damaged oil pan, or stuck relief valve.
Normal - inspect for maintenance and change oil as
needed.
High - possible restriction in the oil galleries or stuck
closed relief valve in the oil pump, this may cause hyper
extended hydraulic lifters and valves not closing fully
(leaking).
OIL ANALYSIS An oil analysis is not a common test method for most
concerns. However, it can be useful for persistent concerns
or for customers who are meticulous about their Kia.
NOTE: The oil analysis can be useful for customers who also
experience an oil consumption concern.
Summary
PROGRESS CHECK QUESTIONS 1. During which of the strokes listed below for a 4-cycle
engine are air and fuel drawn into the engine?
A. Intake
B. Compresion
C. Combustion
D. Exhaust
A. Worn rings
B. Late Valve Timing
C. Major Vacuum Leak
D. Burnt Valves
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician B
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician B
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician B
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician B
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician B
Notes Page
Vacuum Gauge
Compression Gauge
Leak Down Gauge
Borescope
Block Check Dye
Cooling System Pressure Tester
DVOM
Chassis Ears & Stethoscope
GDS Scantool
Oil Pressure Gauge
INSTRUCTIONS Carefully read through the material and take notes based on
the classroom discussion. Throughout the guided practice,
there will be activities for you to participate in.
REQUIRED MATERIALS In order to complete this guided practice, you will need the
following items:
Pen or Pencil
Safety Glasses
6. Snap the throttle (not rev the engine). What does the
Vacuum Gauge do? ______________________________
Why? _________________________________________
8. Turn off the engine, put the Vacuum Guage back in its
case and reconnect the disconnected hose from the
engine.
TASK 1 1. Open the Compression Tester Kit and make sure all of
DRY COMPRESSION TEST the appropriate accessories are available.
5. Set the parking brake and pull the Main Relay, Fuel
Pump relay or the Sensor 1 or 2 fuse.
Cylinder 1 2 3 4 5 6
Dry
Reading
TASK 2 Follow all shop safety rules. This test will ONLY be
RUNNING performed on one cylinder.
COMPRESSION TEST
NOTE: Use the technique that will give you the best reading
to complete the exercise.
Cylinder 1 2 3 4 5 6
Running
Snap
6. Put the components back into their case, install the spark
plug and ignition coil, and clear any DTCs using GDS or
KDS.
In this activity, you will use a leak down gauge to check the
sealing of the cylinder (rings, valves, head gasket). Follow all
shop rules.
4. Insert the adapter hand tight into the spark plug hole of
the cylinder to be tested.
Cylinder 1 2 3 4 5 6
Reading
[ ] Yes [ ] No
ACTIVITY 3: (CONT)
ACTIVITY 4: BORESCOPE
[ ] Yes [ ] No
4. Place the glass test unit onto the radiator filler neck by
securing and gently twisting the rubber base.
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
ACTIVITY 6: (CONT.)
[ ] Yes [ ] No
ACTIVITY 7: DVOM
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
In this activity you will check the following using the Global
Diagnostic System (GDS) or Kia Diagnostic System (KDS)
Scantool:
STFT
LTFT
DTCs
Follow all shop rules.
1. Connect the VCI and GDS or the VCI-II and the KDS
Scantool to the vehicle.
STFT __________
LTFT __________
3. Check the vehicle for DTCs. Are there any DTCs present
that can be cause by an engine mechanical concern?
If so, please list the DTCs
[ ] Yes [ ] No
6. Use a Mighty Vac, and apply 7 psi to the oil hole of the
switch.
Is there continuity?
[ ] Yes [ ] No
[ ] Yes [ ] No
NOTES PAGE
INSTRUCTIONS Carefully read through the material, take notes based on the
classroom discussion and study each illustration. Throughout
the material there will be Progress Check questions for you
to answer. You may use the material to answer the
questions.
SPARK PLUG ANALYSIS One of the simplest checks that can be performed on an
engine is to closely analyze the spark plugs. Racers have
known for years that proper combustion and engine
operating conditions can be determined with a spark plug
inspection.
WORN – This spark plug shown has served its useful life
and should be replaced. Voltage required to fire the plug has
approximately doubled and will continue to increase the
longer the engine operates.
TIMING BELT AND The timing belt and chain is a critical component that keeps
TIMING CHAIN the camshafts mechanically timed to the crankshaft. The
marks on the camshaft sprockets and crankshaft must line
up perfectly with their corresponding alignment marks. If the
marks do not line up, whether it is due to age or the timing
belt slipped, then there will be a drivability concern and
possible damage on an interference engine.
Over time, the belts and chains tend to wear and need
service. Symptoms of belt stretch could include performance
or a MIL illumination. Some timing chains may also produce
excessive noise due to chain stretch.
While the timing belt is off, be sure to check all pulleys and
accessory drives for smooth operation. If a customer is
concerned with a noise under the hood, it may be a result of
an accessory, pulley, or bearing wearing out.
The oil pumps are part of this balance shaft module as well.
Balance Shaft
Tensioner
Timing Chains:
Do not require replacement as a maintenance item.
There are two types of Valve Lash Adjustors used in the KIA
Types of Valve Lash Adjusters family of engines, these are:
Oil flows into the HLA, where it flows past the check ball into
a chamber in the inner plunger and forces the inner plunger
away from the outer plunger. This action takes up the space
between the camshaft and the valve. When the cam lobe
contacts the HLA, the oil trapped inside cannot be
compressed and therefore applies pressure to the valve to
open it. As the lobe rotates away and the valve closes, the
oil trapped inside can flow out through holes in the side of
the HLA.
MLA In the KIA family of engines, two types of MLAs are used:
Bucket-style shim
Puck-style shim
VALVE CLEARANCE Selecting the correct shim (bucket or puck) to obtain the
ADJUSTMENT PROCEDURE correct valve clearance adjustment is critical to proper
operation of the engine.
A = Measured Clearance
B = Installed Shim Measured Thickness
X = Service Info Clearance Specification
Y = New Shim Thickness for proper Clearance
CAMSHAFT INSPECTION We will discuss measuring the camshaft lobes using digital
calipers to identify a worn camshaft lobe, in addition to
measuring camshaft end play using a dial indicator.
NOTE: Use care not to pry too hard against the cam lobe or
bearing cap to prevent damage.
E-CVVT Newer engines such as the 2.4L in the 2016 Sorento use a
combination of a CVVT along with an E-CVVT (Electric
Continuous Variable Valve Timing). In this configuration, the
intake cam is adjusted using an electric motor, while the
exhaust uses a traditional hydraulic CVVT unit.
Sprocket
Rotor (aka Vane)
Spring Loaded Locking Pin
Vane Seals
Housing
The CVVT uses hydraulic pressure from the engine oil supply
to either pressurize the advance or retard side of the vane.
The vane moves clockwise or counter-clockwise within the
housing depending on which side of the vane is pressurized.
A spring loaded locking pin holds the intake CVVT unit in the
at rest position (fully retarded). When the oil supply is fed to
the CVVT unit, the locking pin will release and the vane can
advance the intake camshaft incrementally between 0° and
40°.
The Oil Control Valve (OCV) controls the flow of oil to either
CVVT Oil Control Valve the advance or the retard chambers of the CVVT unit. When
pressure is sent into either of the advance or retard
chambers, the opposite chamber releases pressure back
through the valve.
Use care not to damage the OCV when installing the engine
cover on 1.6L GDI engines. Clearance between the OCV and
the bottom of the engine cover is minimal; therefore, dealer
personnel should refrain from using excessive force when
trying to ensure the engine cover is fully seated.
* Refer to PS296
The Oil Control Valve (OCV) can be tested using the GDS or
KDS Actuation Tests.
This should put the CVVT to full advance, and the idle should
stumble. If it doesn’t change, then debris may be clogging
the OCV Filter or the supply oil passages may be clogged.
Filter
Refer to:
PitStop PS415
Tech Times Vol 18, Issue 3
OIL PAN It may seem obvious not to raise a vehicle by the oil pan as
pan damage does occur. Oil must circulate throughout the
entire engine and any restriction to oil flow that isn’t
designed by the manufacturer is not recommended.
Coking builds up in the oil galleys over time and an oil filter
in bypass mode may increase the deposit rate in the oil
galleys.
Kia Motors only recommends genuine Kia parts for air filters.
Turbocharger Maintenance (Air If an aftermarket filter is used or if the air filter has been
Filter) removed, then small bits of debris may enter the compressor
side of the turbo housing. The turbine wheel blades are
balanced from the manufacturer and are at risk of being
nicked or cracked. A turbocharger can spin at very high
speeds. If the blades are damaged on the turbine and it is
out of balance, this can damage the bearings and the turbo
housing as well.
NOTE: Make sure that the air filter is clean and not full of
debris. This can result in low flow to the compressor or could
lead to debris in the compressor itself.
The waste gate is used to protect the turbo and engine from
The Waste Gate being harmed from too much boost. The waste gate is a
valve that acts as a short cut for excessive exhaust gas to be
diverted away from the turbine when there is too much
boost being produced. With an excessive amount of exhaust
flowing over the compressor turbine, the turbo can over rev
and permanently damage the turbo or cause damage to the
engine. The waste gate opens to divert exhaust gases away
from the exhaust turbine to slow it down. This in turn slows
the compressor turbine (being connected by a common
shaft) to reduce boost pressure.
2. Verify that the feeler gauge DOES NOT fit between the
straight edge and the head or block surface.
Check in multiple locations.
You will measure in multiple directions as shown.
The feeler gauge you use to check depends on the
specifications for in KGIS for the specific vehicle.
Summary
PROGRESS CHECK QUESTIONS 1. A vehicle is being serviced with new spark plugs.
Technician A says that dielectric grease should be applied
to the spark plug coil boots.
Technician B says that it is best to install the spark plug
with an air tool.
Who is correct?
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician
A. E-CVVT
B. CVVT
C. D-CVVT
D. All of the above.
PROGRESS CHECK QUESTIONS 4. A vehicle pulls into a Kia Service Center with a
(CONT.) Continuously Variable Valve Timing concern.
Technician A says that oil viscosity can affect CVVT
operation.
Technician B says that a clogged OCV filter could affect
CVVT operation.
Who is correct?
A. Technician A only
B. Technician B only
C. Both Technician A and Technician B
D. Neither Technician A nor Technician
A. True
B. False
Notes Page
INSTRUCTIONS Carefully read through the material and take notes based on
the classroom discussion. Throughout the guided practice
there will be activities for you to participate in.
REQUIRED MATERIALS In order to complete this guided practice, you will need the
following items:
Pen or Pencil
Safety Glasses
3. Connect the Air Hose to the air supply, and then connect
the Air Nozzle to the Air Hose. Use the Air Nozzle to test
the CVVT unit. If a camshaft is not available, then find
the appropriate hole on the CVVT unit.
4. Does the CVVT unit rotate freely after the locking pin has
been released? _________________________________
5. If the CVVT unit does not rotate after the locking pin has
been released, what could be the concern?
In this activity, you will measure the intake and exhaust cam
lobe height on a 2008 Kia Spectra 2.0L (LD) camshaft using
digital calipers.
INTAKE: __________
EXHAUST: __________
INTAKE: __________
EXHAUST: __________
In this activity, you will use the straight edge and feeler
gauges to measure the flatness of a 2008 Kia Spectra 2.0L
(LD) cylinder head to check for warpage.
TASK 1 In this task, you will test the oil control valve resistance
OCV TESTING using a DVOM.
TASK 2 In this task, you will test the Oil Control Valve (OCV) of the
OCV OPERATION CVVT system.
TASK 2 (CONT.) 4. Plug the loose oil control valve into the harness
connector. Start the vehicle and rev the engine. Observe
the OCV operation through its ports.
6. Shut off the vehicle, plug in the loose OCV, start and rev
the engine, and watch the two values on the GDS.
TASK 3 In this task, you will identify the type of oil control valve
OCV FILTER filter that a vehicle is equipped with.
TASK 3 (CONT.) 2. List the items that must be removed to service the
internal filter?